SuperstructuralSeminar_3_06_06

DuPont Superstructural Web SeminarPUSHING BACK THE BARRIERS TO METAL REPLACEMENT

February 28, 2006

DuPont Superstructural Web SeminarPUSHING BACK THE BARRIERS TO METAL REPLACEMENT

The information and suggestions provided in this on-line seminar are based on data believed to be reliable, but the DuPont Company makes no warranties express or implied as to their accuracy and assumes no responsibility or liability arising out of its use by others. Further, the information and suggestions are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a particular material for a particular purpose. DuPont makes no guarantee of results and assumes no obligation or liability in connection with the use of the information or suggestions provided in this seminar.

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Pushing Back the Barriers to Metal Replacement

Presented by:

Bob TabaskoSuperstructural Market Development Leader

Gary KozielskiTechnical Consultant Superstructural Products

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Agenda

Introduction to Superstructural1

Product Line Portfolio2

Key Properties3

Major Benefits Versus Metals & Other High Performance Polymers4

Applications5

Summary6

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Family of resins with exceptional structural properties

Potential to provide: ultra high, consistent stiffness and strength capability outstanding impact performance excellent creep resistance structural performance at elevated temperatures

Based upon: Zytel® HTN high performance polyamide technology (greater than 35% glass reinforced) Long glass fiber reinforced Zytel® HTN and PA66 resins Rynite® glass-reinforced polyester

The Introduction to Superstructural

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The Introduction to Superstructural

Less than 4% of metal applications have been converted to engineering plastics.

Superstructural grades open up a host of new metal replacement opportunities!

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Agenda

Key Properties3


Applications5

Summary6



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Unreinforced

Tens

ile S

tren

gth

Tensile Modulus

Reinforced StandardEP Resins

Steel

ZnAl

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Unreinforced

Tens

ile S

tren

gth

Tensile Modulus

Reinforced StandardEP Resins

Steel

ZnAl

Future

Superstructural

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Superstructural Key Grades

75LG60HSL60

75LG50HSL50

75LG40HSL40Long Length

70G60HSL60

Rynite® 555 (55% glass)54G50HSLR53G50HSLR50

Rynite® 54552G45HSL51G45HSL45Standard Fiber Length

Rynite®

PETZytel®PA66

Zytel®HTN54

Zytel®HTN53

Zytel®HTN52

Zytel®HTN51

Filler Level

Reinforcement Type

51LG50HSL

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Key Features of the Zytel® HTN Product Families

Good toughness

High burst pressure and knit line strength

Retention of propertieswith moisture

Retains high level of stiffness up to 110°C

Water heated tools

PPA resin

Highest stiffness/strength at ambient temperatures

Good toughness

Outstanding surface finish

Water heated tools

Highest melting point and deflection temperature

Moldable in water heated tools

PPA resin

Outstanding retention of properties with moisture

Improved dimensionalstability

Retains high level of stiffness up to 140°C

PPA resin

HTN54 SeriesHTN53 SeriesHTN52 SeriesHTN51 Series

Superstructural • Ultra Stiff• High Strength• Excellent Creep Resistance

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Agenda

Key Properties3


Applications5

Summary6



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What is Zytel® HTN

Zytel® HTN high performance polyamides are partially aromatic nylons.

Most, but not all, Zytel® HTN resins fall within the narrower family of polymers known as PPA (Polyphthalamide), within which they offer perhaps the best combination of highest performance and ease of processing.

