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P L A S T I C S
E N G I N E E R I N G
D S M
Contents
Introduction 4 DSM
2
With polymerization and compounding Complemented in some regions by Production sites
facilities for a range of polyamides, products as:
polyesters and polycarbonates, we serve Electrafil® (conductive products) Europe
our global customers base and assure a Fiberfil® (reinforced polypropylene) Emmen - Netherlands (polymerization
constant, reliable supply of products. Nylatron® (PA66 specialties) and compounding)
Plaslube® (lubricated products) Geleen - Netherlands (polymerization)
Recently, DSM completed major Genk - Belgium (compounding)
investments in the building of Akulon These materials all have their specific Stade - Germany (polymerization)
polyamide 6 polymerization plants both properties, yet they share the same high
in the USA and in the Netherlands, as quality, thanks to state-of-the-art North America
well as finalizing a joint venture with production processes and quality Evansville - Indiana (compounding)
Xinhui in China for the production of systems, like Total Quality Management, Augusta - Georgia (polymerization)
polyamide 6 polymer. The capacity of ISO 9001 and QS 9000. Stoney Creek - Ontario Canada
the polymerization plant for Stanyl It’s an approach to quality that can be (compounding)
P L A S T I C S
polyamide 46 in the Netherlands was found throughout the DSM organization:
increased by 30% to meet the high - in relations with industry partners, Asia Pacific
growth demand for this product. working closely together in true co- Jiangsu - China (compounding)
Access to polycarbonate was secured makership, ready to meet any Pune - India (compounding)
under a long term capacity sharing technical challenge Tokyo - Japan (M/S joint venture and toll
E N G I N E E R I N G
agreement with Dow Chemical. - in technical service and after sales, compounding)
providing support to help customers
All our compounding facilities in the optimize their processes
world (in the Netherlands, Belgium, USA, - in logistics and delivery, shipping
Canada, China and India) are being products anywhere in the world,
expanded continuously to keep up with quickly and reliably.
the growing demand.
From product concept, through
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As a result of a constant product processing, to final application DSM
innovation and creation process, DSM Engineering Plastics brings the portfolio,
Engineering Plastics can offer a cohesive the skills and the global presence to help
portfolio of high performing engineering its industrial partners create world-class
plastics. Established trade names are: products and solutions.
Akulon® (PA6 and PA66)
Akulon® Ultraflow™ It’s surprising what we can do
(high flow Akulon PA6) together!
Akulon® XP
(Xtreme Performance PA6 for film)
Arnite® (PBT, PET)
Arnitel® (TPE-E)
Stamylan® UH (UHMWPE)
Stanyl® PA46 (PA46)
Stanyl PA46 High Flow™
(high flow PA46)
Stapron® (PC-blends)
Xantar® (PC)
Yparex® (extrudable adhesive resins)
3
Introduction
product line. improved flow, shorter cycle times, distribution, industrial connectors,
The company’s vast expertise enables it better surface appearance and less power tools and E&E components
to play a unique role as a resin producer wear. - other industries: railway systems,
and compounder. furniture, castor wheels, sports goods,
Polyamide 6 versus polyamide 66 consumer durables, building products
New plant. In 2000 DSM Engineering and industrial goods.
Plastics started up a new state-of-the-art Polyamide is the most common
PA6 polymerization plant in Emmen, the engineering thermoplastic in use today. Polyamide has an excellent combination
Netherlands. Downstream of this Annual consumption of polyamide for of properties:
polymerization unit is a large engineering plastic applications exceeds - high stiffness and strength at elevated
compounding plant. Another 2000 ktons. Polyamides cover a broader temperatures
polymerization unit is located in Augusta range of applications than any other - toughness at low temperatures
(Georgia, US), with compounding engineering plastic. The Akulon grades - excellent heat ageing resistance
facilities in Evansville (Indiana) and are suitable for all major processing - good abrasion and wear resistance
Stoney Creek (Canada). In Japan, the techniques, such as injection moulding, - chemical resistance
group has formed a joint venture with blow moulding and extrusion. - excellent surface appearance.
Japan Synthetic Rubber Co., Ltd.
(Tokyo), and in China it has a strong These properties can be enhanced by
foothold via a fully owned and strongly the use of glass fibre and beads,
expanding compounding facility. minerals, flame retardants, toughening
agents and other additives.
4
Table 1. The most important PA6 grades in our portfolio.
These advantages can lead to lower
Type Additive Remark Grade system costs and/or better safety
Unreinforced Low viscous F223-D margins in your applications. The high
High viscous F130-B stiffness levels at elevated temperatures
and higher absolute values for strength
Reinforced Glass fibres 30% GF K224-G6 levels measured after heat ageing, imply
30% GF, HS K224-HG6 savings in material costs (because wall
35% GF, HS K224-HG7 thickness can be reduced) or a higher
safety margin (at a certain wall
Hybrid (glass 10% GF, 20% M, K223-HGM24 thickness). Also, the broader processing
fibres/minerals) HS window and lower melting point of
polyamide 6 mean easier processing.
Flame retardant Glass fibres 20% GF, K222-KGV41) Processing costs can be reduced as a
halogen free result of lower energy costs and/or
P L A S T I C S
shorter cycle times. The higher
Hybrid (glass 5% GF, 20% M, K222-KGMV14 toughness level leads to lower reject
fibres minerals) halogen free levels in production. The higher weld
strength of polyamide 6 provides better
1) K222-KGV4 and K222-KGMV14 are halogen free materials; HS = heat resistant. safety margins in the applications, whilst
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its superior surface appearance leads to
an improved image in the marketplace.
