EPDM rubber

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material may be challenged and removed. (July 2011)

EPDM rubber (ethylene propylene diene monomer (M-class) rubber),[1][2][3] a type of synthetic
rubber, is anelastomer characterized by a wide range of applications. The M refers to its
classification in ASTM standard D-1418; theM class includes rubbers having a saturated chain of
the polymethylene type. Dienes currently used in the manufacture of EPDM rubbers are
dicyclopentadiene (DCPD), ethylidene norbornene (ENB), and vinyl norbornene (VNB). EPDM
rubber is closely related to ethylene propylene rubber (ethylene propylene rubber is
a copolymer of ethylene andpropylene, whereas EPDM rubber is
a terpolymer of ethylene, propylene, and a diene-component).

A roll of EPDM foil, used for waterproofingroofs

The ethylene content is around 45% to 85%. The higher the ethylene content, the higher the loading
possibilities of the polymer, better mixing, and extrusion. Peroxide curing these polymers gives a
higher crosslink density compared with their amorphous counterpart. The amorphous polymer is also
excellent in processing. This is very much influenced by their molecular structure. The dienes,
typically comprising from 2.5% to 12% by weight of the composition, serve as cross-links when
curing with sulphur and resin; with peroxide cures, the diene (or third monomer) functions as a
coagent, which provides resistance to unwanted tackiness, creep, or flow during end use.

Properties[edit]

EPDM exhibits satisfactory compatibility with fireproof hydraulic fluids, ketones, hot and cold water,
and alkalis and exhibits unsatisfactory compatibility with
most oils, gasoline,kerosene, aromatic and aliphatic hydrocarbons, halogenated solvents, and
concentrated acids.
The main properties of EPDM are its outstanding heat, ozone, and weather resistance. The
resistance to polarsubstances and steam are also good. It has excellent electrical insulating
properties. It has good resistance to ketones, ordinary diluted acids, and alkalines.
Typical properties of EPDM vulcanizates are given below. EPDM can be compounded to meet
specific properties to a limit, depending first on the EPDM polymers available, then the processing
and curing method(s) employed. EPDMs are available in a range of molecular weights (indicated in
terms of Mooney viscosity ML(1+4) at 125 C), varying levels of ethylene, third monomer, and oil
content.

Mechanical properties of EPDM

Property

Value

Appearance

Hardness, Shore A

4090

Tensile failure stress, ultimate

25 MPa

Elongation after fracture in %

300%

Density

Can be compounded from 0.90 to >2.00 g/cm3

Thermal properties of EPDM

Property

Coefficient of thermal expansion, linear[4]

Value

160 m/mK

Maximum service temperature[5]

150 C

Minimum service temperature[5]

50 C

Glass transition temperature

54 C

Uses[edit]

An EPDM rubber roof

EPDM rubber is used in seals (for example, it is used in cold-room doors since it is aninsulator, as
well as in the face seals of industrial respirators in automotive paint spray environments,
where silicone must be avoided).[citation needed] EPDM is also used in glass-run channels, radiators, garden
and appliance hose, tubing, pond liners, washers, belts,electrical insulation, vibrators, O-rings, solar
panel heat collectors, and speaker cone surrounds.
It is also used as a medium for water resistance in electrical cable-jointing, roofingmembranes (since
it does not pollute the run-off rainwater, which is of vital importance forrainwater
harvesting), geomembranes, rubber mechanical goods, plastic impact
modification, thermoplastic,vulcanizates, and many other applications.[6][7] Colored EPDM granules
are mixed with polyurethane binders and troweled or sprayed onto concrete, asphalt, screenings,
interlocking brick, wood, etc. to create a non-slip, soft, porous safety surface for wet-deck areas such
as pool decks and as safety surfacing under playground play equipment (designed to help lessen fall
injury).
The most common use, however, is probably in vehicles. It is used in door seals, window seals,
trunk seals, and sometimes hood seals. Frequently, these seals are the source of noise due to
movement of the door against the car body and the resulting friction between the EPDM rubber and
the mating surface (painted sheet metal or glass). This can be alleviated using specialty coatings
that are applied at the time of manufacture of the weather seal. Such coatings can also greatly
increase the chemical resistance of EPDM rubber. Some vehicle manufacturers also recommend a
light application of silicone dielectric grease to weatherstripping to reduce noise. Other uses in
vehicles include cooling system circuit hoses where water pumps, thermostats, EGR valves, EGR
coolers, heaters, oil coolers, radiators, and degas bottles are connected with EPDM hoses, as well

as charge air tubing on turbocharged engines to connect the cold side of the charge air cooler
(intercooler) to the intake manifold.

References[edit]
1.

Jump up^ Ravishankar, P.S. (2012). "Treatise on EPDM". Rubber Chemistry and
Technology 85. p. 327-349.

