Additives improve scratch

resistance in automotive
applications
Scratch and mar resistance of automotive plastics is
becoming increasingly important due to the growing use
of plastics in the automotive industry and the trend to
eliminate paint in favour of moulded-in-colour. Plastic
surfaces can be protected by using coatings, laminates,
scratch-resistant resins, or additive formulations
designed for improved scratch and mar resistance.
Jennifer Markarian reports for Plastics Additives &
Compounding.
Scratch and mar resistance (SMR) is
particularly critical for interior parts
such as instrument panels and other trim
because customers perceive scratching
and marring as signs of poor quality. J.D.

Power and Associates, which conducts

customer satisfaction studies, includes
scratch and mar performance in its
automobile survey. The effect of scratch
performance on these ratings appears to

Maintaining the appearance of a vehicle is increasingly important. (Photo: Multibase/

Dow Corning)

Plastics Additives & Compounding March/April 2009

10

be getting attention from OEMs, comments Johanne Wilson, NAFTA marketing manager for automotive plastics at
Ciba Corporation. Another trend is the
use of new grained surfaces, with some
geometric or dual gloss grains showing scratches more readily. OEMs are
looking at scratch-resistant additives as
part of their quest for continually better
SMR, say industry suppliers.
Dr. Ashutosh Sharma, director of
technology at Axel Plastics Research
Laboratories, agrees that the bar is being
raised for scratch and mar resistance.
He predicts that the industrys minimal
standard of 10 Newtons (N) ASTM
scratch resistance is heading towards
15N. Dr. Hung-Jue Sue, director of the
Polymer Technology Center and Scratch
Consortium at Texas A&M University
(TAMU), notes that many Japanese and
U.S. automotive companies and their
suppliers are conducting significant
research in improving scratch resistance. Once the economy stabilizes, you
will see scratch research accelerating,
predicts Dr. Sue.
In the past, OEMs required short-term
scratch-resistance (during assembly and
at the dealer), but in the last year or two
OEMs have begun demanding longer-

ISSN1464-391X/09 2009 Elsevier Ltd. All rights reserved.

Automotive
term scratch resistance, because consumers
want their vehicle to look good over time.
Indeed, the importance of overall interior
quality is increasing. Besides scratch and
mar resistance, key properties include gloss,
haptics (typically a soft-touch feel), and
low fogging or emissions due to volatile
organic compounds (VOCs).
While requirements are increasing, there
is also a trend towards replacing more expensive, scratch-resistant resins with more
scratch-susceptible polypropylene (PP) or
PP/olefinic TPE (TPO) compounds. This
is driving increasing use of anti-scratch
additives, say suppliers. For example, one
customer replaced glass-fibre filled PA
with talc-filled PP containing an antiscratch additive in a door handle application, says Kathrin Lehmann, group leader
of plastics technical service and development at Evonik.
The largest market for additives targeting improved scratch and mar resistance
is moulded-in-colour (MIC) interior
applications such as instrument panels,
report industry sources. In many exterior
applications, TPOs still face challenges

The TAMU Scratch-4 Surface Testing System for ASTM and ISO tests.

like minimizing warpage and shrinkage,

or matching body paint colours. While
designers are working on these, scratch resistance will remain a secondary issue, say
sources. However, MIC parts are already
widely used for exterior applications such
as bumpers and rocker panels, and these

applications are beginning to use SMR

additives, especially in the U.S., notes Ms.
Lehmann. MIC-TPO is expanding into
front-end modules, where SMR will be
very important, adds Sara Robinson, business development manager for minerals at
R.T. Vanderbilt Company.

Improving scratch resistance on vehicles with Ciba Irgasurf SR100.