C- -C-]O O

[- NH-(CH 2 ) 6 - NH -

Aromatic Di-acid

n

Di-amine

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What is Zytel® HTNDue to its Aromatic Ingredient, Parts Made With Zytel® HTN Have Excellent Chemical Resistance, and High Temperature Performance

Polyamide

Aliphatic Aromatic (Partially) Aromatic (Partially) PPA

Aromatic (Fully) Aramid

0% Less Than 55% 55% or More 100%

AromaticDi-Acids

Zytel® PA66 Zytel® PA6 Zytel® PA612

KEVLAR®

NOMEX®

HTN51HTN52HTN54Other PPAs

HTN53PAMXD6PA66 + PA6I/6T

Examples:

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Long Fiber Reinforced Thermoplastics

Superstructural: LFRTs

Fiber length in granules—12 mm

Fiber length in molded parts are typically 3–4 mm versus 0.3 mm for standard glass fiber resins

Component design plus processing conditions govern average fiber length and therefore part performance

Knit line strength of LFRTs may also be an issue for certain designs

Specific guidelines are available from DuPont for both of these points

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Ultra High Strength and StiffnessSt

ress

at B

reak

(MPa

)

ISO

527

Tensile Modulus DAM (GPa) ISO 527

260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GFPPS 40% GF

PPS 50% Long Glass

PP 50% Long glass

PBT 50% GF

Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH

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ress

at B

reak

(MPa

)

ISO

527


260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GFPPS 40% GF

PPS 50% Long Glass

PP 50% Long glass

PBT 50% GF


DuPont EP Superstructural standard glass fiber reinforced products Zytel® HTN51G45HSL

Zytel® HTN53G50HSLR

Zytel® HTN52G45HSL


Rynite® 545Zytel® 70G60HSLRynite® 555

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ress

at B

reak

(MPa

)

IS

O 5

27


260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GFPPS 40% GF

PPS 50% Long Glass

PP 50% Long glass

PBT 50% GF


DuPont EP Superstructural standard glass fiber reinforced products Zytel® HTN51G45HSL


Zytel® HTN52G45HSLZytel® HTN54G50HSLR

Rynite® 545Zytel® 70G60HSL Rynite® 555

DuPont EP Superstructural long glass fiber reinforced products

Zytel® 75LG40HSL

Zytel® 75LG50HSL

Zytel® HTN51LG50HSL

Zytel® 75LG60HSL

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Long Glass—High Notched Impact Strength and ModulusN

otch

ed C

harp

y Im

pact

Str

engt

h (k

J/m

2 )

ISO

179

Tensile Modulus (GPa) ISO 527

70

60

50

40

30

20

10

0

Polyamides conditioned to 50% RHGlass fiber reinforced engineering polymers

DuPont EP Superstructural standard glass fiber reinforced products

PA46 50% GF

PA66 43% GF

PPS 40%GF

PP 50% Long glass

Zytel® HTN51G45HSL


Zytel® HTN54G50HSLRRynite® 545

Zytel® 70G60HSL

Rynite® 555

6 10 12 14 16 18 208

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Long Glass—High Notched Impact Strength and ModulusN

otch

ed C

harp

y Im

pact

Str

engt

h (k

J/m

2 )

ISO

179

Tensile Modulus (GPa) ISO 527

70

60

50

40

30

20

10

0

6 10 12 14 16 18 20

Polyamides conditioned to 50% RH

8

PA46 50% GF

PA66 43% GF

PPS 40%GF

PP 50% Long glass

Zytel® HTN 51G45HSL


Zytel® HTN54G50HSLRRynite® 545

Zytel® 70G60HSL

Rynite® 555

Glass fiber reinforced engineering polymers

DuPont EP Superstructural standard glass fiber reinforced products

DuPont EP Superstructural long glass fiber reinforced products

Zytel® 75LG40HSL

Zytel® 75LG50HSL

Zytel® 75LG60HSL

Zytel® HTN51LG50HSL

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Long Glass—Resins Increase Multiaxial Impact PerformanceZytel® Long Glass resins not only offer higher drop weight impact and notched impact resistance, but the nature of the break is more contained

0

5

10

15

20

25

PA66 50% GR BK Zytel® 75LG50L NC010

Energy to Max Load Total Energy

Joul

es

PA66 50% GR BK Zytel® 75LG50L NC010

DAMISO 6633 mm Disc

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Benefits Through Mechanical Properties

