SILESIAN UNIVERSITY OF TECHNOLOGY

MATERIAL SELECTION OF TEFLON LEVEL 2 Dr inz. Zbigniew BRYTAN Institute of Engineering Materials and Biomaterials Prepared by Efekan BAKIR

 CONTENTS 1.INTRODUCTION 2.HISTORY OF TEFLON 3.PROPERTIES 3.1. Characteristics Of Teflon 3.2. What Properties Make Teflon Non-Stick? 4.1. Raw Materials 4.2. The Manufacturing Process 4.2.1. Making the TFE 4.2.2. Suspension Polymerization 4.2.3. Dispersion polymerization 4.2.4. Nonstick cookware 4.3. Quality Control 4.4. Byproducts/Waste 5.1. Teflon PTFE 5.2. Teflon ETFE 5.3. Teflon FEP 5.4. Teflon PFA 5.5. Teflon-S One Coat 5.6. Silverstone SUPRA

4. MANUFACTURING OF TEFLON

5.TYPES OF TEFLON COATINGS

6.MATERIAL SELECTION 7.CONCLUSION 8.REFERENCES

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1.INTRODUCTION
Teflon is the registered trade name of the highly useful plastic material polytetrafluoroethylene (PTFE). PTFE is one of a class of plastics known as fluoropolymers. A polymer is a compound formed by a chemical reaction which combines particles into groups of repeating large molecules. Many common synthetic fibers are polymers, such as polyester and nylon. PTFE is the polymerized form of tetrafluoroethylene. PTFE has many unique properties, which make it valuable in scores of applications. It has a very high melting point, and is also stable at very low temperatures. It can be dissolved by nothing but hot fluorine gas or certain molten metals, so it is extremely resistant to corrosion. It is also very slick and slippery. This makes it an excellent material for coating machine parts which are subjected to heat, wear, and friction, for laboratory equipment which must resist corrosive chemicals, and as a coating for cookware and utensils. PTFE is used to impart stain-resistance to fabrics, carpets, and wall coverings, and as weatherproofing on outdoor signs. PTIZE has low electrical conductivity, so it makes a good electrical insulator. It is used to insulate much data communication cable, and it is essential to the manufacture of semi-conductors. PTFE is also found in a variety of medical applications, such as in vascular grafts. A fiberglass fabric with PTFE coating serves to protect the roofs of airports and stadiums. PTFE can even be incorporated into fiber for weaving socks. The low friction of the PTFE makes the socks exceptionally smooth, protecting feet from blisters. [1]

Figure1:Polytetrafluoroethylene

2.HISTORY OF TEFLON
PTFE was accidentally discovered in 1938 by Roy Plunkett, in New Jersey while he was working for Kinetic Chemicals. As Plunkett was attempting to make a new chlorofluorocarbon refrigerant, the tetrafluoroethylene gas in its pressure bottle stopped flowing before the bottle's weight had dropped to the point signaling empty. Since Plunkett was

measuring the amount of gas used by weighing the bottle, he became curious as to the source of the weight, and finally resorted to sawing the bottle apart. Inside, he found it coated with a waxy white material which was oddly slippery. Analysis of the material showed that it was polymerized perfluoroethylene, with the iron from the inside of the container having acted as a catalyst at high pressure. Kinetic Chemicals patented the new fluorinated plastic (analogous to known polyethylene) in 1941, and registered the Teflon trademark in 1945. DuPont, which founded Kinetic Chemicals in partnership with General Motors, was producing over two million pounds (900 tons) of Teflon brand PTFE per year in Parkersburg, West Virginia, by 1948. An early advanced use was in the Manhattan Project as a material to coat valves and seals in the pipes holding highly reactive uranium hexafluoride at the vast K-25 uranium enrichment plant at Oak Ridge, Tennessee.[2]