11

Plastics Additives & Compounding March/April 2009

Automotive
Scratch and mar test
methods
Scratch and mar properties are affected
by a complex mix of variables including
polymer type, mineral properties and
content, additives, and the parts surface
texture. The industry uses several different scratch tests to measure performance. Formulations may perform differently depending on the test method
used, notes Frederic Jouffret, director of
polymer and paint development at Rio
Tinto Minerals. The Erichsen method,
commonly used in Europe, emphasizes
mar or abrasion, while the Ford 5 finger
test, prevalent in the U.S., emphasizes
scratching. The Scratch Consortium,
part of the Polymer Technology Center
at Texas A&M University (TAMU),
developed a test that was established in
2005 as ASTM standard D7027-05 and
in November, 2008 as ISO standard
19252. Consortium director Dr. Sue

predicts increasing use of the method

now that the ISO standard has been
published, noting that many companies are buying the TAMU Scratch-4
Surface Testing System. A key benefit
of the new Surface Testing Machine is
that the testing is straightforward and
allows direct comparisons of scratch
resistance between radically different
materials or additive formulations, and
can evaluate textured surfaces, which
cannot be reliably achieved using earlier
test methodology, says Dr. Sue. This
system, currently the only commercial
device for the ASTM and ISO scratch
methods, is manufactured through an
exclusive license by Surface Machine
Systems, LLC. Industry members agree
that the ASTM/ISO test is slowly
gaining acceptance, but expect continued use of Erichsen, Ford, and other
company-specific tests. In addition,
long-term scratch resistance is being
tested by putting a part through heat

Automotive glazing: a new opportunity for additives

Polycarbonate (PC) is taking off in automotive glazing applications because it
brings greater design freedom and allows lightweighting. Suppliers use coatings
to add necessary weatherability and a high level of scratch resistance to PC
glazing parts. UV absorbers are an important part of the formulation, protecting
PC from UV degradation and maintaining clarity. Colorants used in glazing are
typically dyes that maintain high clarity and can meet 10 year weatherability
requirements.
Additives are finding a new role in controlling solar-energy transmission. Exatec
LLC, the glazing arm of SABIC Innovative Plastics, offers two grades of Lexan
PC resins containing infrared (IR) absorbing additives that reduce the heat load
inside the vehicle, improving both passenger comfort and fuel economy, explains
Stephen Shuler, Exatecs chief technology officer. He notes that solar-energy
control is an ongoing development area, with both IR absorbing and IR reflecting
additives being investigated for further improvement. Dr. Kerry Kirwan, PC
glazing expert in the University of Warwicks WMG (formerly the Warwick
Manufacturing Group), comments: Polymer glazing is years behind the glass
industry in incorporating thin metal oxide layers for IR-reflectance. The hightemperature application methods used in glass do not work as well in plastics, so
the industry is searching for solutions.

Contacts:
SABIC Innovative plastics
Tel: +1 248 926 4200
Website: www.exatec.de
WMG
Tel: +44 24 7652 4871
Website: www.wmg.warwick.ac.uk

Plastics Additives & Compounding March/April 2009

12

cycles to simulate the changes in temperature a vehicle might go through in

years of use.

Additives improve scratch

and mar resistance
Migratory additives such as erucamide
have traditionally been used to improve
scratch and mar performance. However,
due to concerns about vehicle interior
air quality (VIAQ), OEMs, particularly
in Europe and Asia, are increasingly cautious about using additives that bloom to
the surface and contain volatile organic
compounds (VOCs) that contribute to
fogging or malodours and can be measured as emissions. Automotive manufacturers, such as the Japanese Automobile
Manufacturers Association (JAMA),
now specify emission limits for interior
materials. In addition to VOC concerns,
erucamides can potentially interact with
stabilizers and cause surface stickiness.
Amides provide only short-term scratch
protection, typically measuring 6-7 N in
the ASTM test, says Dr. Sharma. Advanced scratch and mar resistant additives
from several suppliers overcome some of
these shortfalls with permanent scratch
resistance approaching 10 N or more, low
or no migration, no odour or fogging,
and other advantages, say suppliers.