Zytel® HTN Superstructural grades provide an excellent balance of strength, stiffness and impact performance compared to other glass fiber reinforced polyamides. Very low moisture effects give a major advantage…

Stress at Break (MPa) Tensile Modulus (GPa)

0

50

100

150

200

250

300

HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR

DAM 50% RH

0

2

4

6

8

10

12

14

16

18

20

HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR

DAM 50% RH

ISO 527

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Extending Temperature Extremes

Long glass fiber increases the deflection temperature, allowing higher loads as temperatures heat up.

235

240

245

250

255

260

265

270

275

280

285Standard Glass Long Glass

DTU

L, ºC

I

SO

75

PA66 50% GR

Zytel® 75LG50HSL

HTN51G45HSL

HTN51LG50HSL

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Agenda

Key Properties3


Applications5

Summary6



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The Superstructural family offers a superb combination of stiffness, strength and impact resistance coupled with specific grades that are able to deliver a high temperature capability.

Superstructural: Key Benefits

They Can Provide The opportunity to enjoy the benefits of replacing metals in high performance components

that were previously unable to be made in standard engineering polymers

The possibility of producing plastic components with superior performance or alternatively with thinner section thereby reducing total cost and weight of parts

We will look at these areas more closely…

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DuPont Superstructural gradesoffer many major benefits versus metals.

Let’s remember the key advantages...

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Major Weight Savings Opportunities

Lighter weight provides savings in many different ways:

• Easier handling of parts• Reduced shipping costs• Automotive fuel efficiency

COPPER

BRASS

STEEL

CAST IRON

DIECAST ZINC and ZA ALLOYS

ALUMINUM ALLOYS

MAGNESIUM ALLOYS

SUPERSTRUCTURAL POLYMERS

10

9

8

7

6

5

4

3

2

0

1D

ensi

ty (g

/cc)

Incr

easi

ng w

eigh

t per

com

pone

nt

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Benefits Through Light Weight Strength

Specific Tensile Strength (MPa/s.g.)

0 50 100 150 200

Zinc

Mild Steel

Aluminum Alloy

Magnesium Alloy

Superstructural Polymers

versus Aluminum = >40%

weight savings with

comparable strength !

up to 163

133

95

52

34

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Time and Cost Saving Through Reduced Number of Processing Steps

Diecasting

Metal Ingots

Meltdown - cold chamber

MoldingFinishing

Painting

Finished part

6 Steps6 steps

Granules

Injection

Molding

Finished Part

Injection molding

Only 3 Steps

Sheet metal construction

Sheet metal

Stamping

DrillingCuttingBending

Assembly

Painting

Finished part

6 Steps

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Beware: when replacement costs of diecast tools are amortized into your part cost, the expense can really add up!

Cost Savings Through Much Longer Average Tool Life

200

400

600

800

1,000

1,200

Num

ber o

f Sho

ts (k

)

150 k

Aluminum

300 k

Magnesium

450 k

Zinc

1000 k

DuPont Superstructural

Engineering Polymers

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Opportunity for cost saving and functional benefits through part integration

Other Major Benefits versus Metals

Potential for highly innovative new designs

Higher corrosion resistance

Better surface finish with integral colors

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Other Major Benefits versus Other High Performance Polymers

DuPont Superstructural grades offer key benefits over some other polymers that you may consider...