Figure2:Shape of PTFE

In 1954, French engineer Marc Grgoire created the first pan coated with Teflon non-stick resin under the brand name of Tefal after his wife Collete urged him to try the material he had been using on fishing tackle on her cooking pans. In the United States, Kansas City, Missouri resident Marion A. Trozzolo, who had been using the substance on scientific utensils, marketed the first US-made Teflon coated frying pan, "The Happy Pan", in 1961.In the 1990's, it was found that PTFE can be radiation cross-linked above its melting point and in an oxygen free environment. Electron beam processing is one example of radiation processing. Cross-linked PTFE has improved high temperature mechanical properties and radiation stability. This is significant because for many years irradiation at ambient conditions has been used to break down PTFE for recycling. The radiation induced chain scissioning allows it to be more easily reground and reused. [3]

3.PROPERTIES
PTFE is a thermoplastic polymer, which is a white solid at room temperature, with a density of about 2200 kg/m3. According to DuPont, its melting point is 600 K (327 C; 620 F). Its mechanical properties degrade gradually at temperatures above 194 K (79 C; 110 F).PTFE gains its properties from the aggregate effect of carbon-fluorine bonds, as do all fluorocarbons. The only chemicals known to affect these carbon-fluorine bonds are certain alkali metals and most highly reactive fluorinating agents. [4]

Table1:Properties about Teflon

3.1. Characteristics Of Teflon Below you can find the most uprising characteristics of this material which makes it useful for tons of industrial and domestic applications in our daily life:

- Resistant to many chemicals This includes ozone, chlorine, acetic acid, ammonia, sulfuric acid and hydrochloric acid. The only chemicals known to affect these coatings are molten alkali metals and highly reactive fluorinating agents. - Weather and UV resistance - Non stick Very few solid substances will permanently adhere to a Teflon coating. While tacky materials may show some adhesion, almost all substances release easily. - Excellent optical properties - Outstanding performance at extreme temperatures In fact it can temporarily withstand temperatures of 260C and cryogenic temperatures of -240C and still have the same chemical properties. It has an initial melting point of 342C (+- 10C) and a secondary melting point of 327C (+- 10C). - Low coefficient of friction. It is the ratio of the force required to make two surfaces slide over each other. A low number equals low resistance and smooth operation. This indicates the difficulty in sliding one surface against another. The coefficient of friction is generally in the range of 0.05 to 0.20, depending on the load, sliding speed, and type of Teflon coating used. - Non wetting Teflon finishes are both hydrophobic and oleophobic, cleanup is easier and more thorough. - Exceptional dielectric properties Teflon has a high dielectric strength over many different frequencies, low dissipation factor and high surface resistivity. Dielectric strength is the high voltage that the insulating material can withstand before it breaks down. In addition it has a low dissipation factor; this is the percentage of electrical energy absorbed and lost when current is applied to an insulating material. A low dissipation factor means that the absorbed energy dissipated as heat is low.The high surface resistivity refers to the electrical resistance

between opposite edges of an unit square on the surface of an insulating material.[5] 3.2. What Properties Make Teflon Non-Stick? Teflon is DuPonts Tradmarked brand name for PTFE polytetrafluoroethylene, a polymer. It is a long chain polymer, one of the biggest known to science. It is a solid fluorocarbon, and is hydrophobic. This means that it rejects water. It is very stable and inert, due the high strength of the carbon-fluorine bonds, but its properties do degrade with temperature. Slipperiness is measured by a materials coefficient of friction. It has a waxy feeling to the touch. Only two other solids are more slippery aluminium magnesium boride, and diamond. Both these are very hard materials, unlike PTFE. Stickiness is due to what are known as Van Der Waals forces. These forces operate at a molecular level between materials. They give the Gecko its ability to climb walls unless of course they are coated with Teflon. Teflon is unique in this respect. The pads on a Geckos feet have a relatively high Van der Waals force (actually a sum of three different forces), but Teflons are very low. So, there is little attraction or stickiness.

