Stanyl Aplicacoes Gerais - Dsm

DSM Engineering Plastics

Our mission is to

satisfy customers with engineering resins

and specialty compounds

supported by leading-edge

technologies and

services resulting in

cost-effective solutions.

Production Sites

Europe

Emmen NetherlandsPolymerization & Compounding

Geleen NetherlandsPolymerization

Genk BelgiumCompounding

Stade GermanyPolymerization

North America

Evansville IndianaCompounding

Augusta GeorgiaPolymerization

Stoney Creek Ontario CanadaCompounding

Asia Pacific

Jiangsu ChinaCompounding

Pune IndiaCompounding

Tokyo JapanM/S Joint Venture & Toll Compounding

1Contents

Introduction 2Stanyl PA46 overview 2Stanyl PA46 product scope 3

Automotive Applications 4Engine 5Transmission 6Engine-management systems 7Sensors 7Alternators, starters and small

electric motors 10Tubing 10Charge air cooler end caps 11

Electrical and Electronic Applications 13

Electrical industry 13Electronics industry 13Stanyl High Flow 14Challenges for the E/E industries 14Connectors 15Wire-wound components 17Electric motors 18

Gear Wheels, Bearings, and Bearing Cages 19

Gear wheels 19Bearings and bearing cages 20

Characteristic Propertiesof Stanyl PA46 21

General 21Crystallinity 22Temperature performance 22Mechanical properties 24Electrical properties, flammability,

and UL classifications 27Chemical resistance 28

Designing with Nylons 29Product design 29Tooling design 30

Processing Nylon 32Machinery 32Material handling 33Processing conditions 34Secondary-treatment 36

DSM Product Portfolio 37

Contact Information back cover

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DSM Engineering Plastics is aBusiness Group in the performancematerials cluster of DSM, with sales in2001 of $558 million (Euro 603 million)and approximately 1,350 employeesworldwide. It is one of the worlds lead-ing players in the field of engineeringthermoplastics offering a broad portfolioof high performing products.

DSM Engineering Plastics operates in allmajor markets of the world including theAmericas, Asia, and Europe. Withineach region customers can count on ourinnovative research, development, andsupport facilities. Our in-houseresources are backed by a corporateresearch and development center that isutilized in creating new solutions forcustomer needs. The advanced level ofaccount management, in combinationwith our effective global communicationnetwork, secures the support customersneed wherever it is required.

With polymerization and compoundingfacilities for a range of polyamides, poly-esters, polycarbonates, and Ultra HighMolecular Weight PE and extrudableadhesive resins, we serve our globalcustomer base and assure a constant,reliable supply of products.

All our compounding facilities in theworld (in the Netherlands, Belgium,USA, Canada, China, and India) arebeing expanded continuously to keepup with the growing demand.

As a result of a constant product innova-tion and creation process, DSMEngineering Plastics can offer a cohesiveportfolio of high performing engineeringplastics. Established trade names are:

Akulon (nylons)Akulon Ultraflow (a high flow nylon 6)Arnite (thermoplastic polyester)Arnitel (copolyester elastomers)Stamylan UH (UHMWPE)Stanyl PA46 (PA46)Stanyl PA46 High Flow (high flow PA46)Stapron (PC-blends)Xantar (polycarbonate)Xantar C (PC/ABS-blends)Yparex (extrudable adhesive resins)

Complemented in some regions byproducts such as:

Electrafil (conductive thermoplastics)Fiberfil (reinforced & filled thermoplastics)Nylatron (lubricated thermoplastics)Plaslube (lubricated thermoplastics)

These materials all have their specificproperties, yet they share the same highquality thanks to state-of-the-art produc-tion processes and quality systems likeTotal Quality Management, ISO 9001,and QS 9000.

Its an approach to quality that can befound throughout the DSM organization:

- in relations with industry partners,working closely together in truecooperation, ready to meet any tech-nical challenge

- in technical service and after sales,providing support to help customersoptimize their processes

- in logistics and delivery, shippingproducts anywhere in the worldquickly and reliably.

From product concept, through pro-cessing, to final application, DSMEngineering Plastics brings the portfolio,skills, and global presence to help itsindustrial partners create world-classproducts and solutions.

DSM is active worldwide in life scienceproducts, performance materials, andindustrial chemicals. The group has annu-al sales of close to $5.5 billion (Euro 6billion) and employs about 20,000 peopleat more than 200 sites worldwide. DSMranks among the global leaders in manyof its fields. The companys strategic aimis to grow its sales (partly through acqui-sitions) to a level of approximately $9.2billion (EUR 10 billion) in 2005. By thattime at least 80% of sales should be gen-erated by specialties, i.e. advancedchemical and biotechnological productsfor the life science industry and perfor-mance materials.

2Stanyl PA46 overview

Stanyl (polyamide 46) is the heat-resistant nylon of DSM. Stanyl is usedin demanding applications in the auto-motive and electrical/electronicsindustries, but it also meets manyother application requirements. It is analiphatic polyamide formed by thepolycondensation of 1,4-diaminobu-tane and adipic acid (see Figure 1).Although there are similaritiesbetween the molecular structure ofStanyl and that of PA66, the highernumber of amide groups per givenlength of chain and the more symmet-rical chain structure of Stanyl result ina higher melting temperature 295C(560F), a higher crystallinity, andfaster crystallization (see Table 1).

The crystallinity of Stanyl is approxi-mately 70%, compared with 50% forPA66. This results in a high heat distor-tion temperature of 170C (340F) forunreinforced Stanyl and 290C (555F)for glass fiber reinforced Stanyl. Thesefeatures give Stanyl a technical edgeover other engineering plastics likepolyamide 6 and 66, polyesters, andPPA's with regard to heat resistance,mechanical properties at elevated tem-peratures, wear and friction behaviorand, due to an advantage in cycle-time, economical processing.

Stanyl is produced and marketedexclusively by DSM and is availableworldwide. Compounding is carried outin the USA, Europe, Asia, and Japan.The Stanyl business has been ISO9001 certified since 1991. Technicalsupport in design, molding, and materi-al selection is provided by a dedicatedstaff of specialists. This support is pro-vided locally and on a global basis.

The excellent properties of Stanyl

lead to important advantages for thecustomer such as cost reduction,longer lifetime, and high reliability (seeFigure 2). Stanyl bridges the gapbetween conventional engineeringplastics such as PA6, PA66, and poly-esters, and exotic materials such asLCP, polysulphones, and PEEK.

Benefits for both molders and endusers include:

- resistance to high temperatures- lower material costs due to excel-

lent mechanical properties allowingthinner walls which lead to weightreduction and lower part prices

- 30% productivity increase of molding equipment

- greater design freedom due to excellent mechanical properties and good mold-flow behavior

- economical, safe, and convenient processing due to the use of 80C (175F) water-heated molds

- no post-treatment due to absence of flash

- no retooling necessary when switching from PA6, PA66, or polyesters.

Introduction

Figure 1 Differences in the structures of polyamides.

Table 1 Typical properties based on structure.

Melting point C (F) 225 (435) 265 (510) 295 (560)

Density kg/m3 (lb/ft3) 1140 (71) 1140 (71) 1180 (74)

Crystallization rate:- at 200C (390F) 0.2 6 >15- at 230C (445F) 0 0.7 10

Properties PA 6 PA 66 Stanyl

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Stanyl PA46 product scope

Stanyl is offered in a wide variety ofgrades including unfilled (non-rein-forced), as well as grades containingglass fiber, mineral, lubricants, and/orflame retardants. A complete list canbe found in Table 2.

Product cost analysis. DSM hasdeveloped a computer software tool,Product Cost Analysis (PCA), to cal-culate the cost price of components,taking into consideration factorssuch as raw-material price, materialdensity, mold cost, and labor andmachine costs (both strongly relatedto cycle times).

PCA will also calculate the optimumnumber of cavities depending on thenumber of parts to be produced. Thisanalysis, combined with design rec-ommendations (e.g. on optimum wall-thickness, ribbing and gating) fromDSM's technical and design servicesdepartment, has in many cases led toa cost saving solution or an improvedprice/performance ratio with Stanyl.

Non-flame-retardant TW341 TW200F6 30

(HB or V-2) TW441 TW200F8 40

TW363 TW241F10 50TW241F12 60

Flame retardant (V-0) TE351 TE250F6 30

TE250F8 40

TE250F9 45

46HF5040 40

Wear & Friction TE373 TW271F6 30

TW275F6 30

Grades Non-reinforced GF-reinforced (%)

Table 2 The Stanyl product portfolio.

Figure 2 Stanyl's excellent properties at elevated temperatures 160C (F) lead toimportant advantages for the customer.

4Heat-resistant plastics are increasinglyreplacing traditional engineering plas-tics in automotive applications. Thedriving force behind this developmentis the need to respond to three majorindustry trends:

the growing use of new electronicsystems for improved safety, comfort, and motor management

the demand for longer warranty periods and operating lifetime

the increase in under-the-hood temperatures caused by:

- lower coefficients of drag, which result in less air flow under-the-hood

- encapsulation of the engine for acoustic-insulation and/or aesthetic reasons

- introduction of turbo chargers and catalytic converter systems,which radiate considerable amounts of heat

- size reduction of the engine compartment due to more compact design.

Stanyl has proven to be an idealreplacement for metal for economicreasons. It offers excellent creepresistance, strength, stiffness (seeFigure 3), and fatigue resistance at

high temperatures, while at the sametime providing the well-known advan-tages of plastics. These are easierprocessing and limited finishingrequirements, freedom to developcomplicated designs and integratedfunctions, weight and noise reduc-tion, and corrosion resistance.