The most important polyamide 6 - higher toughness levels at low
injection moulding grades in our portfolio temperatures but comparable More details can be found in the
are presented in Table 1 on this page. stiffness levels at elevated technical chapter in the second part of
An overview of the available extrusion temperatures up to 185 °C this brochure.
grades can be found on page 13. - better heat ageing resistance
You will find a more detailed overview of - easier processability (broader There are many reasons to choose
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our portfolio and the corresponding set processing window, the use of lower Akulon PA6 for your applications!
of properties at the end of this brochure. processing temperatures can lead to
The nomenclature is explained on page shorter cycle times)
29, Table 13. - higher weld strength after various
welding processes;
PA6 versus PA66. The Akulon - better surface appearance of
product line encompasses a range of reinforced grades;
polyamide compounds based on - the possibility of halogen-free flame
polyamide 6 and 66 types. However, retardancy in reinforced PA6 grades.
given our backward integration, our core
product line is Akulon PA6.
This fits in with our vision that in most
applications polyamide 6 outperforms
polyamide 66 at temperatures up to
185 °C, since PA6 yields in comparison
to PA66:
Ski-bindings
Akulon K224-TG9.
5
Automotive applications
parts. DSM Engineering Plastics is in the excellent surface appearance, paint some milliseconds. The materials to
position to offer post consumer PA6 ability and UV-resistance, but also good enable the airbag to do his job have to
grades under the trade name Akulon mechanical properties, like stiffness and fulfil the most stringent specifications.
Recap globally, partly coming from its toughness. DSM is one of the market They must carry specific mechanical and
depolymerization plant in Augusta. leaders in these applications and offers a thermal properties and a certain product
broad portfolio of tailor made Akulon consistency. The super toughened
Polyamides have been used for many solutions for door handles, for painted Akulon K224-PG6 and K224-PG8 (PA6
years in the automotive industry. Due to and unpainted use. Akulon is easy to GF30 and GF40) withstand these
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their performance profile, they can offer process, even in the most difficult challenging requirements. The polymer
the appropriate solution for many processes for door handle applications, enables the system suppliers to design
different applications. Akulon polyamides like gas assisted technology or foaming. cost effective and state-of-the-art airbag
have been successfully applied in (see containers.
Table 2):
- automotive exterior;
- automotive interior;
- electrical and electronic applications;
- under-the-bonnet.
6
Relay box, Akulon K224-HGR24. Air intake manifold, Akulon K224-HG6. Radiator grille, Akulon K224-HG3.
P L A S T I C S
applications game, be it a standard Akulon K224-
HG6/HG7, a burst pressure/welding
Relay boxes. In automotive E&E- optimized Akulon K230-HXG6 or even
applications, Akulon PA6 plays an one of the blow moulding specialties for
important role when it comes to relay airducts, like Akulon K249-HG4. DSM
E N G I N E E R I N G
boxes. Akulon K224-HGR24 (PA6 GF10 Akulons are in the position to cover all of
GB20) offers good mechanical our customers’ needs in this important
properties and excellent weld line segment.
strength at elevated temperatures, Airducts, Akulon F249-HG4.
combined with the required dimensional Engine covers. Also for this segment
accuracy. Where higher stiffness fit-for-use Akulon grades are available
combined with excellent flow like K223-HGM24 (10% GF, 20%
characteristics is demanded, Akulon Mineral) and K220-HGM44 or
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K-FHGM44 (PA6 GF20 M20) can do the K-FHGM44 (both 20% GF, 20% Mineral;
job. That’s why many OEM’s rely on highly flowable with superb surface
Akulon. appearance.
These grades do offer the requested
Under-the-bonnet combination of high toughness and
stiffness, of low warpage and good
Air intake manifolds and air surface appearance, and of easy and
ducts. ‘Fuel economy’ and ‘weight speedy processability, which explains Secondary Air Supply (SAS) pump,
reduction’ are the main challenges of the the many approvals at all major OEMS. Akulon K224-HG6.
automotive OEM’s and their suppliers of
today. A big step towards these goals
can be made by the integration of
functions and replacements of aluminium
and steel by plastics, e.g. for air intake
components.
7
Akulon in electrical and electronic applications
The segment of ‘Low Voltage requirements with respect to the - short term and long term temperature
Switchgear’ can be sub-segmented into thermoplastics used, especially due to resistance
the following categories of applications trends in design, Comparative Trackking - stiffness combined with good
(which are covered by the different IEC Index (CTI) requirements shift to ‘CTI ≥ elongation at break
standards, quoted between brackets): 400 V’ and Relative Temperature Index - specific CTI-value dependent on the
E N G I N E E R I N G
- miniature circuit breakers; domestic (RTI) requirements towards ‘RTI electrical actual creep age distance realized in
(IEC 898) or industrial (IEC 947) ≥ 130 °C’ and ‘RTI mechanical ≥ the application
- residual current devices 120 °C’. All this preferably realized in a - specific values for other, specific
(IEC 1008/1009) halogen free and phosphorous free electrical properties (electric strength,
- fuses (IEC 269) system. Other requirements are: resistivity,..)