Figure3:Temparature-time graphic

Its other properties include creep. This is the ability to stretch without relaxing to its previous dimensions when strain is removed. It makes PTFE ideal for seals. Hence, it is loved by plumbers.It is subject to wear where surfaces have regular relative movement, despite its slippery nature. It is now being combined with lubricants such as molybdenum disulphide which result in advanced composites which are ideal for hi-tech bearings typically used in aerospace applications.[6]

4. MANUFACTURING OF TEFLON
4.1. Raw Materials PTFE is polymerized from the chemical compound tetrafluoroethylene, or TFE. A non-stick pan is composed of varying non-stick layers. TFE is synthesized from fluorspar, hydrofluoric acid, and chloroform. These ingredients are combined under high heat, an action known as pyrolosis. TFE is a colorless, odorless, nontoxic gas which is, however, extremely flammable. It is stored as a liquid, at low temperature and pressure. Because of the difficulty of transporting the flammable TFE, PTFE manufacturers also manufacture their own TFE on site. The polymerization process uses a very small amount of other chemicals as initiators. Various initiators can be used, including ammonium persulfate or disuccinic acid peroxide. The other essential ingredient of the polymerization process is water.[7]

Figure4:Raw Material

4.2.The Manufacturing Process PTFE can be produced in a number of ways, depending on the particular traits desired for the end product. Many specifics of the process are proprietary secrets of the manufacturers. There are two main methods of producing PTFE. One is suspension polymerization. In this method, the TFE is polymerized in water, resulting in grains of PTFE. The grains can be further processed into pellets which can be molded. In the dispersion method, the resulting PTFE is a milky paste which can be processed into a fine powder. Both the paste and powder are used in coating applications. 4.2.1. Making the TFE Manufacturers of PTFE begin by synthesizing TFE. The three ingredients of TFE, fluorspar, hydrofluoric acid, and chloroform are combined in a chemical reaction chamber heated to between 1094-1652F (590-900C). The resultant gas is then cooled, and distilled to remove any impurities. Teflon con be used on a wide variety of cookware.

Figure5:Teflon being process

4.2.2. Suspension Polymerization The reaction chamber is filled with purified water and a reaction agent or initiator, a chemical that will set off the formation of the polymer. The liquid TFE is piped into the reaction chamber. As the TFE meets the initiator, it begins to polymerize. The resulting PTFE forms solid grains that float to the surface of the water. As this is happening, the reaction chamber is mechanically shaken. The chemical reaction inside the chamber gives off heat, so the chamber is cooled by the circulation of cold water or another coolant in a jacket around its outsides. Controls automatically shut off the supply of TFE after a certain weight inside the chamber is reached. The water is drained out of the chamber, leaving a mess of stringy PTFE which looks somewhat like grated coconut.

Next, the PTFE is dried and fed into a mill. The mill pulverizes the PTFE with rotating blades, producing a material with the consistency of wheat flour. This fine powder is difficult to mold. It has "poor flow," meaning it cannot be processed easily in automatic equipment. Like unsifted wheat flour, it might have both lumps and air pockets. So manufacturers convert this fine powder into larger granules by a process called agglomeration. This can be done in several ways. One method is to mix the PTFE powder with a solvent such as acetone and tumble it in a rotating drum. The PTFE grains stick together, forming small pellets. The pellets are then dried in an oven. The PTFE pellets can be molded into parts using a variety of techniques. However, PTFE may be sold in bulk already pre-molded into socalled billets, which are solid cylinders of PTFE. The billets may be 5 ft (1.5 m) tall. These can be cut into sheets or smaller blocks, for further molding. To form the billet, PTFE pellets are poured into a cylindrical stainless steel mold. The mold is loaded onto a hydraulic press, which is something like a large cabinet equipped with weighted ram. The ram drops down into the mold and exerts force on the PTFE. After a certain time period, the mold is removed from the press and the PTFE is unmolded. It is allowed to rest, then placed in an oven for a final step called sintering.