Stanyl has been approved by allmajor automotive manufacturers. Itwith-stands high loads and stresses,high temperatures and exposure toaggressive environments, and is there-fore suited for under-the-hood applica-tions. Stanyl can be found in the fol-lowing applications:

- engine (chain tensioners, oil-filterparts, engine covers)

- transmissions (clutch rings, shift forks, thrust washers, bearing cages)

- motor-management- air-system intercooler (emmision

control systems, end caps, turbo-charger parts)

- brake and electronic systems(alternator parts, sensors and switches, connectors)

- tubing- sensors and connectors for

under-the-hood- air-intake devices- cable fasteners- alternators and starter-motor parts - valves and pump housings for

exhaust-gas control and sec-ondary air-supply systems.

Automotive Applications

Figure 3 Stanyl retains its stiffness at elevated temperatures.

Wheel Nuts

Plastic wheel nuts are exposed to harsh environments and potentialabuse. The outstanding toughness Stanyl exhibits extends the life ofthe wheel nuts and provides improved performance.

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Engine applications are generallyused in very demanding environmentswhere Stanyls high melting point,toughness, and excellent wear prop-erties provide outstanding perfor-mance regardless of engine size orconfiguration. With trends in weight,cost, and noise reduction Stanyl

offers opportunities in Overhead Valve(OHV), Overhead Cam (OHC), andhybrid engines for both metal replace-ments and clean sheet thermoplasticdesigns. Metal replacement withStanyl has been especially success-ful in part consolidation, NVH andcomponent wear, and durabilityimprovement. Successful and poten-tial high performance engine applica-tions include:

- valve lifter guides- rocker arm fulcrums- chain tensioners and guides- threaded oil filter housings- sensors- timing and starter gears- cam gears and sprockets- gasket carriers.

With guarantees exceeding 100,000miles for engines between tune-upsand roadside service at the car com-panies expense, engine and powertrain components must be lasting anddurable. Stanyls proven successmakes it an ideal candidate for enginecomponent improvement.

Engine

Stanyl is highly suitable for applica-tions that involve contact with hotmotor oil or transmission oil. Extensivetesting has shown that Stanyl retainsa high degree of stiffness, goodimpact resistance, excellent stabilityand wear properties in such environ-ments. Even in the more aggressiveenvironment of automatic transmissionoils the decrease in properties overtime is remarkably low.

Stanyl displays a clear advantageover PA66 with its superior mechanicalperformance before and after aging at150C (300F) for 1,000 hours.

Under normal running conditions, thetemperature of motor oil variesbetween 130C (265F) and 150C(300F), while peak temperatures of165C (330F) can occur. At thesetemperatures the retention of proper-ties of the plastics used is crucial.

A successful application of Stanyl inthese conditions is the chain tension-er. Chain tensioners from Stanyl arecommercially used by various auto-motive manufacturers all over theworld. The requirements formaterials used in chain ten-sioners are high stiffness atelevated temperatures,

excellent resistance to wear, andgood resistance to oils. Chain tension-ers made of Stanyl wear consider-ably slower than those made of PA66.Moreover, the high stiffness at elevat-ed temperatures enables the replace-ment of the frequently used system (ametal frame with a PA66 top layer) bya full-plastic Stanyl solution.

This results in a very cost-effectivesystem. Its operating life is three toseven times longer than that of a PA66 system.

For high temperature automotive under-the-hood components like valve lifterguides, Stanyl is the material solution.

Chain Tensioners

Stanyl is used in automotive platforms around the globe by major chain drive manufacturers to replace multi-componentmetal arms in chain tensioning systems for high performanceengine applications.

6Transmission

Stanyl's properties remain at anacceptable level in applications whereaggressive oils and high temperatureslimit the use of conventional poly-amides. Stanyl can therefore replaceexotic material such as PEEK.

An example is the use of Stanyl inthe self-adjusting clutch ring. Theself-adjusting clutch allows pedalefforts to remain constant as theclutch disk wears. Its spring-loadedthermoplastic ring features serrationswhich are wedged forward to main-tain the proper gap between thepressure plate and cover fulcrums.This results in a consistent feel forthe driver throughout the vehicleslife. The self-adjusting feature fullyeliminates traditional threaded cablemechanisms for manual clutches,thus reducing maintenance andassociated costs. Dimensional toler-ances for the serrations are extreme-ly narrow, and Stanyls low post-mold shrinkage makes it the idealmaterial for a clutch ring.

Stanyl can be used in other transmis-sion components such as thrust wash-ers, gear-shift forks, housings and

speedometer gear wheels. Fatigue,limiting PV, wear and torque resis-tance are critical in these applica-tions. The thrust washer, for example,has to absorb the high compressionloads that arise in the differential dur-ing acceleration.

Stanyl and PA66 were tested forspeedometer gear wheels undersevere conditions as describedabove. Only Stanyl was able to offerthe desired performance, due to itssuperior mechanical properties com-pared with PA66 and PPA.

Stanyl is also used in a two-mass fly-wheel containing flexible elements consisting of springs mountedbetween two plastic seats. This fly-wheel is used in luxury cars to damp-en vibrations and thereby enhancecomfort. Neither PPS (with 40% glassfiber) nor PA66 meets the require-ments specified for the flywheelregarding creep resistance.

The temperature at the friction surfacecan rise to 290C (555F). Stanyl hasclearly demonstrated its suitability forthis demanding application.

Figure 4 Stanyl offers the highest stiffness at elevated temperatures.

Balance Shaft Cover and Chain Guide

This injection-molded single piece combined two components in aneffort to consolidate parts, integrate functions, and reduce partweight. Stanyl provided structural integrity for the balance shaftcover and wear and abrasion resistance for the chain guide. Bothfunctional areas use temperatures of up to 155C (310F).

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Engine-management systems

The heat-resistance properties ofStanyl have led to the commercializa-tion of a number of devices for emis-sion-control systems. These includesecondary air supply (SAS) systems.Continuous-use temperatures canreach 160C (320F), while peak tem-peratures can touch 200C (390F).

In other automotive management sys-tems such as ABS, TCS (traction con-trol system), and direct ignition, differ-ent kinds of housings, sensors, con-nectors, and switches are applied. Forreasons of creep, fatigue, and vibra-tion resistance, Stanyl is often select-ed in these cases.

PA66 often fails to fulfill the high-tem-perature requirements, whereas PPShas insufficient impact resistance andis more difficult to process.

Stanyl is also used in recyclable oilfilter housings that must withstandhigh temperatures from the engineand road abuse such as rocks,bumps, and weather. Stanyl deliversthis typical under-the-hood environ-ment performance with heat resis-tance, toughness, and high impactproperties. Stanyls excellent heatand creep resistance properties helpto maintain torque retention and pre-vent oil leaks in the housing.

Sensors

Todays vehicles obtain their maxi-mum performance by using complexmicroprocessor technology to performthousands of calculations per secondbased on input from sensors locatedthrough out the vehicle. To obtain cru-cial input data sensors are mounted insome very harsh environments. Toaccess data in a variety of locationsdifferent mounting techniques are nec-essary. Techniques include snap in

mounting for less demanding applica-tions, bolt on sensors for moredemanding applications, and thread-ed mounted applications for the mostdemanding. Many powertrain sensorsare installed by threading them directlyinto engine blocks, oil pans, transmis-sion housings, or intake manifolds.

Installation without breakage.In the past, the only way to produce asensor that could thread into a power-train housing was to make it from metal.Thats no longer the case. Demandingthreaded powertrain sensors can nowbe made out of engineering thermo-plastics, specifically Stanyl.

Stanyl provides toughness for recyclable oil filter housings.

Stanyl PA46 provides strength at hightemperatures for wheel speed sensors.

Sensors

Stanyl sensors and connectors, used in areas where high-temperature resistance is required, replace multi-part,machined metal components in high performance sensors.

8When you think about threading a plas-tic sensor application into a metal sub-strate you might assume that the partwont be able to meet the tighteningdemands in an application such as anoil pan. Stanyls balanced combina-tion of high tensile strength, high shearmodulus and toughness allow it tomeet the torque requirements duringinstallation. Inherent to thread design inany material is the production of stressconcentration at the root of the thread.When tightening a threaded part inplace this area is where cracking andfailure usually occur. Stanyls combi-nation of properties lend the necessarystrength qualities to the part to resistcracking and allow threaded sensors tobe installed without breaking.

Ensuring mounting integrity.Once the part is installed it must beable to perform, and continue to per-form, over the life of the vehicle. Athreaded sensor must stay tight toprevent leakage and ensure correctsensor position. Maintaining sufficientclamping force is what keeps athreaded part tight. When threadinga part into a substrate there is verylittle torque produced because the

only resistance to the rotation of thepart is the friction between thethreads. The part has no stress orstrain in it. As the flange makes con-tact with the substrate the rotation ofthe part continues to draw the partdown while the flange resists beingpulled down. Strain and inducedstress start to occur at the smallestcross-sectional area of the part andincreases with every degree of rota-tion. The stress and retention of thatstress force is what retains theclamping force.