- switches and relays (IEC 947-3) - limited, controllable warp age level
- contactors (IEC 947-4) Minimum general requirements: - colour consistency (base colour) and
- cabinets (IEC 439-5). - Glow Wire Flammability Index of colour stability (as well in processing
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8
its melting point of 220 °C is sufficient to Circuit breakers. Circuit breakers
withstand the short-term temperature protect wiring systems from over-current
rises. Its stiffness is the same as that of situations and protect equipment from
PA66 up to 190 °C); short circuits. Ball pressure temperature
with its high RTI values it can easily meet and glow wire flammability index are
the long-term temperature requirements. important requirements for domestic
Typically continuous temperatures applications (as laid down in IEC 898).
seldom exceed 70-90 °C. Glow wire flammability index and
There is however a trend to higher comparative tracking index are
continuous temperature exposures); requirements for industrial applications,
it is available in halogen free and as described in IEC 947-2. The devices Miniature Circuit Breaker (MCB), Akulon
phosphorous free flame retardant have to exhibit high impact resistance K222-KGV4.
versions, which also comply with the CTI (polyamide is preferred above polyester)
≥ 400 V requirement; and must pass cyclic thermal and
P L A S T I C S
it is tough and easy process able. mechanical endurance tests. Akulon
PA6, in the standard colours such as
Especially the halogen free and electro-grey RAL7035 and black, is used
phosphorous free flame retardant as well for the enclosures as well for
requirement in combination with a CTI various internal parts.
E N G I N E E R I N G
≥ 400 V is difficult to be met by PBT or
PA66. Other deficiencies of these Contactors. Contactors connect and
materials are: too much warp age interrupt electrical power. In general they
sensitivity, less stiffness and strength at are subject to higher currents than
elevated temperatures, less impact switches. They can be controlled Motorstarter, PA66 GF V-0.
resistance in the case of PBT and more remotely, or by an integrated switch, as
difficult process ability and limited for example in motor starters. The main
electrical properties in the case of material related requirements are
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phosphorous based flame retardant described in IEC 947-4 and include a
PA66. Despite its moisture absorption, glow wire flammability index of 960 °C.
PA6 still easily manages to meet the Also the comparative tracking index is
various specifications with respect to important here, because it is strongly
dimensional stability and electrical related to the level of design freedom of
requirements. these contactors.
Table 4. The Akulon PA6 portfolio for the low voltage switchgear segment consists of:
Contactor
Akulon K225-KS, K222-KGV4.
9
Switch, Akulon K223-KMV6. CEE Connectors, Akulon F223-D. Terminal blocks, Akulon S225-KS.
Switches and relays for industrial Industrial connectors (CEE). The Terminal blocks. Terminal blocks are
applications. Switches connect or CEE-connectors (CEE = International either modular or one-piece (multi-
P L A S T I C S
interrupt electrical power. There exists a Commission on Rules for Approval of contact). They connect individual wires
wide range of switches, like rotary Electrical Equipment) are found in by means of a screw or spring contact.
switches and push buttons. Their industrial environments as devices for They are primarily found in industrial
requirements are described in IEC supplying and coupling of electrical switch cabinets and on printed circuit
947-3. The main material-related power. Important requirements for this boards (PCB’s) to provide the wire-to-
E N G I N E E R I N G
requirement is again glow wire market are laid down by the industry board connection. Important
flammability index. The CTI plays an standard EN 60309-1. It states that requirements, as described in EN 60998
important role in designing these connector materials supporting current and EN 60947, are:
devices. This because of its relation to carrying parts must: - high levels of CTI, HWI and HAI
environmental pollution requirements. If a - exhibit resistance to chemicals and a - and in addition, resistance to soldering
compact design is needed, materials ball pressure of at least 125 °C heat at 260 °C (pin-through-hole, wave
should have a CTI-value as high as - impact resistance also at -25 °C soldering technique). A trend is
possible (preferably > 600 V). In many - UL94 V-2 and resistance to ageing up observed towards surface-mount-
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cases additionally dimensional stability is to 100 °C. technology. This implies: the necessity
required, while thermal requirements are of the application of a high temperature
often not as high compared with MCB’s Other, more or less customer specific restant material as Stanyl (PA46).
or RCD’s. requirements, are: Other requirements are:
- high stiffness to prevent creep age - halogen and phosphorous free flame
Connector applications and possible bad connections retardancy (UL94 V-0 at 0.4 mm) in
- high ductility because of film hinges combination with a CTI level > 600 V
The segment of connectors can be sub- and dovetailing interconnections - a high flowability, because of thin
segmented into: - and good flow ability because of thin sections down to 0.2 mm
- automotive connectors sections. - a low corrosivity in injection moulding
- PCB-connectors - a high stiffness to prevent creep age
- industrial connectors (CEE) This set of requirements explains why and possible bad connections
- terminal blocks PA6 (and especially Akulon) is preferred - and a high ductility because of film
- wire-to-wire-connectors above PBT (which has a too low impact hinges and dovetailing
- and various other type of connectors. resistance, a limited flow ability and only interconnections.
UL94 HB in unreinforced version) and In the case of PCB terminal blocks are
Below a special emphasis is given to the PA66 (which is too expensive). The main also required:
sub-segments of ‘’industrial connectors” Akulon grades used are F223-D - a low warp age level (necessary for a
and “terminal blocks”. Information on (unreinforced PA, V-2), K224-G0 (PA6, good fit to the PCB)
the other sub-segments can be obtained 50% GF) and K223-KMV6 (PA6, 30% - and high levels of stiffness and
via our sales engineers or application mineral reinforced, V-2). Some are strength, combined with low creep
development engineers. available in company specific colours as levels (necessary for sufficient high
well as in signal (cadmium free) colours. levels of pin retention).
The main Akulon grade used here is
S225-KS (unreinforced PA66, halogen
10 free, UL94 V-0).