Advanced anti-scratch
additives
Ciba Irgasurf SR100, an anti-scratch
additive commercialized in 2005, is
being used globally for both interior
and exterior automotive parts as well as
non-automotive PP/TPO applications
like snowmobiles. Customers report that
it shows improved SMR in filled TPO,
high-gloss TPO, and soft TPE, says Ms.
Wilson. Irgasurf can also boost the performance of recycled PP.
Multibases Dow Corning MB50-001/
MB50-321siloxane masterbatch contains
a non-migrating, anti-scratch additive
that improves scratch and mar resistance
in rigid, mineral-filled TPOs. The ultrahigh molecular weight siloxane offers
long-term scratch and mar resistance with
no fogging or emissions and very little ef-

Automotive
fect on gloss, says Alexis Von Tschammer,
global marketing manager for Multibase,
a Dow Corning Company. MB50 masterbatches can be used in TPOs, TPVs,
TPEs, and other engineered plastics and
elastomers. For soft-touch overmoulding, Multibase offers siloxane-enhanced
TPE (SiE-TPE) and cross-linked silicone
thermoplastics (TPSiV) that give longterm scratch and mar protection with very
low emissions.
Evonik introduced the organic modified
siloxane (OMS) Tegomer AntiScratch 100
(TAS100) additive, targeting improved
scratch and mar resistance in talc-filled PP
and PP/TPO parts (see Plastics Additives &
Compounding March/April 2008). TAS100
does not migrate, yielding permanent
scratch resistance and no fogging or gloss
change, as well as no odour, reports Ms. Lehmann. Recently, TAS100 has been shown
to boost scratch resistance of glass-filled
PA, says Ms. Lehmann. She explains: The
scratch appearance in PA is different from
that in PP. In PA, the scratch is seen as a
change in gloss. TAS100 reduces the scratch
depth, resulting in a smaller gloss difference. In 2008, Evonik commercialized an
anti-scratch additive for high gloss PC/ABS
or PMMA/ABS parts. Tegomer M-Si2650,
originally used in TPEE, improves scratch
and mar resistance for these high-gloss parts.
AXEL Plastics Research Laboratorys
non-migratory additives are a complex
mix of polymeric materials and amides
that have no fogging, odour, or interaction with UV stabilizers. Axels scratch
resistant additives have a double advantage not only do they improve scratch
resistance but also improve dispersion of
rubber and talc within a TPO, leading
to improved impact resistance, comments Dr. Sharma. Since TPO rubber
and talc content greatly affect scratch
resistance, additive formulations should
be designed for a given TPO formulation.
In tests at Axel, MoldWiz INT-35CPD
showed best results for a high rubber
content TPO with 20 per cent talc, and
the new MoldWiz INT-701S was best
for lower rubber content TPO with 13
per cent talc. MoldWiz INT-701S shows
no scratch whitening up to 15N in the
TPO compounds tested. Because of their
affinity for the rubber and talc particles

Wollastonite has a needle-like structure. (Photo: Nordkalk).

Scratch visibility in mineral filled polypropylene compounds with the Erichsens Cross
Cut Test.
10 N

5N

20 N

Talc

Wollastonite

in a TPO, the additives can be used at

low levels of 1-2 per cent. explains Dr.
Sharma. These two additives are being
used commercially in applications such as
instrument panels, and a third, MoldWiz
XP-I-702S, is in development.

Minerals affect scratch

performance
Automotive TPO parts are typically filled
with minerals like calcium carbonate,

13

talc, kaolin, or wollastonite that have

a significant effect on scratch performance. When a part is scratched, exposed
mineral particles reflect light and make
the scratch more visible. As the mineral
loading increases, scratches become more
easily visible. Morphology and particle
size play a role, with better scratch resistance from finer particle sizes. Minerals
with a surface treatment like silane show
improved scratch and mar resistance
over formulations with untreated grades.