Stress relaxation, which takes place inall materials, is accelerated by heat.Resistance to this, especially at hightemperature, is what permits threadedsensors to be made with Stanyl. Theconsistency at which the material per-forms over elevating temperatures andtime is key to Stanyls performance.Stanyl maintains consistency from80C (176F) and conditioned through140C (284F). Engineers designingwith Stanyl will appreciate the unifor-mity of this material property and canbe assured that the clamping force willbe maintained through the varyingenvironmental conditions of a power-

train component. This means that onceit is installed the sensor will stay tightto prevent leakage and ensure sensorperformance over the life of the part.

Stannyl PA46 performs even inharsh automotive fluids. Stanyl

products are well known for theirresistance to a wide range of chemi-cals. Sensors are continually placedin harsh automotive environments andare only exposed to automotive fluids,but many times they are immersed inthese fluids at elevated temperaturesof 160C (320F).

Stanyl retains its properties after heataging even while immersed in fluidssuch as ATF, engine oil, and fuel.

Chemical resistance is key for materi-als used in the engine and powertrain.Even after 1000 hours at 160C Stanyl

retains about 60% of its flexural modu-lus. After 1000 hours at 150C (302F)in ATF, another harsh chemical envi-ronment, Stanyl retains more than60% of its stiffness properties andalmost 100% of its toughness.

Threaded SensorStanyl was chosen for this innovative sensor that threads into the oil panand measures inputs such as oil level and temperature. A 50% glassfiber reinforced grade of Stanyl (TW241F10) was selected for its highstiffness and resistance to stress relaxation and creep at both room tem-perature and elevated service temperatures. Parts must withstand con-stant oil exposure and must maintain dimensional stability to avoid leak-age around the threads.

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Today Stanyl is being used in thread-ed sensor applications in engine oiland transmission fluid with years ofproven performance without failure.

Easy and cost effective. Workingwith Stanyl is easy, cost effective,and reduces sensor costs. Stanyl

allows greater design freedom andpart integration opportunities due toits mechanical and good mold flowproperties. Stanyls excellent flowcharacteristics minimize damage tointernal sensor elements and partsand it minimizes movement of theencapsulated items during molding.When you use Stanyl to design metalreplacements for sensors you are pre-sented with opportunities to integrateparts. For example, you can combinethe connector, the body and themachined threaded part all out of onematerial. This can elimimate pur-chased parts, provide greater internalcontrol of the process and parts, and

insure the quality of the final product.It can reduce the assembly process ofthe sensor and produce a cost sav-ings. Replacing metal parts anddesigning the sensor in Stanyl canyield cost savings up to 30% overconventional sensor design for youroverall sensor costs.

Backed by 100 years of materi-als experience and engineeringsupport. DSM Engineering Plasticsautomotive technical support team isavailable to help you realize yourdesign objectives. Our knowledge-able and experienced applicationsengineers expand the boundarieswhere versatile materials like Stanyl

can be utilized. With 100 years in thematerials business, DSM has theresearch and application experience tohelp you realize the value from yourproduct ideas.

Unmatched material perfor-mance for threaded sensorpackaging. A proven performer inthreaded sensors, Stanyl combineshigh strength and toughness to guar-antee installation without breakage. Itshigh temperature resistance to stressrelaxation ensures mounting integritywhile its excellent chemical resistanceprovides protection from harsh auto-motive fluids. No other engineeringplastic offers this combination ofmaterial performance. Together withthe experience of our design andengineering team there are no limits tothe value captured by converting frommetal to Stanyl.

Transmission Speed SensorThe transmission speed sensor inputs data to the ECM which determinesoptimum RPM shift levels and enables maximum engine efficiency. Stanyl

provides resistance to stress relaxation and creep to prevent loosening ofthe threads and chemical resistance to aggressive fluids at elevated tem-peratures. In addition, it offers good toughness over a wide temperaturerange, retains stiffness at peak temperature, and maintains excellent fatigueresistance for durability. Utilizing Stanyl in the sensor provided a costreduction through injection molding and part consolidation as well as weightreduction through metal replacement and design flexibility.

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Alternators, starters andsmall electric motors

Stanyl applications are also found inalternators, starters, and electricmotors. One very interesting applica-tion is the diode carrier in the alterna-tor. The diode converts the alternat-ing current generated in the alterna-tor into a direct current.

Diode carriers typically consist of ametal plate and polyether sulfone(PES) inserts, over-molded with PA66.These PES inserts are necessarybecause the local temperature is200C (390F), at which the creepresistance of PA66 is insufficient.Thanks to the use of Stanyl it is possi-ble to integrate the PES and PA66parts into one part. The result is a dropin the final price of the component.

The use of Stanyl in starter gearsoffers several advantages over theuse of steel such as lower weight andcorrosion resistance. Stanyl alsolends toughness and superior ther-mal performance to starter gears.Temperature requirements have alsoled to brush holders being manufac-tured in Stanyl instead of PA66.

Tubing

Stanyl TW363, an impact modifiedgrade, can be extruded into thin,automotive vacuum tubing that canbe used for actuation purposesunder the hood. Such tubing madefrom Stanyl has been extensivelytested by automotive companies for4,500 hours on light trucks and mini-vans operating in desert climates andwere found to be superior to the tub-ing previously in use.

Stanyl is used in under-the-hoodapplications because of its excellentlong-term mechanical properties athigh temperatures in aggressive auto-motive environments. At the sametime Stanyl offers an economicadvantage due to wall thicknessreduction, longer lifetime expectancyof the parts, and easy and fast pro-cessing. Stanyl also allows increaseddesign freedom and part integration,leading to reduced handling costs.

Convoluted Tubing

The switch to Stanyl PA46 from PA6 for convolut-ed tubing provides savings to the manufacturersince Stanyl extrudes 20-30% faster than PA6.Stanyl also provides a high melting point of295C (562F), retention of properties, abrasionresistance, and low stiffness.

Stanyl can be used to overmold metaland reduce the number of parts need-ed for a finished component like thisalternator.

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Charge air cooler end caps

The demand for economical high out-put from small engines has driven themotor vehicle OEMs to use tur-bochargers for boosting horsepower.Added components translate toadded weight which counters otherefforts to increase fuel economy.Turbocharger and engine cooling sup-pliers have been challenged to mini-mize the added weight in these sys-tems without sacrificing system perfor-mance. Replacing metal with engi-neering plastics in system compo-nents has led to a focus on charge aircoolers as well as air ducts.

Proven success of engineering plas-tics in radiator end tanks madecharge air cooler end tanks an obvi-ous area to explore. Unlike radia-tors, charge air coolers are typicallyair-to-air heat exchangers. Chargeair reaches temperatures of 200C(392F) so cast aluminum has tradi-tionally been the metal of choice dueto its high temperature performance,stiffness and strength and its rela-

tively low weight. Any charge aircooler end tank made from engineer-ing plastic would need to have simi-lar performance, be much lighterand, offer lower costs. With thedemands of 200C (392F) charge airtemperatures, high internal pres-sures, vibration fatigue and shock, atrue high temperature engineeringplastic was needed.

Stanyl high performance polyamide isa proven performer in charge air cool-er end caps. Internationally, all themajor charge air-cooling system sup-pliers use it for their most demandingcharge air cooler end caps. Stanyl

has superior elevated temperaturecreep resistance when compared toother high temperature engineeringplastics. That means sealing integrityat elevated temperatures is veryrobust. It also has the best stiffness toweight ratio [above 120C (248F)],which means you need less material tomake a high performance component.Stanyl offers design and manufactur-ing possibilities that cost more withother high temperature engineering

plastics both in material, processing,and weight. If youre looking to reduceweight and lower cost by replacingmetal in charge air cooler end caps,Stanyl is the best material choice.

Sealing integrity at elevatedtemperatures. Stanyl exhibitssuperior elevated temperature stressrelaxation resistance when comparedto other high temperature engineeringplastics. During assembly the crimp-ing operation of the metal tube headerto the end cap imparts a substantialstress on the plastic material. Stanyl

offers a significant increase in stressrelaxation resistance over other hightemperature polymers. This resistanceto relaxation is important in order tomaintain an adequate seal load,ensuring an airtight assembly. Thanksto its high level of crystallinity, Stanyl

offers the best combination of creepresistance, stress relaxation resis-tance, and specific gravity of all thehigh temperature polymers, especiallyat temperatures above 120C (248F).

Charge Air Cooler End CapsCharge air coolers are used to cool down the turbocharged air in order toobtain the maximum power out of diesel engines. The charge air coolerand the plastic end caps have to withstand temperatures up to 185C(365F) with pressures up to 1.15 bar. Stanyl TW200F6, well suited forthis high demanding application, demonstrates an excellent fatigue resis-tance and an E-modulus of 4700 MPa at 185C (365F).

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Turbo charging systemsbecome lighter in weight andeconomically attractive. Stanyl

with 30% glass fiber reinforcement is8.5 14.5% lighter than PPS with 40%glass and PPA with 45% glass.Because of its lower specific gravity, aStanyl end cap is significantly lighterthan either of these other two materi-als. Stanyl with 40% glass fiber rein-forcement is 4 - 67% stiffer at 185C(365F) than either of these two othermaterials (its specific gravity is stilllower than either of these). Due to theexceptional strength of Stanyl an endcap that is thinner (and lighter) thanend caps made from either of the twoother materials is possible. Yet, stiff-ness remains unchanged!

Using Stanyl will allow a designer orengineer to develop a part that is thin-ner and lighter than if they were to useeither of the two other materials. Inaddition, due to its rapid rate of crys-tallization, Stanyl will cycle up to 20%faster than the other materials.Because of that, on an annualizedbasis, using Stanyl can reduce yourper-part molding cost by 20%.