Other injection moulding applications
P L A S T I C S
an insulator of Arnitel.
Railway systems comprises in most
cases the insulators or railway pads. For Sports
this application good mechanical
properties are required. In most cases Polyamide 6 is also used in large
E N G I N E E R I N G
Akulon K224-G6 is the best choice. applications in sport, like ski-bindings
and inline skates. DSM Engineering Power tool, Akulon K224-G6.
Power tools Plastics has extensive experience with
K224-TG9 for ski-bindings, because of
For many years polyamide 6 has been its excellent fatigue properties. For inline
the dominant material for power tool skates, Akulon K224-PG6 is used, which
housings because it is heat resistant, provides high impact and mechanical
tough and process able. The heat of strength.
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electric motors and the continued
downsizing of units result in high Consumer durables
operating temperatures in power tools.
And as with lawn and garden, power Consumer durables are an avery broad
tool manufacturers know the abuse their area, which includes kitchen tools,
units might withstand. They want consumer tools (like hammers and Ski-bindings, Akulon K224-TG9.
materials that can take impact without screwdrivers) and garden tools (like
failure. In power tools colours and hedge cutters, axes and scissors).
aesthetic appeal are important. Akulon K224-G6 is used for these
Polyamide 6 delivers exceptional surface applications, but also materials like
appearance with good colour stability. Akulon K224-PG6 or K224-PG8 are
used if impact is required for the
Castor wheels application. The latter material provides
an excellent impact/stiffness balance.
Polyamide 6 is also the preferred
material for castor wheels, which in this Building & construction
case means everything between furniture
wheels and heavy-duty industrial Like consumer durables, this application Various types of castor wheels,
applications like air cargo container area is fragmented but contains one Akulon F223-D and F130-C.
wheels. Material in use is essentially large application: wall plugs. Usually
unreinforced polyamide; ranging from pullout force and flexibility during
higher viscous material like F130-C for mounting of plugs are key requirements.
high impact and mechanical strength to Akulon F223-D and K223-P2 meet these
Akulon F223-D for less demanding criteria.
applications.
11
Extrusion applications
Film
They feature good barrier resistance to Semi-finished materials (stock
Akulon 6 is our range of polyamides 6 for oxygen, carbon dioxide and aromas. shapes)
P L A S T I C S
extrusion and injection moulding. They Additionally they have very high
are commonly used for the production of transparency. Akulon 6 also excels in Stock shapes are semi-finished materials
mono and multiplayer films and made by critical properties like purity and low gel. and extruded or cast rods, mandrels,
cast and blown film extrusion methods. thick-walled tubes, thick sheets and
These films are mostly used for food In food packaging, Akulon 6 is usually profiles. They are easily machined to
E N G I N E E R I N G
packaging applications. The films can be used with a polyolefine material (LDPE or make all kind of products. The excellent
both thermoformed and bi-axially LLDPE). A tie layer is needed to allow properties of engineering plastics give
stretched. co-extrusion of these materials. DSM them very high strength and rigidity,
supplies Yparex, a very suitable C8 and dimension stability, low creep, very good
Monolayer films are used primarily in C6 LLDPE-based-tie-layer material. The tribological and electrical insulation
sausage casings and sauce packaging polyolefines can also be added to properties.
pouches. Multiplayer films are used for monolayer polyamide films by either
cheese and meat packaging and lamination or extrusion coating. Products made from engineering plastics
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medical applications. DSM’s polyamides include all kind of bearings, gear wheels,
have excellent mechanical properties, More information about the bushes, guide rolls, guide strips, pulleys,
including very high puncture resistance. crystallization, barrier properties, buffers, hammer heads, seals, scrapers
mechanical properties and processing of and electrical insulation parts. The most
Akulon 6 is available in an extended important engineering plastics for stock
brochure. shapes are PA6, PA66, POM and PET.
DSM Engineering Plastics offers PA6,
PA66 and PET.
Film for flexible packaging (multilayer); Akulon F126-C, F132-E, F136-C, F136-E and F136-EN.
12
Table 6: Film grades.
The main characteristics of PA6 and
PA66 are: Grade Description
- high mechanical strength, rigidity, F126-C Grade with low viscosity, applicable for multilayer film
hardness and toughness F132-E Grade with medium viscosity, nucleated for flat film
- good shock absorption F136-C Grade with high viscosity, applicable for flat and blown film
- good resistance to fatigue F136-E Grade with high viscosity, nucleated for blown film
- good sliding and bearing properties, F136-EN Grade with high viscosity, improved thermoformability
both dry and lubricated S240-C Grade with high viscosity, applicable for blown film
- excellent wear properties
- good electrical insulation properties.
Table 7: Semi-finished grades.
P L A S T I C S
electrical insulation and good chemical thick-walled tube
resistance, make PA6 an ideal ‘universal’ F160-Z Highest viscosity PA6 grade for thick-walled vacuum seized tube
material for industrial and maintenance S240-C High viscosity PA66 grade for rods and sheet
parts. It is also suitable for use in dirty or S245-C Very high viscosity PA66 grade for big rods and thick-walled
sandy environments, for example for vacuum seized tube
E N G I N E E R I N G
bearings on agricultural equipment, or
support rolls for tracks.
Table 8: Convoluted tube grade.
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moderately lower. The requirements for tubes in these
segments, as well as in the
There is a more extended brochure on electrical/electronic markets, are very
this subject available. This also includes strict, especially on the chemical and
PET and a comparison of DSM materials thermal properties of the material.
to POM.