Figure 6:Shaping the materials

The molded PTFE is heated in the sintering oven for several hours, until it gradually reaches a temperature of around 680F (360C). This is above the melting point of PTFE. The PTFE particles coalesce and the material becomes gel-like. Then the PTFE is gradually cooled. The finished billet can be shipped to customers, who will slice or shave it into smaller pieces, for further processing.

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4.2.3. Dispersion polymerization Polymerization of PTFE by the dispersion method leads to either fine powder or a paste-like substance, which is more useful for coatings and finishes. TFE is introduced into a water-filled reactor along with the initiating chemical. Instead of being vigorously shaken, as in the suspension process, the reaction chamber is only agitated gently. The PTFE forms into tiny beads. Some of the water is removed, by filtering or by adding chemicals which cause the PTFE beads to settle. The result is a milky substance called PTFE dispersion. It can be used as a liquid, especially in applications like fabric finishes. Or it may be dried into a fine powder used to coat metal. 4.2.4.Non-stick Cookware One of the most common and visible uses of PTFE is coating for nonstick pots and pans. The pan must be made of aluminum or an aluminum alloy. The pan surface has to be specially prepared to receive the PTFE. First, the pan is washed with detergent and rinsed with water, to remove all grease. Then the pan is dipped in a warm bath of hydrochloric acid in a process called etching. Etching roughens the surface of the metal. Then the pan is rinsed with water and dipped again in nitric acid. Finally it is washed again with deionized water and thoroughly dried.

Figure7:Coating of Teflon

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Now the pan is ready for coating with PTFE dispersion. The liquid coating may be sprayed or rolled on. The coating is usually applied in several layers, and may begin with a primer. The exact makeup of the primer is a proprietary secret held by the manufacturers. After the primer is applied, the pan is dried for a few minutes, usually in a convection oven. Then the next two layers are applied, without a drying period in between. After all the coating is applied, the pan is dried in an oven and then sintered. Sintering is the slow heating that is also used to finish the billet. So typically, the oven has two zones. In the first zone, the pan is heated slowly to a temperature that will evaporate the water in the coating. After the water has evaporated, the pan moves into a hotter zone, which sinters the pan at around 800F (425C) for about five minutes. This gels the PTFE. Then the pan is allowed to cool. After cooling, it is ready for any final assembly steps, and packaging and shipping. 4.3. Quality Control Quality control measures take place both at the primary PTFE manufacturing facility and at plants where further processing steps, such as coatings, are done. In the primary manufacturing facility, standard industrial procedures are followed to determine purity of ingredients, accuracy of temperatures, etc. End products are tested for conformance to standards. For dispersion PTFE, this means the viscosity and specific gravity of the dispersion is tested. Other tests may be performed as well. Because Teflon is a trademarked product, manufacturers who wish to use the brand name for parts or products made with Teflon PTFE must follow quality control guidelines laid down by Du Pont.

Figure8:Laser Controling

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In the case of nonstick cookware manufacturers, for example, the cookware makers adhere to Du Pont's Quality Certification Program, which requires that they monitor the thickness of the PTFE coating and the baking temperature, and carry out adhesion tests several times during each shift. 4.4.Byproducts/Waste Though PTFE itself is non-toxic, its manufacture produces toxic byproducts. These include hydrofluoric acid and carbon dioxide. Work areas must be adequately ventilated to prevent exposure to gases while PTFE is being heated, or when it cools after sintering. Doctors have documented a particular illness called polymer fume fever suffered by workers who have inhaled the gaseous byproducts of PTFE manufacturing. Workers must also be protected from breathing in PTFE dust when PTFE parts are tooled. Some waste created during the manufacturing process can be reused. Because PTFE was at first very expensive to produce, manufacturers had high incentive to find ways to use scrap material. Waste or debris generated in the manufacturing process can be cleaned and made into fine powder. This powder can be used for molding, or as an additive to certain lubricants, oils, and inks.Used PTFE parts should be buried in landfills, not incinerated, because burning at high temperatures will release hydrogen chloride and other toxic substances. One study released in 2001 claimed that PTFE also degrades in the environment into one substance that is toxic to plants. This is trifluoroacetate, or TFA. While current levels of TFA in the environment are low, the substance persists for a long time. So TFA pollution is possibly a concern for the future.[8]