Not only will Stanyl process faster,but because of this speed you willrealize significant savings inmachine operating expenses.Furthermore, using Stanyl will giveyou up to 20% extra capacity withyour existing equipment!

Only Stanyl can offer you the combi-nation of weight and cost savingsalong with superior high temperatureperformance and faster processing.Stanyl allows for the production ofturbocharging systems that arelighter weight and less expensive!

Stanyl is the answer for the perfor-mance and cost challenges posedwhen replacing metal in charge aircooler end caps. Ensuring sealingintegrity with its resistance to stressrelaxation at high temperature is justthe beginning. Couple that with excel-lent stiffness well above 120C (248F)with a low density and designers canmake a robust, light weight end capwith less material and lower cost thanwith any other high temperature engi-neering plastic.

Charge Air Cooler End Caps

Stanyl allows you to make lightweight, cost-effective charge air coolers thatare capable of withstanding high pressures, stresses, and heat loads.

Stanyl is 10-20% lighter than othermaterials while maintaining an equivalent stiffness.

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Electrical industry

The temperatures encountered at theinner parts of electrical applicationsare sometimes rather high. This is aresult of the trend towards miniatur-ization or the increase in operatingcurrents. Consequently there is anincreasing demand for materials with:

- higher continuous-use temperatures

- higher stiffness- less creep at elevated

temperatures.

In applications like electric-motor parts,internal parts of circuit breakers, wire-wound components, and switches,Stanyl offers cost-effective solutionsand can easily compete with materialssuch as PPS, PEI, PES, PPA, and LCPin terms of price/performance ratio. Asa result of its outstanding intrinsic prop-erties Stanyl has been successfullyapplied in the following applicationsand end markets:

- connectors- circuit breakers- wire-wound components- SMD components- switches- electric-motor parts- computers and peripherals- telecommunications- electrical and domestic

appliances- consumer electronics.

Electronics industry

The continuing trend towards miniatur-ization of printed-circuit boards leadsto even smaller surface-mount devices(SMD) with even smaller wall thick-nesses. These electronic componentsare more susceptible to the high peaktemperatures involved in modernreflow-soldering techniques.

For these SMD applications materialswith a high heat distortion tempera-ture must be used. Stanyl combinesa heat distortion temperature (HDT)of 290C (555F) with an excellenttoughness and outstanding flowbehavior. Therefore it yields economi-cal solutions and meets the latestdesign requirements for all kinds ofend markets.

Electrical and Electronic Applications

Figure 5 Stanyl out-performs well-known polymers such as LCP and PPS.

Connectors

Stanyl is ideally suited for such applications as disc drive connectors.

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Stanyl High Flow

Stanyl High Flow 46HF5040, a rein-forced, flame retardant PA46, is anew generation of DSM's Stanyl

PA46. Stanyl High Flow combinesthe high strength and toughness lev-els of the standard Stanyl PA46flame-retardant materials with excel-lent flow characteristics virtually thesame as Liquid Crystal Polymers(LCP), a material often used forInformation and CommunicationTechnology (ICT) equipment (seeFigure 6). The Stanyl High Flow V-0grade can replace LCP, resulting in acost savings of up to 50%.

Stanyl High Flow 46HF5040 has anUnderwriters Laboratories (UL) 94 V-0rating at 0.8 mm for all colors and aUL approval for 50-100% regrind use(UL yellow card file number for Stanyl

4/6 is E119177). Stanyl PA46 inher-ently offers high toughness, even indry-as-molded condition. The weld-line strength of the new grade is threetimes higher than that of LCP, enablingconnector manufacturers to post-insertpins directly after injection moldingwithout the risk of cracking, therebyreducing reject level.

Components made of Stanyl HighFlow maintain their dimensionalintegrity during reflow soldering up to280C (535F) due to the extreme highstiffness level of the material at thesetemperatures. This is especially impor-tant for the new lead-free soldering

techniques. While LCP is often speci-fied for such components, the cost ofLCP is significantly higher than that ofStanyl. This costly "overdesign" cannow be eliminated because Stanyl'snew High Flow series, specificallyStanyl 46HF5040, meets the endusers' performance requirement andcan reduce part costs up to 50%.Stanyl can withstand the higher reflowtemperature profiles being driven bythe higher melt temperatures of leadfree solders.

Challenges for the E/Eindustries

Stanyl is ideally suited for variouscomponents in the electrical and elec-tronics industries. Its main feature isits resistance against soldering heat initems such as surface-mount connec-tors, switches, and bobbins.

Surface-mount technology.Stanyl's high heat distortion tempera-ture of 290C (555F) means that com-ponents maintain their dimensionalintegrity during soldering. A clearexample is a surface-mount jack madeof Stanyl, which will retain its dimen-sional integrity at a soldering tempera-ture of 280C (535F), at which otherhigh-performance plastics deform.

Figure 6 With respect to strength, Stanyl High Flow is best in class.

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Connectors

Stanyl meets the requirements forvarious connector designs such asmodular jacks, shrouded headers,power connectors, fine-pitch connec-tors, breakaway connectors, sub-miniature D-connectors, memory-cardconnectors, SIMM sockets, edge-cardconnectors, ZIF-PGA connectors,[DIMM (SDRAM), RDRAM, DDR], andtelephone-handset connectors. All ofthese connectors can be made offlame-retardant Stanyl grades.Connectors used in the automotiveindustry are discussed on page 7.

Processing. With Stanyl an overallcycle-time reduction of up to 30% canbe achieved compared to polyamidesand polyesters, resulting in a clear eco-nomic advantage. It has been demon-strated that the cycle time of an edge-card connector, originally made fromPPS, can be reduced by 50%, withoutany flash being produced and withdimensional specifications being met.

The shrinkage of Stanyl is close to thatof commonly used polyesters andpolyamides. Thus existing tools can beused without any adjustments.

The on-going miniaturization of con-nectors means that wall sections arebecoming thinner and more complex.The excellent flow properties of Stanyl

enable sections as small as 0.1 mm(0.004 in) to be filled without any prob-lem (see Figure 7).

Stanyl is specified in surface-mountfine-pitch connectors with pitches of 0.5 mm (0.02 in). These are used inproducts such as printers, video cam-eras, and lap-top computers.

Even the best-flowing grades of Stanyl

show no flash, in contrast with manyother high flow polymers, such as PPS.

Figure 7 Stanyl's excellent flow properties compared with other glass fiber reinforced, flame-retardant materials.

Stanyl shows no flash, PPS does.(Identical memory-card connectorsmolded with the same tool.)

Stanyl

PPS

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Post-insertion. Stanyl exhibitsexcellent toughness even in dry-as-molded condition, enabling connectormanufacturers to post-insert directlyafter molding without the risk ofcracking (see Figure 8). After condi-tioning, Stanyl is superior to otherthermoplastics.

Pin retention. In Figure 9 the pinretention of Stanyl is compared to thatof PPS, before and after soldering.Stanyl shows a 50% higher retentionforce than PPS after an infrared solder-ing cycle at 260C (500F).

End-wall break-out strength.Shrouded headers are versatile head-ers found in up-market disk drives andswitchboards. As shown in Figure 10,the end-wall break-out strength ofStanyl is higher than that of PPS, PBT,PCT, PPA and PA6T. This enablesdesigners to reduce the wall thicknesswithin existing specifications. More-over, the excellent flow characteristicsof Stanyl enable designers to com-bine the shrouded header with thepower connector and to integrateother functions (all-in-one connectors).For notebook computers these combi-connectors are miniaturized to a 2.0mm (0.08 in) pitch, 50-positioninput/output connector.

Snap-fits, latches, and pegs.Stanyl's toughness allows designersgreat freedom in the design of snap-fits, latches, and pegs. In the case ofhigh-current connectors, safe con-struction is needed to prevent acci-dental separation of mating connec-tors. Stanyl is chosen because itcombines high stiffness with hightoughness, especially in thin sections.This ensures excellent behavior duringrepeated mating cycles.

Figure 9 30% glass fiber reinforced, flame-retardant Stanyl offers a far better pinretention before and after soldering than 40% glass fiber reinforced PPS.

Stanyl and the miniaturization in thedisk-drive industry.

Figure 8 Positioning of glass fiber reinforced, flame-retardant thermoplastics.

Stanyl for SIMM sockets up to 150 mm(6.0 in) in length.

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Moisture absorption. Like allpolyamides, Stanyl absorbs moisturefrom the environment. However,Stanyl offers grades with the requireddimensional stability even when sub-jected to tropical environments. Thesegrades meet even the stringent speci-fications required for SIMM sockets upto an overall length of 150 mm (5.9 in).See Page 25 for more information onmoisture absorption.

Wire-wound components

Many different wire-wound compo-nents are used in transformers, filters,relays and electric motors. They areeither of the standard pin-through-hole or the surface-mount type.Stanyl is chosen for these applica-tions for various reasons pertaining tothe production process.

Winding. The high stiffness andhigh toughness of Stanyl improvethe quality of the bobbin and dimin-ish the reject level after winding.When thermosets or PPS are usedthe reject level can be high due to the

brittleness of these materials. Due toits superior creep performance,Stanyl is better than other polyamidesand PPA's when it comes to with-standing heat-treatment procedures(such as encapsulation) on wire-wound components. For example,Stanyl shows a superior creep perfor-mance at 140C (285F) under a loadof 20 MPa (2,900 psi).