Still, in the machine construction market
Convoluted tubes metal tubing is being used to a great
extent. But due to its weight and better
Akulon is an excellent material to use as flexibility, there is a trend to use plastics
tube for the protection of electrical wiring more and more often. An emphasis on
and cables. Due to its higher halogen free material and safety issues,
temperature resistance, flexibility and like smoke density, levels direct material
chemical resistance, these tubes are towards polyamide.
often used in under-the-bonnet
Stockshapes.
13
Designing with polyamides
Dimensions
14
Yield stress, modulus of elasticity and Corners and radii Assembly
hardness decrease with increasing
moisture absorption. Toughness, or Sharp internal corners and the resulting Akulon polyamides are suitable for a
impact resistance, shows considerable stress risers are among the most number of assembly techniques,
increase. common causes of structural plastic including heat staking, sonic welding,
product failure. All polyamides are moulded-in or post-mould-insertion
Surface appearance somewhat notch sensitive and glass threaded inserts and snap fits. While
reinforced versions are particularly making allowances for any of these
Some Akulon polyamides are capable of susceptible. The stresses arising from assembly methods, the designer should
a high level of reproduction of the mould internal corners can be minimized by the keep in mind the standard design rules
surface. In general, unreinforced grades use of generous radii. In general, internal for polyamides, i.e. avoiding notches or
offer the best reproduction and glass radii equal to one half the wall thickness - in the case of snap fits - exceeding the
reinforced the worst. Mineral filled best distributes the loads over the strain limits of the material, etcetera.
grades fall somewhere in between. surface of the part. Smaller radii causes
P L A S T I C S
Polyamide 6 will almost always stress concentrations. Larger ones do While adhesive bonding of polyamides
reproduce a mould surface more not significantly help the situation. has been done successfully, the superior
accurately than polyamide 66. All these External corners should maintain a chemical resistance makes this a difficult
guidelines are particularly true of high constant wall thickness around the option. For the best results, the
gloss moulds. Often textures can be radius of the internal corner. This recommendations of the adhesive
E N G I N E E R I N G
used to hide the surface imperfections reduces variations in wall thickness and manufacturer should be followed
inherent to moulding these products. helps prevent warpage and sinks. precisely.
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shorten moulding cycles, reduce part weight and shorten cycle times by outperform PA grades with respect to
weight and optimise material usage. The eliminating heavy cross sections, which the weld strength achieved after the
minimum wall thickness, which can be can substantially reduce costs. Ribs welding process. Lower filler content
used in injection moulding, depends on have their problems, however. Sink grades typically perform better and
the size and geometry of the part and marks may appear on the surface cause fewer processing problems than
the materials flow behaviour. In general, opposite the ribs. Often these can be highly reinforced versions do.
Akulon type 6 grades flow easier than hidden by the strategic use of texture. If
type 66 materials. proper design rules are not followed, ribs
may also cause stress at their
Uniform wall thickness assists consistent intersection with the wall of the part.
even filling of the mould and results in They can be helpful for the product
more predictable shrinkage. When designer if they are only used when they
varying wall thickness are unavoidable are necessary to provide the
for reason or design, there should be mechanical performance of
gradual transitions. the application.
Tailgate handle
Akulon K224-HG6.
15
Injection moulding of polyamides
taper of a polyamide nozzle doesn’t add reinforced polyamide parts have a important to prevent moisture absorption
much benefit. propensity to warp during the post- before moulding, when working with
mould shrinkage phase. For precision polyamides. Akulon is hygroscopic and
Tooling. Akulon polyamides need parts with very tight dimensional absorbs moisture from the air relatively
similar specific tooling requirements as tolerances, it is best to build a prototype quickly. Should this occur prior to
E N G I N E E R I N G
other polyamide materials. For mould. It requires the same gate type, moulding, there can be an adverse effect
unreinforced Akulon, the gates and size, location, etcetera as the production on the quality of the moulding. During
runners can be very small, to save mould to predict shrinkage and warpage storage, containers should be kept
material scrap and reduce cycle times. accurately. closed and undamaged.
Larger parts and/or more highly
reinforced materials require more Auxiliary equipment. The key pieces During moulding the following measures
generous gates and runners. However, of auxiliary equipment include the are recommended:
sub-gates are the most common material dryer, mould heater and scrap - open the container just before filling
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because of their automatic de-gating granulator. Dryers must be sized to the hopper
capability. handle the throughput rate of the - close the container securely if all
moulding machine used. However, the contents have not been used
Most of the major hot manifold key requirement of the dryer is its ability - keep the hopper closed
manufacturers have built manifolds to maintain a dew point between -40 - bring cold granules up to ambient
which have been successfully used with and -30 °C. Dew points above this level temperature in the moulding shop
Akulon polyamides. do not facilitate drying. Mould heat can while keeping the containers shut.
be provided via water or oil. In general,
the temperature requirements of Akulon Every batch is tested for moisture
between 50 and 90 °C can be met using content and viscosity level after
water. production. A certificate with relevant lot
data can be delivered with the materials.
Room-installation
Akulon K222-KGMV14, K223-HM6 and K225-KS.
16
Figure 3. Guideline for cylinder temperatures.