5.TYPES OF TEFLON COATINGS

DuPont Teflon coatings are just one of the many industrial coatings solutions offered at Plas-Tech Coatings.Teflon is DuPont's registered trademark for its non-stick coatings. Teflon coatings are specially formulated finishes that are based on PTFE, PFA, FEP, and ETFE fluorocarbon resins. Teflon-S is a related family of fluorocarbon coatings containing binding resins which provide increased hardness, abrasion resistance, and other desirable properties. 5.1. Teflon PTFE PTFE (Polytetrafluoroethylene) nonstick coatings are typically two-coat (primer/topcoat) systems. These products have the highest operating temperature of any fluoropolymer (290 C/550 F), an extremely low coefficient of friction, good abrasion resistance and good chemical resistance.

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5.2.Teflon ETFE ETFE is a copolymer of Ethylene and Tetrafluoroethylene, and is also sold under the Tefzel trademark. Although not fully fluorinated, ETFE has excellent chemical resistance and can operate continuously at 150 C/300 F. This resin is the toughest of the fluoropolymers and can be applied at film builds up to 1,000 micrometers (40 mils) to provide a highly durable finish.

Figure9:Tefzel(ETFE)

5.3. Teflon FEP FEP (Fluorinated Ethylene Propylene copolymer) nonstick coatings melt and flow during baking to provide non-porous films. These coatings provide excellent chemical resistance. In addition to low friction, FEP coatings have excellent nonstick properties. Maximum use temperature is 205 C/400 F. 5.4.Teflon PFA Like FEP, PFA (Perfluoroalkoxy) nonstick coatings melt and flow during baking to provide non-porous films. PFA offers the additional benefits of higher continuous use temperature (260 C/500 F), film thicknesses up to 1,000 micrometers (40 mils) and greater toughness than PTFE or FEP. This combination of properties makes PFA an excellent choice for a wide variety of uses, especially those involving chemical resistance. 5.5. Teflon-S One Coat These solvent-based liquid coatings are formulated with special blends of fluoropolymers and other high-performance resins to improve toughness and abrasion resistance. Because the film components stratify during baking, most of the fluoropolymer properties (such as low friction and nonstick) are retained. The resins provide adhesion and abrasion resistance.

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These products can sometimes be applied to smooth, clean metal. Bake requirements vary, depending on the specific coating, from 165 C/325 F to 370 C/700 F. 5.6. Silverstone SUPRA Silverstone is a specialty line of superior nonstick finishes produced by DuPont. Silverstone coatings are three-coat (primer/midcoat/topcoat) systems formulated with PTFE and PFA. Characteristics of Silverstone coatings are similar to other PTFE coatings, however durability is greatly increased. A reinforced version with higher scratch and abrasion resistance is also available. Maximum continuous use temperature is 290 C/550F. [9]

6.MATERIAL SELECTION
How to choose Teflon? Here is table for answering this question and decide which kind of teflon is better then others. (Most common of 4 teflon) Properties Points Specific gravity Tensile Strength Mpa (psi) Flexural Modulus Mpa (psi) Impact Strength J/m (ft.lb/in) Melting point C(F) Total Points 1point Teflon PTFE Teflon (FEP) Teflon PFA Tefzel(ETFE)