Dip soldering. After winding, thewire is soldered to the connectingpin. This is done by passing the pinthrough a solder bath. The solderbath operates at temperaturesbetween 193C (380F) and 260C(500F). Although the plastic itself isnot in direct contact with the heatsource, heat conducted via the pinsmay soften the plastic and allow thepins to move. Stanyl performs betterin this respect than the widely usedPA66 or PC. PPS is too brittle andshows too much flash.

Processing, post-treatment, and environmental issues such as recy-cling make the use of thermosetsincreasingly unattractive.

Eliminating wrapping film andpotting. Before encapsulation, poly-ester film may be wrapped around thecoil. Stanyl has enabled designers toleave out this extra production step byreplacing the film by hinges which areintegrated with the bobbin, with sec-tions of less than 0.3 mm (0.01 in).The excellent flow of Stanyl enablesprocessors to over-mold the completebobbin. This eliminates the expensivepotting procedure.

Stanyl, a cost-effective solution forwire-wound components.

Figure 10 With Stanyl wall thicknesses can be reduced due to better end-wall break-out strength.

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Electric motors

When a motor is miniaturized while itspower supply remains the same orincreases, its internal temperaturemay rise significantly depending onthe design. Overloading or blockedrotors can lead to temperatures rapid-ly exceeding 250C (40F). Safetymargins may be required for ade-quate functioning.

The UL 1446 classification of Stanyl

guarantees that it will withstand theheat generated during both normaloperation and overload conditions of an electric motor (see Table 3).

Stanyl can be found in various partsof an electric motor, including endlaminates, brush holders, gears, andend brackets.

End laminates. The windingprocess exerts a considerable stresson the end laminate. Brittle materialssuch as thermosets, polyesters, andPPS need a highly controlled windingprocess to prevent cracking.

Production costs are consequentlyhigh. The high toughness of Stanyloffers improved reliability and lowerproduction costs. After winding, the

load on the end laminate can be per-manent, requiring high creep resis-tance at elevated temperatures. Inblocked-rotor situations peak temper-atures of more than 250C (480F)may occur. When combined with aload, these may result in deformationof the plastic, leading to malfunction-ing of the motor. The high HDT ofStanyl [290C (550F)] prevents theoccurrence of such deformations.

Brush holders. Due to the use ofbrushes, significant power lossoccurs at high currents. This, in com-bination with internal friction betweenbrushes and commutator, can resultin temperatures exceeding 220C(425F). Only a limited number ofmaterials can with-stand these condi-tions. Initially thermosets were used, but high production costs led to the

search for alternative thermoplasticmaterials. PPS was found to be toobrittle. Stanyl offers an ideal combi-nation of high stiffness at elevatedtemperatures and toughness, givinggreater reliability at lower cost.

End Laminates

Stanyl is used in vacuum cleaners, lawn mowers, and washing-machine motors for end laminates.

Table 3 UL 1446 Insulation System Recognition for Stanyl PA46.

B 130C (265F) TE350, TE250F6, TE250F8, TE250F9, TW250F6

C 155C (310F) TE200F6, TE250F6, TE250F8, TE250F9

TW200F6, TW250F6, TW300, TW341

H 180C (355F) TE200F6, TE250F6, TE250F8,

TE250F9, TW200F6, TW250F6

For high temperature E/E components,Stanyl is the solution for motor endlaminates.

UL 1446 classes Stanyl Grades

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Gear wheels

The properties of Stanyl make it ide-ally suited for gear wheel applicationswhere severe demands are made on:

- toughness- fatigue resistance- wear resistance- tooth strength.

The advantages of Stanyl becomemore prominent as the temperature of the gear wheels operating environ-ment increases.

Moreover, Stanyl's stiffness at elevat-ed temperatures, its excellent fatiguebehavior and high impact strengthenable gear wheel manufacturers to

use Stanyl instead of metal (see Figure 11). This leads to smootherrunning of the motor combined withnoise reduction. In most casesreplacement of metal will also reducethe total cost price of the assembledgear. Complex shapes can easily bemade in Stanyl and production costswill thus be reduced.

Injection molded gears are used inapplications ranging from motiontranslation in copiers and printers totransmitting torque in the horsepower

range. The ability to be used unlubri-cated, the reduction or elimination ofrunning noise, and the high productivi-ty/low cost potentials of plastics gear-ing are some of the reasons for thehigh growth seen in this area. DSMproduces a broad portfolio of thermo-plastic resins and compounds that canprovide the correct balance of thesecritical properties, meeting the mostdemanding performance criteria in acost-effective form.

Gear Wheels, Bearings, and Bearing Cages

Figure 11 Excellent performance of Stanyl in starter reduction gear wheel.

Starter Gear

The use of Stanyl in this starter gear offered several advantages over theuse of steel such as lower weight and corrosion resistance. In addition,Stanyl provided superior toughness and thermal performance.

Stanyl is used in a variety of gear designs.

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Bearings and bearing cages

Thermoplastic materials havereplaced metal in a number of partsin bearing systems. Stanyl offers aproperty profile which providesdesigners and engineers with theopportunity to improve the perfor-mance or reduce the cost of bearingsand bearing cages:

- high stiffness and creep resis-tance at elevated temperatures

- excellent toughness even in dry-as-molded condition

- superior resistance to chemicals, including lubricant oils such asATF, TAF, and EP oils

- outstanding fatigue resistance- high limiting pressure velocity (PV)

and wear resistance.

As Stanyl retains its superior stiff-ness at elevated temperatures aswell as in aggressive environmentssuch as lubricant oils, designers canuse the parts:

- at higher pressure velocity (PV) limits

- at higher operating temperatures.

Moreover, Stanyl extends the operatinglife of the bearing. At temperatureswhere the diameter of the PA66 bear-ing cage begins to decrease rapidly,the Stanyl bearing cage remainsdimensionally stable (see Figure 12).

Figure 12 Stanyl retains its superior stiffness at elevated temperatures, even inaggressive environments.

Stanyl provides a cost savings for bearing cages.

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General

Stanyl PA46 properties. Theexcellent properties found in Stanyl

lead to important advantages for thecustomer including cost reduction,longer lifetime, and high reliability.Stanyl bridges the gap between con-ventional engineering plastics such asPA6, PA66 and polyesters, and exoticmaterials such as LCP, polysulfonesand PEEK.

- excellent short-term and long-termheat resistance

- high stiffness at elevated temperatures

- high creep resistance, especiallyat elevated temperatures

- outstanding toughness- excellent fatigue behavior- good resistance to chemicals- excellent flow- lower material costs due to

excellent mechanical propertiesallowing thinner walls which leadto weight reduction and lower part prices

- 30% productivity increase ofmolding equipment

- greater design freedom due to excellent mechanical propertiesand good mold-flow behavior

- economical, safe, and convenient processing due to the use of 80C(176F) water-heated molds

- no post-treatment due to absence of flash

- no retooling necessary whenswitching from PA6, PA66 or polyesters.

Stanyl components. Offering aheat deflection temperature of 285C(545F) and a continuous use temper-ature of 166C (330F), Stanyl is an

excellent engineering material for highheat components in the automotive,mechanical, and electrical/electronicsindustries. Stanyl is the material ofchoice for components that mustmaintain structural integrity under highshort-term temperatures (as in IR andwave soldering) or wherever snap-fitdesign or other critical assembly con-siderations are paramount.

High heat. Stanyl's performancecompared with the most importantengineering plastics is illustrated inFigures 18 and 19. With respect to

temperature resistance, unreinforcedStanyl is positioned above the well-known engineering plastics such aspolyamide 6 or 6/6 and polyesters,and just below high performancematerials such as polysulphones,polyetherimides, and polyketones.

If we compare 30% glass fiber rein-forced materials, the heat distortiontemperature of Stanyl even comesvery close to that of PEEK (seeFigure 19).

Characteristic Properties Of Stanyl PA46

Figure 18 High-heat properties of unreinforced engineering plastics.

Figure 19 High-heat properties of 30% glass fiber reinforced engineering plastics.

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Crystallinity

The high crystallization rate of Stanyl

results in the formation of many smallspherulites. This explains the superiortoughness of Stanyl compared withother engineering plastics. In addition,the high crystallization rate of Stanyl

enables faster cooling and thus a short cycle time.

Glass fiber reinforced Stanyl showsan unmatched elongation at break(see Figure 21).

Temperature performance

The temperature performance of everyengineering plastic can be dividedinto:- a peak-temperature resistance or

a short-term temperature resis-tance, expressed by the HeatDistortion Temperature (HDT)

- a resistance to long-term exposureat elevated temperatures underzero-load conditions, expressedby the Continuous- UseTemperature (CUT).

Heat Distortion Temperature.The HDT is a measure of the tempera-ture resistance under a given load. Itis defined as the temperature at whicha test bar shows a pre-defined strain; this is related to the stiffnesslevel at elevated temperatures. TheHDT of Stanyl is much higher thanthat of other engineering plastics:170C (335F) for unreinforced Stanyl

and 290C (555F) for 30% glass fiberreinforced Stanyl.

Figure 20 Impact and temperature resistance of unreinforced engineering plastics.

Figure 21 Tensile and temperature behavior of 30% glass fiber reinforced engineering plastics.

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130C (265F) 20,000 h 12,000 h145C (290F) 10,000 h 6,000 h160C (320F) 5,000 h 3,000 h175C (345F) 2,500 h 1,500 h

Continuous-Use Temperature.The CUT is defined as the temperatureat which a given mechanical property(e.g. tensile strength) of the material isreduced to 50% of its original valuewithin a pre-defined period of time(usually 5,000 or 10,000 hours).