Akulon Polyamide 66
Unreinforced 55-80 270-295 270-295 280-295 275-295 270-290 80
P L A S T I C S
Glass Reinforced 55-95 280-305 280-295 275-290 290-300 280-295 80
All polyamides are hygroscopic and Safety. Under normal conditions, Use of regrind. Regrinding levels of
E N G I N E E R I N G
require special handling to prevent the Akulon does not present a toxic hazard 25% hardly influence short and/or long
absorption of moisture from the through skin contact or inhalation. term properties of Akulon. They are
atmosphere. Akulon polyamides are During processing contact with the therefore recommendable under the
packaged at a maximum level of 0.15% polymer and inhalation of fumes should prerequisite that the regrind must be dry
moisture content. Moisture levels above be avoided. A material safety data sheet as moulded and free from dust and/or
0.2% will cause surface splay on the (MSDS) can be requested from your longs.
moulded parts. local DSM account manager.
In order to achieve the best appearance
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and performance Akulon polyamides Cylinder temperatures. Akulon
should be dried to the recommended polyamide 6 with a melting point of
levels. The equipment for this task 220 °C, can be processed within a
includes dessicant bed dryers, which are broad temperature range, for example
capable of holding the dew point of the 230-290 °C. The melting point of Akulon
circulating air to between -40 and polyamide 66 is 260 °C. It can be
-30 °C. processed at temperatures between
270 and 300 °C (see Figure 3 for
recommended processing parameters).
Keep in mind that these can vary
depending on the specific grade and the
size and condition of the moulding
machine.
Relay box
Akulon K224-HGR24.
17
Characteristic properties of Akulon (PA6 and PA66)
lactams (like PA6, PA11 and PA12). exhibit an even higher temperature showing any signs of flash
PA6 is produced in a ring-opening resistance. - limited dimensional stability due to the
polymerization process starting from absorption of moisture.
caprolactam. The main characteristics of Akulon
Commercial use of the aliphatic PA6 and PA66 are: This combination of properties, which
E N G I N E E R I N G
polyamides is dominated by PA6 and - an excellent short term heat resistance will be discussed more detailed in the
PA66. They are characterized in Table 9. due to the high melting points of following chapters, makes Akulon
220 °C and 260 °C excellently suitable for high performance
The Akulon product line comprises both - high stiffness and strength at elevated technical applications in the automotive,
polyamide 6 (PA6) and polyamide 66 temperatures above 100 °C electrical/electronical and general, other
(PA66) grades. PA6 and PA66 belongs - high creep resistance, especially at industries. In the following sections PA6
together with the polyesters PET and elevated temperatures and PA66, among themselves, are
PET and the polyacetal POM to the - good long-term heat resistance, compared with the polyesters PBT and
D S M
Power tool
Akulon F232-D, K224-G6 and K224-TG9.
18
Figure 4a. Stiffness - with load: creep resistance,
versus temperature respectively without load: Continuous
Use Temperature or Absolute Real
Operating-value.
P L A S T I C S
stiffness/strength level should be
considered as is the critical level to
design for, since room temperature
levels for stiffness/strength are much
higher (even after moisture absorption) in
E N G I N E E R I N G
general.
The shear modulus offers one of the
means of measuring and comparing the
variation of the stiffness of plastic
Figure 4b. Stiffness materials with changing temperature. Its
versus temperature high level of crystallinity in combination
with its high melting point enables
Akulon to retain its stiffness to a
D S M
high extent at elevated
temperatures. This ensures either
more safety margins for critical
applications in comparison to other
competitive materials like polyesters
(see Figure 4). It also implements the
possibility of the reduction of the wall
thickness of the part. lt also should be
noted that up to 185 °C there is hardly
any difference between the stiffness
of PA6 and that of PA66. Only above
185 °C PA66 exhibits a clear advantage.
Engine cover
Akulon K220-HGM44.
19
Stanyl (PA46) of course outperforms Figure 4c. Stiffness
both polyamides with respect to stiffness versus temperature
20
The melting point in combination with Figure 5.
the Heat Distortion Temperature (HDT) Creep modulus
P L A S T I C S
yields only 190 °C).
E N G I N E E R I N G
optimum performance and maximum
lifetime engineering plastics, which are
subjected to long-term loading, must
have a high creep resistance (i.e. a low
Figure 6. Different properties of PA6 30% GF, HS (23 °C) after heat ageing at 170 °C.
plastic deformation level under a certain (Charpy Notched in kJ/m2, Tensile Modulus in MPa, Tensile Elongation in %, Tensile
applied load). Materials specifications for Strength in MPa).
engineering parts therefore often include
a creep modulus, defined as the ratio of
D S M
a constant load and a time dependent
deformation level, or a maximum
allowable elongation. Exposure to higher
temperatures results in lower levels of
creep moduli. Akulon’s high level of
crystallinity results in a high retention of
the stiffness at elevated temperatures
(above 100 °C). It therefore gives rise to
a creep resistance that is superior to that
of other engineering plastics. Again, up
to certain temperatures and exposure
times PA yields a similar performance as
PA66 (see Figure 5).
21
Heat ageing resistance in air. Figure 7. Tensile
Designers must know the performance strength (23 °C)
after heat ageing
level of the material after exposure of
at x °C.
thousands of hours to heat in an oxygen
environment. The performance (the heat
air ageing resistance) can be expressed
in various ways. To monitor the
performance after heat ageing over time,
different parameters can be selected,
like strength, stiffness, impact
resistance, elongation at break
measured either at room temperature
(see Figure 6) or at the elevated
temperature. Again, the results of these
P L A S T I C S
P L A S T I C S
Certain materials, starting at a very low E-modulus (MPa)
level but retaining to a high degree, are 150 °C 4000 4000 5000 4000
better rated in CUT-terms than other 170 °C 3500 3500 4700 3500
materials that start at a higher level and
Note: ARO is the only true measure for heat ageing resistance.
show a stronger reduction. The latter
E N G I N E E R I N G
however can in absolute values still
outperform the former materials after the
heat ageing exposure. Next to that, the
CUT-concept is based on
measurements of properties at room
temperature, whilst the more critical
design levels for stiffness and strength
are to be expected in the elevated
D S M
temperature range (as demonstrated in
Short Term Heat Performance).