2.

Jump up^ Green, Mark M.; Wittcoff, Harold A. (July 2003). Organic Chemistry Principles
and Industrial Practice. Weinheim, Germany: Wiley. p. 170. ISBN 978-3-527-30289-5. In addition
to natural rubber, many synthetic rubberssuch asethylene-propylene-diene monomer
rubber

3.

Jump up^ Louie, Douglas K. (2005). "Elastomers". Handbook of sulphuric acid

manufacturing. Richmond Hill, Canada: DKL Engineering, Inc. pp. 16116. ISBN 978-0-97389920-7. EPDM (Ethylene Propylene Diene Monomer is a M class Rubber containing a saturated
chain of the polyethylene type.

4.

Jump up^ "Designing with Rubber", Technical Documentation Orings, Eriks, p. 33

5.

^ Jump up to:a b http://www.allsealsinc.com/oilsseals.html

6.

Jump up^ Azom.com, Ethylene Propylene Rubbers, Friday, 20 April 2012

7.
Categories:

Jump up^ iisrp, Ethylene-Propylene Rubbers & Elastomers, Friday, 20 April 2012

Elastomers

Plaster mold casting

From Wikipedia, the free encyclopedia

Plaster mold casting is a metalworking casting process similar to sand casting except the molding
material is plaster of paris instead of sand. Like sand casting, plaster mold casting is an expendable
mold process, however it can only be used with non-ferrous materials. It is used for castings as
small as 30 g (1 oz) to as large as 45 kg (99 lb). Generally, the form takes less than a week to
prepare. Production rates of 110 units/hr can be achieved with plaster molds.[1][2]
Parts that are typically made by plaster casting are lock components, gears, valves, fittings, tooling,
and ornaments.[2]
Contents
[hide]

1 Details
o

1.1 Process

2 Advantages & disadvantages

3 References
o

3.1 Bibliography

Details[edit]
The plaster is not pure plaster of paris, but rather has additives to improve green strength, dry
strength, permeability, andcastability. For instance, talc or magnesium oxide are added to prevent
cracking and reduce setting time; lime andcement limit expansion during baking; glass fibers
increase strength; sand can be used as a filler.[1] The ratio of ingredients is 7080% gypsum and 20
30% additives.[2]
The pattern is usually made from metal, however rubber molds may be used for complex geometry;
these molds are called Rubber plaster molds. For example, if the casting includes reentrant angles
or complex angular surfaces then the rubber is flexible enough to be removed, unlike metal. [1] These
molds are also inexpensive, reusable, more accurate than steel molds, fast to produce, and easy to
change.[citation needed]
Typical tolerances are 0.1 mm (0.0039 in) for the first 50 mm (2.0 in) and 0.02 mm per additional
centimeter (0.002 in per additional inch). A draft of 0.5 to 1 degree is required. Standard surface
finishes that are attainable are 1.3 to 4 micrometres (50125 in). [1]

Process[edit]
First, the plaster is mixed and the pattern is sprayed with a thin film of parting compound to prevent
the plaster from sticking to the pattern. The plaster is then poured over the pattern and the unit
shaken so that the plaster fills any small features. The plaster sets, usually in about 15 minutes, and
the pattern is removed. The mold is then baked, between 120 C (248 F) and 260 C (500 F), to
remove any excess water. The dried mold is then assembled, preheated, and the metal poured.
Finally, after the metal has solidified, the plaster is broken from the cast part. The used plaster
cannot be reused.[1][2]

Advantages & disadvantages[edit]

Plaster mold casting is used when an excellent surface finish and good dimensional accuracy is
required. Because the plaster has a low thermal conductivity and heat capacity, the metal cools
more slowly than in a sand mold, which allows the metal to fill thin cross-sections; the minimum
possible cross-section is 0.6 mm (0.024 in). This results in a near net shape casting, which can be a
cost advantage on complex parts.[1] It also produces minimal scrap material.[3]
The major disadvantage of the process is that it can only be used with lower melting temperature
non-ferrous materials, such as aluminium, copper, magnesium, and zinc. The most commonly used
materials are aluminium and copper. The maximum working temperature of plaster is 1,200 C
(2,200 F), so higher melting temperature materials would melt the plaster mold. Also, the sulfur in
the gypsum reacts with iron, making it unsuitable for casting ferrous materials. [1][2]
Another disadvantage is that its long cooling times restrict production volume. [1]

Plaster is not as stable as sand, so it is dependent on several factors, including the consistency of
the plaster composition, pouring procedures, and curing techniques. If these factors are not closely
monitored the mold can be distorted, shrink upon drying, have a poor surface finish, or fail
completely.[4]

References[edit]
1.

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