From Figure 22 it can be concludedthat the CUT of glass fiber reinforcedStanyl at 5,000 hours is 170C (335F).The different CUTs for different agingtimes are summarized in Figure 22 fora number of Stanyl grades.

The drop in tensile strength is 50% atthese conditions. The CUTs of Stanyl

and PPA are similar. However, theabsolute value of the tensile strengthof Stanyl at 170C (335F) is signifi-cantly higher than that of PPA. Thisadvantage remains after aging asdemonstrated in Figure 23.

In Table 5 the half-lives (based on ten-sile strength) of two 30% glass fiberreinforced materials, PA66 and Stanyl,are shown at different thicknesses andtemperatures. It is evident that 30%glass fiber reinforced Stanyl offers asuperior performance. The tensile half-life is about 60 to 70% longer than thatof the comparable PA66 grade.

Table 5 Half-life based on tensile strength.

Figure 22 Continuous-use temperatures of some Stanyl grades.

Figure 23 Tensile strength after heat aging.

30% Glass fiber reinforcedTemperature Stanyl PA66

Test specimen 2 mm (0.070 in) thick

Test specimen 4 mm (0.157 in) thick

140C (285F) 20,000 h 12,000 h155C (310F) 10,000 h 6,000 h170C (335F) 5,000 h 3,000 h185C (365F) 2,500 h 1,500 h

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Mechanical properties

The mechanical properties ofpolyamides depend in general on:

- the temperature of their environment- the moisture content - the aging time.

The main factor which influences theabsolute level of these properties is thecomposition of the compound, particu-larly the type and amount of reinforce-ment and additives.

Stiffness. Due to its high crystallini-ty, Stanyl retains a high level of stiff-ness up to temperatures very close toits melting point. This provides widersafety margins for critical applica-tions in comparison with materialslike PA6, PA66, and polyesters. PPAand PPS have a very high modulus atroom temperature but show a signifi-cant drop in stiffness at elevatedtemperatures [above 100C (210F)](see Figures 3, 4, and 25). In prac-tice, Stanyl has a higher stiffness attemperatures >100C (210F).

The stiffness advantage offered byStanyl at elevated temperatures canbe exploited by designing compo-nents with reduced wall sections,some 10 to 15% thinner than thosenecessary for other engineering plas-tics with the same level of glass fiberreinforcement. The weight savingsachieved with Stanyl not only reducesthe price difference between otherengineering plastics and Stanyl, but isalso important for automotive and avia-tion applications where weight savingsis a vital issue.

By adding reinforcements, stiffness lev-els can be increased further (seeFigure 26).

Figure 24 Shear modulus of unreinforced polyamides.

Figure 25 Shear modulus of 30% (PPS 40%) glass fiber reinforced engineering plastics.

Figure 26 Shear modulus of some Stanyl grades. (GF = glass fiber reinforced).

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Creep resistance. For optimumperformance and maximum lifetime,engineering plastics which are sub-jected to long-term loading must havea high creep resistance (i.e. low plas-tic deformation under load).

Stanyl's high crystallinity results in anexcellent retention of stiffness at elevat-ed temperatures [above 100C (210F)]and hence in a creep resistance whichis superior to that of most engineeringplastics and heat-resistant materials.

Figure 27 shows the effect of glass-fiber reinforcement on the creep mod-ulus of Stanyl at 140C (285F) .Creep behavior is one of the factorsthat limit the maximum applicationtemperature of a material. The maxi-mum application temperature ofStanyl is 30C (85F) higher than thatof PA66 and well above that of PPA.

When Stanyl and PA66 are comparedat the same temperature exposure,several alternatives exist:

decrease the wall thickness by using Stanyl (with an equivalent level of reinforcement) reducing material usage and

cost use a Stanyl grade with a lower

level of reinforcement than is possible with PA66 (for equal wallthicknesses) giving greater design freedom

due to a higher elongation at break

facilitating the use of snap-fits lowering material consumption per part due to a lower density.

Figure 27 Creep modulus of unreinforced polyamides.

Figure 28 Creep modulus of glass fiber reinforced (30% or 33%) engineering plastics.

Figure 29 Relaxation behavior.

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Toughness, fatigue, and wearbehavior. While tensile and flexuralstrength decrease with increasing tem-perature, toughness as measured byelongation at break and impact resis-tance increases. Therefore the criticalfactor is usually the toughness perfor-mance at lower temperatures. Due toits fine crystalline structure, unrein-forced Stanyl exhibits extraordinaryimpact resistance in comparison withmany other engineering plastics (seeFigure 20). Notched izod impact valuesremain at a high level even at tempera-tures below 0C (32F) .

The effect of different amounts of glass fiber reinforcement is differentfor both toughness parameters. Withincreasing reinforcement percent-ages, the elongation at breakdecreases while the izod impactresistance increases.

The izod impact resistance of glass-fiber reinforced Stanyl is alsounmatched (see Figure 30). Thismakes Stanyl the material of choicefor demanding applications like inlet-manifold devices and facilitates furtherassembly steps, for instance usinginserts and snap-fits.

Since this is combined with a veryhigh elongation at break (see Figure21 on page 30), Stanyl offers the bestsolution for thin-walled parts, snap-fits,film hinges, and insert molding suchas gears, pulleys, and dip switches.

The high crystallinity and fine crys-talline structure of Stanyl lead to afatigue resistance superior to that ofmost other engineering and heat-resistant plastics (see Figure 31).

The fatigue resistance of Stanyl ismuch better than that of PPA, PPSand PA66. Fatigue resistance is par-ticularly important for gears andchain tensioners.

Figure 30 Impact resistance of glass fiber reinforced engineering plastics.

Figure 31 Fatigue resistance at 140C (F) of glass fiber reinforced engineering plastics.

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Stanyl also has an excellent abra-sion (or wear) resistance and outper-forms many other engineering plas-tics under most conditions. Figure 32shows a comparison betweenStanyl, PA66 and POM with respectto the Taber Abrasion Test (ASTMD1044). Although the coefficients offriction of standard grades of thesematerials are quite similar, Stanyl

outperforms its competitors. The mainreason is its higher PV rating, whichpermits higher pressures or velocities

to be used (see Figure 33). ModifiedStanyl grades with even better wearproperties are available in unrein-forced as well as glass fiber rein-forced form. Its smooth and toughsurface, combined with its stiffness atelevated temperatures, make Stanyl

an ideal material for sliding parts.These include valve lifter guides,chain tensioners, and thrust washers.

Electrical properties, flammability, and UL classifications

Stanyl exhibits high levels of surfaceand volume resistivity, dielectricstrength, and comparative trackingresistance. The exact levels of theseproperties depend on the specificgrade, temperature, and moisturecontent. In general these propertiesare sufficiently retained at elevatedtemperatures to fulfill critical applica-tion requirements.

This fact, in combination with its veryhigh peak temperature resistanceand its high toughness level, makesStanyl an excellent choice for com-ponents which have to be solderedonto a printed-circuit board (PCB).

A number of flame-retardant gradeshave been developed, rated V-0according to the UnderwritersLaboratories UL 94 classification [even at 0.35 mm (0.01 in)].

Figure 33 PV diagram.

Figure 32 Abrasion resistance.

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The unmodified, unreinforced Stanylgrades are rated V-2 and the glassfiber reinforced grades without flameretardant are rated HB. Other classifi-cations according to a number of ULstandards have been obtained for dif-ferent Stanyl grades.

In the Table 3 on page 18 the mostimportant ratings according to ULhave been summarized. Noteworthy isthe class H [180C (355F)] ratingaccording to UL 1446 for the glassfiber reinforced grades of Stanyl.

Chemical resistance

Polyamides are well known for theirresistance to a wide range of chemi-cals. Stanyl is no exception.

Especially at higher temperatures itsresistance to oils and greases isexcellent (see Figures 34 and 35).Stanyl is therefore an ideal materialfor applications under the hood in theautomotive industry and for otherindustrial applications such as gearsand bearings.

Like all other polyamides, Stanyl, too,is attacked by strong mineral acidsand absorbs polar solvents. Infor-mation concerning the resistance ofStanyl to various chemicals and sol-vents is available on request from yourlocal DSM sales office.

Figure 34 Influence of immersion in oil on flexural strength of 30% glass fiber reinforced polyamides.

Figure 35 Retention of mechanical properties (of 30% glass fiber reinforcedpolyamides) after immersion in hot oil.

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Designing With Nylons

Stanyl PA46 are crystalline engineer-ing thermoplastics. Their highly sym-metrical molecular chain structureleads to a high degree of crystallinityand high rate of crystallization. Thisgives Stanyl a decisive technicaledge over other semi-crystalline engi-neering thermoplastics such as nylon6, 6/6, PPA, and polyesters in the per-formance areas of heat resistance,shear modulus at elevated tempera-tures, wear and friction, fatigue resis-tance, and cycle time.

Due to its unique combination of prop-erties, Stanyl can compete across awide range of the engineering plasticsmarket. For instance, some applica-tions which might be designed innylon 6 or 6/6 may actually be moreeconomical to produce in Stanyl ifStanyls faster crystallization ratescan be used to advantage by reduc-ing cycle times enough to more thanoffset the higher cost of Stanyl. Onthe other hand, Stanyl is often used inapplications originally thought to bereserved for high temperature amor-phous resins such as PES, due tothese resins high continuous use tem-perature ratings. In fact, Stanylshigher deflection temperatures underload and higher shear modulus at ele-vated temperatures make it the betterchoice. In recent times, Stanyls highflow characteristics have allowed it towork in application areas oncereserved only for LCPs.