The ARO-concept, the only true
measure, is demonstrated in Figures 9
to 12, which show once more the
superiority of PA6 to PA66 after heat
ageing (see also Table 11). The ARO-
performance of Akulon PA6 comes even
close to that of various aromatic
polyamides (PPA). Only Stanyl (PA46)
outperforms PA6 and PPA in this
respect. From the combination of these
curves with curve 5 it follows that,
despite the slight, non-significant
difference in starting value for stiffness
and strength, heat stabilized PA6 with
30% glass fibre easily can replace
heat stabilized PA66 with 30% glass
fibres!
Clutch pedal
Akulon K224-HG8.
23
Figure 9. Tensile strength (23 °C) after heat ageing at 150 °C. Figure 10. Tensile strength (150 °C) after heat ageing at 150 °C.
P L A S T I C S
E N G I N E E R I N G
Figure 11. Tensile strength (23 °C) after heat ageing at 170 °C. Figure 12. Tensile strength (170 °C) after heat ageing at 170 °C.
D S M
24
Table 12. Toughness at room temperature of polyamides (dam) versus polyesters.
Toughness, fatigue and wear
properties Property PA6 PA66 PBT PET
P L A S T I C S
0 °C the notched and unnotched - conditioned at 50% RH 30 20 11 11
impact resistance values of Akulon Charpy Unnotched (kJ/m2) 95 80 65 50
remain at a high level. As can be seen 50% GF 50% GF 50% GF 50% GF
from Table 12 even in a dry-as-moulded Tensile Elongation (%) 3.0 2.5 2.5 2.0
(dam) state the polyamides outperform Charpy Notched (kJ/m2) 22 17 11 12
E N G I N E E R I N G
the polyesters, which facilitates Charpy Unnotched (kJ/m2) 100 85 55 55
production and assembly steps.
Combined with an unequalled level of
elongation at break Akulon offers an stiffness level in combination with the It permits higher pressures or velocities
optimal solution for thin walled parts, high toughness and the use of superior to be used in combination with Akulon.
snap fits, film hinges and insert glass fibre qualities implies a superior Modified Akulon grades (unreinforced as
mouldings. Table 12 also shows that fatigue resistance for Akulon in well as glass fibre reinforced) are
PA6 is again superior to PA66 and comparison to that of most other available with even better wear
D S M
that the effect of different amounts of engineering plastics. properties. They make external
glass fibre reinforcement is different for lubrification redundant. Its smooth and
both toughness parameters. The Akulon has an excellent abrasion (or tough surface, combined with its
elongation at break level decreases, wear) resistance. It outperforms many stiffness at elevated temperatures,
whilst the Charpy and lzod impact other engineering plastics, like POM, makes Akulon an ideal material for
resistance increases with increasing the under most conditions but especially at sliding parts.
amount of glass fibres. elevated temperature conditions. The
friction coefficients of standard grades of
Engineering parts are frequently these thermoplastics are quite similar,
subjected to dynamic loads and but Akulon can outperform these
alternating stress levels. In order to materials because of its higher PV-rating
predict the performance of plastic (see Figure 13).
materials under these conditions the
fatigue resistance is measured by
plotting the stress level variation against
the number of cycles till break endured
under continuous prestress (the so
called ‘Wöhler diagrams’). The high
Inline skate
Akulon K224-PG6.
25
Figure 13. Wear and
Water absorption and hydrolysis friction behaviour
resistance PA6 30% GF.
Cable channels
Akulon K224-HLG3.
26
Figure 15. Akulon oil
Chemical Resistance (including resistance: PA6 30%
resistance against oils and other GF in motor oil.
automotive fluids)
P L A S T I C S
polyamides attacked by strong mineral
acids and absorbs polar solvents.
E N G I N E E R I N G
(hydrolysis). On request, data concerning
the resistance of Akulon to various
chemicals and solvents are available
from your local DSM sales office.
A number of halogen free or halogen
Electrical properties, containing flame retardant grades of
flammability and UL- Akulon are available, rated according to
classifications the Underwriter Laboratories (UL) 94
D S M
classification, either V-0 or V-2 (GWFI of
As most other engineering plastics 960 °C at 1.6 mm). The unmodified,
Akulon exhibits similarly high levels of unreinforced Akulon grades are rated
surface and volume resistivity, dielectric V-2 and the glass fibre reinforced grades
strength and comparative tracking without flame retarder are rated HB.
resistance. The exact levels of these Several other UL-classifications have
properties depend however on the been obtained for different Akulon
specific grade, temperature and grades as well (see UL File E 47960
moisture content. In general, these levels Components Plastics at UL’s website
will remain high enough in order to fulfil data.ul.com).
critical application requirements. This A complete overview of the total system
fact, in combination with its very high rating and more detailed information
peak temperature resistance and its high concerning optimal processing with
toughness level, makes Akulon an Akulon is available at your DSM
excellent choice for electrical and Sales Office.
electronical connectors, circuit breaker
housings, electromotor parts, bobbins
and switches.