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Zytel® HTN53G50HSLR versus PAMXD6

Components with much better toughness and overall balance of properties

Opportunity for reduced volume cost

Reduced processing costs

Reduced cycle time leads to higher production rates

Significantly better impact and elongation to break values

Lower density (2.5% with 50% glass level)

Mold tool temperature of 90°C compared to 140°C plus

Less flash

Faster set up (crystallization rate)

Versus PAMXD6(Polyarylamide)

Customer BenefitsHTN53 Series Advantages

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Zytel® HTN54 series versus other PPA Resins

Components with greater durability in high abuse situations

Easier molding and potential for reduced cost

Higher overall toughness (impact and elongation to break)

Water heated mold capability

Versus Other PPA Resins

Customer BenefitsHTN54 Series Advantages

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Zytel® LFRTs versus Long Fiber Reinforced PP

Opportunity to have higher performance parts or thinner section components with same performance

Components with greater durability in high abuse situations or new markets

Parts with extended performance capability or opportunity to open up new markets

Ability to develop components for more demanding environments.Greater reliability of part performance

Significantly higher strength (>70% increase)

Much higher notched impact strength (>65%increase)

Higher stiffness particularly at elevated temperatures

Vastly improved thermal properties (DTUL at 1.8 MPa for 75LG50HSL is 260°C versus 160°C for Long Fiber PP)

Versus Long FiberReinforced PP

Customer BenefitsZytel® LFTR Advantages

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Agenda

Key Properties3


Applications5

Summary6



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Applications

The benefits of DuPont Superstructural products in action...

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Tractor Hinge—Zytel® HTN53

•High rigidity, impact resistance and tensile strength

•Lower cost versus aluminum

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Brake Booster—Zytel® HTN51

•High strength and low warp

•Lighter weight due to reduction in wall thickness (60% lighter than thermoset)

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Spline for Auto Arm Rest Retractor Mechanism Zytel® HTN53

• The spline can be subject to high loads and abuse situations

• Previously made from machined diecast metal—heavy and costly

• Zytel® HTN53 series offers high modulus, strength and very good impact properties

• Lighter weight and lower cost than metals, and the parts require no finishing

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Structural Parts for Mobile Telephones Zytel® HTN53

• The main frame of a mobile phone is required to hold the sophisticated electronics firmly in place, protect them if dropped, be dimensionally stable and resist exposure to household chemicals

• Zytel® HTN53 offers high stiffness, very good impact resistance, and outstanding surface finish.

• Zytel® HTN53 can be molded to close tolerances using water heated molds

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Windowlift Motor Gear Housing Zytel® HTN51

•Previously cast aluminum

•Weighs 30% less than cast aluminum housing

•Higher efficiency

•Excellent retention of stiffness and strength at elevated temperatures, chemical resistance, low warpage and low shrinkage

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Boat Propeller—Rynite® 555

The stiffness and strength of Rynite® 555 is a key factor in limiting blade deflection and preventing deformation during fast starts and high-speed running.

•Higher performance

•Cost advantage

•No corrosion

•Engine protection

•Easy mounting

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Agenda



Key Properties3

Major Benefits Versus Other Plastics4

Applications5

Summary6

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Outstanding Strength Rigidity Toughness High Temperature Capability

Allowing you to enjoy the benefits of Polymers in highly demanding application areas

weight saving, anti-corrosion, part cost, colors, integration…

New Superstructural…

Pushing Back the Barriers to Metal Replacement!

Summary

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Thank you for joining us today.Please send in any questions using the Q&A function.

We will be answering questions for the rest of the hour. Depending on demand, we may not be able to answer your question straight away. All questions will be logged and any questions unanswered at the end of the session will be followed-up via email.Alternatively, please contact your local DuPont representative or log on to plastics.dupont.com and click on the Contact Us button.

For questions about our products and how to use them, call us at the following numbers:800-441-0575 or International 302-999-4592

Or visit us at: plastics.dupont.com

Copyright © 2006 DuPont or its affiliates. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles of science™, Rynite®, Zytel®, NOMEX®, and KEVLAR® are registered trademarks or trademarks of DuPont or its affiliates.

SuperstructuralSeminar_3_06_06

Documents

tensile modulus

customer benefits

ultra high

tensile modulus

metal replacement

pushing back

metal replacementsteel

part cost