Product design

The product designer should alwayskeep in mind the unique requirementsof Stanyl when designing a newapplication for this product. Like allengineering plastics, Stanyl shrinks

when it cools during the moldingprocess. Its surface appearance isaffected by the surface of the moldand the processing conditions used inthe molding process. Mechanicalproperties can be compromised ifproper processing guidelines are notfollowed. Notch sensitivity can lead topremature failure if sharp corners aredesigned into the product. Each ofthese requirements will be addressedin the following text.

Dimensions. All thermoplastic mate-rials exhibit mold shrinkage to somedegree. As unreinforced material,Stanyl generally shrinks more thantypical amorphous materialsin therealm of 2.0%. The addition of glassreinforcement reduces this value to0.2% to 0.9%, depending on the glassfiber loading (see Figure 13).

Moisture absorption plays a major rolein the prediction of dimensions inStanyl materials. Moisture absorptionis a time and humidity dependent,reversible process which continuesuntil equilibrium is reached.

The designer should anticipate thehumidity conditions in which theproduct will be used. Like shrink-age, the moisture absorption of rein-forced grades differs from those ofunfilled grades.

Unfilled and mineral filled Stanyl

grades are generally isotropic withrespect to shrinkage; that is to say,shrinkage in the direction of flow ismore or less equal to shrinkageacross flow. Glass reinforced gradeson the other hand, show anisotropicproperties. Due to fiber orientation,shrinkage values across the directionof flow are often substantiallygreateron the order of 50% to 100%greaterthan shrinkage values in thedirection of flow. This is the basic rea-son for the warpage which oftenoccurs in parts molded with glassreinforced crystalline materials.

Figure 13 Percent shrinkage with respect to glass content.

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Surface appearance. SomeStanyl grades are capable of a highlevel of reproduction of the mold sur-face. As a general rule, unfilledgrades offer the best reproductionand glass reinforced the worst.Mineral filled or glass/mineral filledgrades typically fall somewhere inbetween. These guidelines are par-ticularly true of high gloss molds.Often textures can be used to hidethe surface imperfections inherent tomolding Stanyl. Higher mold tem-peratures always improve the repro-duction of the mold surface.

Wall thicknesses. Performanceand spatial requirements typicallydetermine the wall thickness of agiven part. Wall thickness should beminimized with discretion to shortenmolding cycles, reduce part weight,and optimize material usage. Theminimum wall thickness which can beused in injection molding depends onthe size geometry of the part and onthe flow behavior of the material.Stanyl PA46 can be molded in wallthicknesses as small as 0.25 mm(0.01 in) in flow lengths less than 100times the wall thickness.

Uniform wall thickness assists consis-tent, even filling of the mold, results inmore predictable shrinkage and war-page, and produces better mechani-cal properties. When varying wallthicknesses are unavoidable for rea-sons of design, gradual transitionsshould be used.

Corners and radii. Sharp internalcorners and the resulting stress risersare among the most common causesof structural plastic product failure. Allnylons are somewhat notch sensitiveand glass reinforced versions are par-ticularly susceptible.

The stresses arising from internal cor-ners can be minimized by the use ofgenerous radii. As a general rule,internal radii equal to one half the wallthickness best distributes the loadsover the surface of the part. Smallerradii cause stress concentrations whilelarger ones do not significantly helpand may actually reduce performance.

External corners should maintain aconstant wall thickness around theradius of the internal corner. Thisreduces variations in wall thicknessand helps prevent warpage, sinksand voids.

Ribbing. Ribs provide a number ofadvantages to the part designer. Theymay increase both the strength andstiffness of the part. By eliminatingheavy cross sections, they can reduceweight and shorten cycle times, bothof which can substantially reducecosts. Ribs are not without their prob-lems, however. Sink marks mayappear on the surface opposite theribs. Often these can be hidden bythe strategic use of texture. Ribs mayalso cause stress at their intersectionwith the wall of the part if properdesign rules are not followed.

In short, while ribs can be a helpful toolfor the product designer, they shouldonly be used when they are necessaryto provide the mechanical performancerequired for the application.

Tooling design

Good product design does not ensurethe success of a project if the tool isnot properly designed and construct-ed. Stanyl PA46 is almost alwaysused in applications where functionali-ty is the key requirement. Since theseparts tend to be expensive, it is essen-tial that the molds produce high qualityparts in a very efficient manner. Thiscan only be achieved if the tool isdesigned and built to the correct stan-dards using high quality tool steels.

Gates and runners. Stanyl PA46requires similar gate and runner sys-tems as other nylons. For unfilledStanyl, the runners can be verysmall to save material scrap andreduce cycle times. Larger partsand/or more highly filled materialstypically require more generousgates and runners. All types of gateshave been used, however sub-gatesare the most common because oftheir automatic de-gating capability.

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Hot runners. Hot runners are verypopular today because they eliminatede-gating operations, allow moredesign freedom for gate positioning,reduce scrap and reduce cycle times.The disadvantages to hot runner useare the startup problems associatedwith getting these systems on cycleand degraded material in the manifoldsystem from long residence times,poor design or improper startup/shut-down practices.

Most of the major hot manifold manu-facturers have built manifolds whichhave been successfully used withStanyl PA46, however, open, exter-nally heated systems work best. Thisallows the melt to pass freely throughthe system without excessive shear,wear, or opportunities for the materialto hang-up.

Regardless of the type of systemused, the system must have severaldistinct characteristics including:

- precise temperature control- sufficient heating capacity- correct gate size and location- proper insulation at the tip of

the nozzle- minimal residence time in

the manifold.

Venting. Like all engineering thermo-plastics, Stanyl PA46 requires ventingto allow gasses to exit the mold as thecavities are filled. Vents should bestrategically placed to allow thesegases to escape at any point in thecavity where gas may be trapped orat the ends of fill. Vents should be0.018 - 0.023mm (0.0007 0.0009 in)deep with a minimum of 0.75mm (0.03 in) land. Secondary vents(relief) should be the same width asthe primary vent and 0.5mm (0.02 in)deep. All vents must eventuallyexhaust to the atmosphere.

Shrinkage and warpage. Due tothe high degree of crystallinity whichStanyl PA46 can achieve, predictingshrinkage and warpage is extremelydifficult. Linear shrinkage informationis available on the individual productdata sheets, which can be found atwww.dsmep.com. The tool designershould always keep in mind that glassfiber reinforced versions exhibit a highlevel of anisotropy.

CAE simulation tools can be of particu-lar value in determining the flow pat-terns within complex parts. On theother hand, extremely critical parts,such as gears, should always be proto-typed before permanent tooling is built.In order to accurately predict shrinkageand warpage it is essential that proto-type tooling and production tooling usethe same gate and runner system.

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Machinery

Stanyl can considerably reducecycle times in comparison with otherengineering plastics due to its veryfast crystallization (see Figure 14).Stanyl PA46 can be processed onstandard plastic processing equip-ment. Typically, general-purposescrew designs with compressionratios of approximately 2.5:1 withsliding check rings work best. Forunreinforced grades, nylon orreversed taper nozzles work well,while reinforced grades typically dobetter with general purpose, freeflowing nozzles. These tend toreduce shear and provide bettermechanical properties and, since thereinforcement inhibits drool, thereverse taper of a nylon nozzle doesnt add much benefit.

Auxiliary equipment. The keypieces of auxiliary equipment includethe material dryer, mold heater, andscrap granulator. Dryers must besized to handle the throughput rate ofthe molding machine used. The keyrequirement of the dryer, however, isits ability to maintain a dew pointbetween -40 and -30C (-40 and -20F). Dew points above this leveldo not facilitate drying. Both vacuumand desiccant bed dryers have beensuccessfully used with Stanyl.

Mold heat may be provided viawater, oil, or electricity. Generallyspeaking, the minimum temperaturerequirements of Stanyl, 80C (180F)may be met with water. On the otherhand, for higher crystallinity, andtherefore superior mechanical prop-erties, Stanyl often is molded at tem-peratures in the range of 100 to

135C (212 to 275F). Oil or electricheat are typically used in these tem-perature ranges. Superior surface fin-ish can be achieved by using evenhigher mold temperatures. Bestreplication of the mold surface canbe achieved by using mold tempera-tures in the range of 150 to 165C(300 to 330F).

Processing Nylon

Figure 14 Cycle times examples of various glass fiber reinforced engineering plastics.

Aliphatic polyamides (PA6 and PA66) 25 - 40%

Semi-aromatic polyamides (PPA) 30 - 45%

Polyesters 30 - 45%

PPS 30 - 50%

Stanyl versus

Table 4 Potential cycle time reduction.

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Scrap granulators should be able toproduce uniform particles which canbe blended with virgin pellets withoutadversely affecting the homogeneityof the melt. In order to achieve this,the granulator screen should besized accordingly. Additionally, theblades must be kept sharp enough tocut the scrap without producingexcessive fines. For recommendedtemperature settings for injectionmolding of Stanyl refer to data pro-cessing sheet located on the websiteat www.dsmep.com.

Material handling

Stanyl granules are supplied dry inairtight moisture proof packing.When working with nylons, it is impor-tant to prevent moisture absorptionbefore molding. Stanyl is hygro-scopic and absorbs moisture fromthe air relatively quickly (see Figure15). Although Stanyl absorbs moremoisture than PA66, the resultingdimensional change at equilibrium isof a similar order (see Figure 16).