Plastics Additives & Compounding March/April 2009

Automotive
Mineral coatings reduce absorption of slip
or other anti-scratch additives onto the
mineral, leaving more to function at the
part surface. Surface treatments may improve dispersion, which improves scratch
resistance, and create a better bond
between polymer and mineral so that less
of the bright mineral surface is revealed by
scratching, adds Anssi Koikkalainen, sales
manager at Nordkalk.
IMI Fabi recently introduced its NS100
micronized, coated talc for improved
dispersion and scratch and mar resistance
in TPO. Joint research with Evonik has
optimized combinations of NS100 with
Evoniks TAS100 siloxane additive for
scratch-resistant compounds.
Multibase recently introduced a new
microtalc masterbatch to improve SMR in
filled, rigid TPOs. The product combines
a very fine particle size talc with proprietary processing technology to create
excellent dispersion in the PP matrix,
allowing lower filler levels, says Mr. Von
Tschammer. He explains: Processors
typically use 12-20 per cent talc-filled,
ready-to-use compounds. This microtalc
masterbatch can achieve comparable
physical properties with only 3-5 per cent
microtalc. Lower talc levels help reduce
weight as well as improve scratch and
mar resistance. In addition, highly filled
masterbatches are more cost-effective than
compounds. He says that the product
is currently being tested by processors.
Multibase is evaluating mixtures of microtalc and high-molecular weight siloxane
for physical property and scratch and mar
performance.
Rio Tinto Minerals Luzenac R-7 surfacetreated talc is used globally as a scratch and
mar resistant, UV-stable, and high-impact
talc, notes the company. Choosing a

mineral depends on the physical properties required by the part as well as scratch
resistance. For example, microcrystalline
talc with round particles demonstrates better abrasion resistance than lamellar talcs,
but lamellar talcs have better stiffness. Mr.
Jouffret recommends Mistron microcrystalline talcs for SMR performance in SEBS
soft-touch TPEs, but lamellar talcs for PP/
TPO applications that need stiffness and
SMR. Ultrafine, lamellar Jetfine talcs, with
average particle sizes of 1 micron or less,
give a balance of stiffness, toughness, and
scratch and mar resistance, says Mr. Jouffret.
Jetfine talc has been processed in Europe,
and in 2008 Rio Tinto Minerals added
Jetfine processing to a North American
location; products from this facility are in
the customer evaluation phase.
Wollastonite is used in both interior and
exterior automotive engineering thermoplastics, although not as widely as talc in
PP/TPO. Because it is a relatively hard
mineral (about 5 Mohs hardness compared to talc with about 1 Mohs hardness), wollastonite has inherently better
scratch and mar resistance than standard talcs. Wollastonites needle-shaped
structure is not as easily breakable as talcs
lamellar, platy structure, resulting in lower
scratch visibility, says Mr. Koikkalainen.
While the needle structure is good for
shrink control, platy minerals are better
for warp control, notes R.T. Vanderbilts
Ms. Robinson, who points out that binary
systems combining talc and wollastonite
can be beneficial.

Outlook
Despite the poor economy, industry
members expect opportunities for additives to play a big role in innovation and

15

new product development. Ms. Robinson

concludes: Cars are still being built even
in a downturn. A slow economy is a window of opportunity, and I am optimistic
that companies will be competing aggressively and looking for ways to get their
problems solved.
Contacts:
Axel Plastics Research Laboratories, Inc.
Tel: +1 718 672 8300
Website: www.axelplastics.com
Ciba Corporation
Tel: +1 914 785 2000
Website: www.ciba.com/plasticadditives
Evonik Goldschmidt GmbH
Tel: +49 201 173 2824
Website: www.evonik.com/plastic-additives
IMI Fabi
Tel: +39 0342 490311
Website: www.imifabi.com
Multibase
Tel: +33 4 76 671258
Website: www.multibase.com/
www.dowcorning.com
Nordkalk Corporation
Tel: + 358 20 455 7300
Website: www.nordkalk.com
R. T. Vanderbilt Company
Tel: +1 203 853 1400
Website: www.rtvanderbilt.com
Rio Tinto Minerals
Tel: +1 303 713 5000 (US)/+33 5 61 50 20
20 (Europe)
Website: www.riotinto.com
Scratch Consortium of the Polymer Technology
Center at Texas A&M University
Tel: +1 979 458 0918
Website: http://ptc.tamu.edu/cons_scratch.htm
Surface Machine Systems LLC
Tel: +1 979 575 5097
Website: www.surfacemachines.com

Plastics Additives & Compounding March/April 2009