27
Figure 16. Positioning
After treatments of thermoplastics.
pressure levels, than corresponding functionality (metallization). Due to the In the previous sections PA6 and PA66
PA66 grades. By its superb level of better surface appearance of are compared with polyesters and
elongation at break reinforced grades, PA6 grades are among themselves. In this section and in
- especially after moisture uptake - (see preferred above the corresponding Figure 16 a short positioning resume is
Table 12) snap fits designed in Akulon PA66 grades. More detailed information presented.
offer many advantages in comparison to is available at your DSM Sales Office.
the other joining techniques. Polyamides versus polyesters
Advantages of polyamides:
- higher stiffness and creep resistance at
elevated temperatures (above 100 °C)
- better heat ageing resistance in terms
of the ARO-values at elevated
temperatures
- higher toughness at low temperatures;
- more fatigue resistance
- excellent wear resistance
28
Table 13. Akulon product coding.
- less sensitivity for hydrolysis in the
applications and for moisture during K 2 2 4 H G 6
processing F, K = PA6
- halogen free flame retardancy in S = PA66
reinforced PA6 grades is possible.
1 = Film extrusion
Advantages of polyesters: 2 = Injection moulding
- better dimensional stability under
humid conditions 0
- better retention of electrical properties 4 = indication of solution viscosity
as function of temperature and/or 6
humidity
- more chemical resistance in acetic B = easy mould release N - thermoformable (film)
environments. C = lubricated P = toughened
P L A S T I C S
D = nucleated, easy mould release Q = FDA approved
Polyamide 6 versus polyamide 66 E = nucleated, lubricated R = glass-sphere reinforced
F = improved flow S = self extinguishing (V-0)
Advantages of PA6: G = glass fibre reinforced T = incrementally toughened (TG)
- better heat ageing resistance in terms H = heat-stabilized, limited colour stability V = flame retarded (not V-0)
E N G I N E E R I N G
of the ARO-values at elevated K = heat-stabilized, good colour stability W = reserved for ‘laser writable’
temperatures L = light/UV stabilized X = additional, specific feature
- higher toughness at low temperature M - mineral reinforced (e.g. high burst pressure)
- easier process ability (broader
processing window) Reinforced content
- higher weld strength after various # x 5 = % glass (e.g. 3 x 5 = 15% glass)
welding processes
- better surface appearance for
D S M
reinforced grades when keeping the wall thickness the Thus in summary, a lot of
- halogen flame retardancy in reinforced same. An easier process ability economical reasons to choose
PA6 grades is possible. (a broader processing window in Akulon (especially the PA6
combination with a lower melting point) product line) as the most optimal
Advantages of PA66: leads to a possibility to achieve lower material for most of your
- higher melting point processing costs as a result of lower applications!
- more stiffness/strength only above energy costs and/or lower cycle times
185 °C. (due to the lower melting point) or to a
possibility to reduce wall thickness even
The advantages above can lead to further as a result of a better flowability
substantially increased profit and/or of the material by using higher
safety margins in your applications. processing temperatures. Higher
Higher stiffness levels at elevated toughness levels leads to lower reject
temperatures and higher ARO-values levels in production or like higher weld
imply for instance either savings on strengths to higher safety margins in
material costs, through the possibility to the applications, whilst better surface
reduce the wall thickness of the appearance leads to an improved
application, or a higher safety margin, image in the market place.
29
DSM Engineering Plastics product portfolio
Akulon® Polyamide 6 and 66 in both unreinforced and reinforced grades, including flame retardant products.
polyamides
Akulon® Ultraflow™ Polyamide 6 reinforced grades, easy flowing, lower processing temperatures,
polyamide faster crystallization speed, shorter injection and holding time, reduced cycle time.
Arnite® PBT and PET based materials, including unreinforced, reinforced, and flame retardant grades,
thermoplastic polyester offering excellent dimensional stability and low creep with good chemical resistance.
P L A S T I C S
Stamylan® UH A high performance polymer having outstanding abrasion resistance in combination with excellent
ultra high molecular impact and chemical resistance, low coefficient of friction and very good electric and dielectric
weight polyethylene properties.
Stanyl® PA46 High temperature polyamide which bridges the price-performance gap between
46 polyamide traditional polyamides and high-performance materials.
D S M
Stapron® Unreinforced and reinforced PC-blends. Flame retardant grades based on halogen free systems.
PC/PET-blend
Xantar® Unreinforced, reinforced, and flame retardant grades with outstanding impact resistance,
polycarbonate dimensional stability, and high heat deflection temperature.
Yparex® This family of extrudable adhesive resins consists of polyolefins with incorporated functional groups,
adhesive resin which provide the necessary bond between polyolefins and polar materials (e.g. PA, EVOH, glass) or
metals (e.g. steel, aluminium, brass, copper).
30
®
Registered tradenames of DSM
D S M E N G I N E E R I N G P L A S T I C S
31
DSM Engineering Plastics Sales offices Europe
Denmark Grabo
DSM Engineering Plastics DSM Scandinavia A/S Tel. +46 302 463 70
P.O. Box 3333 Espergaerde Fax +46 302 463 65
2267 West Mill Road Tel. +45 45 4913 1018
Evansville, IN 47732-3333 Fax +45 45 4913 1078 Turkey
E N G I N E E R I N G
DSM Turkey
Tel. +1 812 435 7500 Eastern Europe Istanbul
Fax +1 812 435 7702 DSM Eastern Europe Tel. +90 216 425 1455
Moscow Fax +90 216 425 1456
Tel. +7 095 234 5663
Asia Fax +7 095 234 5698 United Kingdom
Asia Pacific DSM United Kingdom Ltd.
France Redditch
D S M
32