At room temperature moistureabsorption will lower stiffness andstrength while increasing toughness.At temperatures above 78C (172F)(the glass transition temperature ofPA46) the effect of moisture absorp-tion on the stiffness of Stanyl is neg-ligible (see Figure 17).

Figure 15 Water absorption of Stanyl PA46.

Figure 16 Dimensional change in length direction due to moisture absorption.

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Should moisture absorption occurprior to molding, there can be anadverse effect on the quality of themolding. During storage, containersshould be kept closed and undam-aged. During molding the followingmeasures are recommended:

- preheat the hopper- open the container just before fill-

ing the hopper- close the container securely if all

the contents have not been used- keep the hopper closed- bring cold granules up to ambient

temperature in the molding shopwhile keeping containers shut.

Every lot of Stanyl is tested for mois-ture content and viscosity. A certifi-cate with the relevant lot data can bedelivered with the materials. Stanyl

PA46 nylons are packaged at a maxi-mum level of 0.08% moisture content.The ideal processing content is0.02% or less. Moisture contents ofbetween 0.02% and 0.05% areacceptable. Higher levels can havea dramatic effect on both flow andmechanical properties.

Regrind. Regrind can often be asource of processing problems. Thekeys to successful use of regrind are:Particle size similar to that of the vir-gin pellets; Regrind is kept clean anddry. For best results, regrind contentshould be limited to 20%, however,some Stanyl grades have UL ratingsup to 100% regrind.

Safety. Under normal conditions,Stanyl does not present a toxic haz-ard through skin contact or inhala-tion. During processing, contact withthe polymer melt and inhalation of thefumes should be avoided. A materialsafety data sheet can be requestedfrom DSM customer service.

Processing conditions

The injection-molding unit shouldalways be clean upon startup.Cleaning can be carried out by purg-ing with HDPE or a number of com-mercially available purging com-pounds. Only purging compoundscapable of withstanding the high pro-cessing temperatures of Stanyl [up to320C (610F)] should be used.

In order to establish the optimum pro-cessing temperatures, one should beaware of the upper and lower temper-ature limits for the processing ofStanyl. Like other nylons, Stanyl

degrades at melt temperatures above330C (625F) even at short residencetimes. Lower temperatures increasethe allowable residence time.

The temperature of the melt is depen-dent upon the setting of the barreltemperatures, the screw configura-tion, the screw speed and the back-pressure. Therefore it is essential tomeasure the actual melt temperatureafter the injection molding processhas been running on line for sometime and the processing conditionshave been stabilized.

Figure 17 Influence of moisture uptake on shear modulus of glass fiber reinforcedpolyamides.

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Barrel temperatures. Due to thehigh melting point and high crys-tallinity of Stanyl, barrel tempera-tures need to be set high enough toprovide a homogeneous melt withoutgetting too near the degradationpoint of Stanyl at 330C (625F).

Screw rotation speeds. Likemost polyamides, Stanyl has excel-lent flow properties due to its relative-ly low melt viscosity. The effect ofscrew rotation speed on the amountof shear which is transmitted to themelt is relatively low and high screwspeeds can generally be used with-out harm to the polymer. With glassreinforced grades, care should betaken not to reduce the glass fiberlength. The lowest screw speedwhich allows the screw to recoverwithin the cooling portion of the cycleshould always be selected.

Back pressure. Effective backpressure of 7.5 bar (100 psi) is rec-ommended for processing Stanyl tohomogenize the melt and preventgas entrapment. If back pressure is

set too high, [~20 bar (300 psi)] itmay cause increased screw recoverytime, nozzle drool and reduction ofglass fiber length.

Injection speeds/pressures.Due to the fast solidification ofStanyl, high injection speeds arerequired in order to obtain goodpacking and surface finish.Generous mold venting is thereforenecessary to avoid burning at theend of the flow path.

Holding pressure/holding time.For optimum appearance and dimen-sional control, holding time plays animportant role. In principle, the hold-ing time should be the time it takesfor the gate to freeze. In general, theholding time of Stanyl is very shortcompared to other engineering plas-tics due to its fast solidification. Sinkmarks and voids caused by volumet-ric shrinkage can be reduced byadequate holding time and pressure,however the holding pressure shouldnot be so high that stresses areinduced. One method of determining

the correct level is by increasing theholding pressure until no sink marksare visible. After completely coolingdown, the part is then cut open at itsthickest cross section and inspectedfor voids. If necessary, the holdingpressure is increased.

One method to determine properholding time is to weigh the partswithout the sprue and increase hold-ing time until constant weight isachieved. A more sophisticatedmethod is to use pressure transduc-ers in the cavity to determine theexact moment of gate freeze-off.This method was used to demon-strate that a 3.2mm (1/8 in) UL barmolded of Stanyl needed only halfthe holding time of a similar nylon 6/6part. This, combined with highermold ejection temperatures, explainsthe very short cycle times comparedto other engineering plastics.

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Mold temperature/cooling time.Because of the fast solidification ofStanyl, the cooling time is very short.For this reason screw recovery timewill generally be the determining stepfor the cycle time. Processing Stanyl

can in principle be done on a widerange of mold temperatures. Moldtemperatures above 80C (180F) arerecommended for good dimensionalstability and flow properties. Toreduce post-mold shrinkage, increaseflow performance, increase weld linestrength, increase toughness andimprove surface appearance, themold temperature may be increasedup to 120C (250F) or even higher.

Mold ejection. Stanyl generallydoes not stick to mold surfaces andhas good ejection properties. Due tothe high crystallization rate, the sur-face solidifies very fast and has a highstiffness at high temperatures. There-fore, Stanyl can be ejected at relative-ly high temperatures, such as 200C(390F), resulting in short cycle times.

Cycle interruptions. When a shortbreak during production is expected,the hopper should be closed, the bar-rel emptied, and the screw put intothe forward position. Barrel tempera-tures may be maintained. For cycleinterruptions of one to two hours, thesame procedure should be used,however the barrel temperaturesshould be lowered to 260C (500F).When starting up, first purge withfresh material. For flame retardantgrades purge the barrel with HDPEbefore allowing the machine to sit idle.

Shutdown/cleanup. Empty thehopper and purge the screw with highmelt viscosity HDPE. Lower the barreltemperatures during purging to therequired level of the next polymer tobe processed.

Secondary-treatment

Plastic parts are often subjected to afinishing operation after the actualproduction step. This can be a func-tional operation such as machining,gluing, welding, screwing or snap fit-ting, or a decorative treatment, suchas vacuum metallization, electroplat-ing, lacquering, printing or laser mark-ing. For more information on thesetreatments please refer to the sec-ondary-treatment technical articles onthe DSM web site at www.dsmep.com.

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Akulon Nylon 6 and 6/6 in both unreinforced and reinforced nylons grades, including flame retardant products.

Arnite Unreinforced, reinforced, and flame retardant grades offeringthermoplastic polyester dimensional stability and low moisture absorption with good

chemical resistance.

Arnitel High performance elastomers based on polyester.copolyester elastomers

Electrafil Electrically conductive thermoplastic materials providing ESD and conductive thermoplastics EMI shielding.

Fiberfil Reinforced and filled polypropylenes.reinforced & filled thermoplastics

Nylatron Internally lubricated nylons to enhance wear and friction properties.lubricated thermoplastics

Plaslube Internally lubricated nylons to enhance wear and friction properties.lubricated thermoplastics

Stanyl High temperature nylon which bridges the price-performance gapPA46 between traditional nylons and high-performance materials.

Xantar Unreinforced, reinforced, and flame retardant grades with outstanding polycarbonate impact resistance, dimensional stability, and high heat deflection

temperature.

DSM EP - Americas Product Portfolio

1-800-333-4237www.dsmep.com

2002 DSM Engineering Plastics Printed in the USA 11/02 2,500

Akulon, Arnite, Arnitel, Electrafil, Fiberfil, Nylatron, Plaslube, Stamylan, Stanyl, Stapron, Xantar, and Yparex are registered trademarks of DSM Engineering Plastics.

North AmericaDSM Engineering PlasticsP.O. Box 33332267 West Mill RoadEvansville, IN 47732-3333Tel. 812 435 7500Fax 812 435 7702www.dsmep.com

EuropeDSM Engineering PlasticsPoststraat 16130 AA SittardThe NetherlandsTel. 31 46 477 04 50Fax 31 46 477 3959www.dsmep.com

Asia PacificDSM Engineering Plastics10A, China Overseas BuildingNo. 25 Chongqing Zhong RoadShanghai 200020 Tel. 86 21 6386 3080Fax 86 21 6386 2198www.dsmep.com

CoverProduction SitesMission StatementTable of ContentsIntroductionStanyl PA46 overviewStanyl PA46 product scope

Automotive ApplicationsEngineTransmissionEngine-management systemsSensorsAlternators, starters and small electric motorsTubingCharge air cooler end caps

Electrical and Electronic ApplicationsElectrical industryElectronics industryStanyl High FlowChallenges for the E/E industriesConnectorsWire-wound componentsElectric motors

Gear Wheels, Bearings, and Bearing CagesGear wheelsBearings and bearing cages

Characteristic Properties of Stany PA46GeneralCrystallinityTemperature performanceMechanical propertiesElectrical properties, flammability, and UL classificationsChemical resistance

Designing with NylonsProduct designTooling design

Processing NylonMachineryMaterial handlingProcessing conditionsSecondary-treatment

DSM EP - Americas Product PortfolioContact Information