2.132.15(0.30p) 2.15(0.30p) 1.70-1.78(0.10p) 2.22(0.30p) 21-35 Mpa 40-47Mpa (3,00023 Mpa(3,400 25 Mpa(3,600 2points (5,800-6,700 5,000 psi) psi)(0.20p) psi)(0.20p) psi) (1,0p) (0,60p) 500 Mpa 600 600 1,000 3points (72,000psi) Mpa(85,000psi) Mpa(85,000psi) Mpa(145,000psi) (0.50p) (0.60p) (0.60p) (1,30p) 189 J/m 4points (3.5ftlb/in) (0.60p) 5points 327 (621) (1,40p) 12,4points No Break(1,20p) 260 (500) (1,10p) 12,8points No Break(1,20p) 305 (582) (1,30p) 13,8points No Break(1,20p)

245-280 (473536) (1,20p) 16,8points

Table 2 : Choosing material which is according to Specific gravity, Tensile Strength, Elongation, Flexural ModulusImpact Strength, Melting point.

Teflon PTFE is always choosen because of price and easy workability but if we analyze whole properties such as specific gravity,tensile

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strength,flexural modulus,impact strength,melting point etc. Tefzel is the best option. New uses are still being found for it, and its utility is being extended by combining it with other chemicals.China is now the worlds biggest producer (and consumer). DuPont produced 900 tons a year in 1948 and worldwide production is forecast to reach 240,000 tons by 2017. So, despite its properties, Teflon is likely to stick with us for many years to come. [10]

7.CONCLUSION
Making the final decision on whether you want Teflon PTFE, Teflon (FEP), Teflon PFA, Tefzel(ETFE) is really a personal decision based on how much time you spend cooking, your expertise in the kitchen and your budget. You should check information from Table 2. Which has lots of information and opinion, also when you look up you will see some points for helping the people who wants to use better teflon. One of the common justifications for the space race was that mankind benefited from the technology spin-offs. Teflon is the usually quoted as an example.Teflon is a proprietary brand name. It actually pre-dates the space race by almost 30 years. It was invented as long ago as 1938 by Roy Plunkett at DuPont (which owns the brand name). Invented is perhaps the wrong word it was observed during some other research, in much the same way that penicillin was discovered. The word Teflon has passed into our everyday lexicon and is used to describe anything slippery especially politicians, of whom Ronald Reagan was the first to enjoy the dubious distinction.Carcinogenic by-products can be released when it is heated beyond 260 Centigrade. This rarely happens in practice.DuPonts original production process used a toxic chemical known as PFOA but alternatives are now available and the use of the chemical is being phased out.

REFERENCES

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[1] http://en.wikipedia.org/wiki/Polytetrafluoroethylene [2]http://www2.dupont.com/Teflon/en_US/products/safety/what_is_it.html [3] http://www.coolquiz.com/trivia/explain/docs/teflon.asp [4] http://whatscookingamerica.net/LindaPosch/ToxicCookware.htm [5] http://www.lenntech.com/teflon.htm [6] http://composite.about.com/od/Plastics/a/What-Is-Teflon.htm [7] http://www.wisegeek.org/what-is-teflon.htm [8] http://www.madehow.com/Volume-7/Teflon.html [9] http://www.plastechcoatings.com/teflon_coating.html [10] ] http://www.lenntech.com/teflon.htm Table1- http://www.omega.com/techref/images/teflon3.gif

Figures References
Figure1- http://en.wikipedia.org/wiki/File:Teflon_structure.PNG Figure2-http://www.800mainstreet.com/7/teflon-ball-stick-polymer%20fragment1.jpg Figure3-http://www.mindfully.org/Plastic/Teflon/Canary-Teflon-ToxicosisAug03a.GIF Figure4- http://www.youtube.com/watch?v=itqTL3knVeM Figure5- http://www.youtube.com/watch?v=itqTL3knVeM Figure6- http://www.youtube.com/watch?v=itqTL3knVeM Figure7- http://www.youtube.com/watch?v=itqTL3knVeM Figure8- http://www.youtube.com/watch?v=itqTL3knVeM Figure9-http://www.microwavejournal.com/legacy_assets/FigureImg/AR_3331_F1_L.jpg

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