NEA - Materials

Research & Development
activities
STASSKOL GmbH
Dr. Marc Langela
August, 28th 2009
Lan / 28.08.09
slide 1 / 73
⇒ Outline
• New Materials: why, who and how?
• Development of polymer processing
• Development of polymer characterization
• Material development
• Material production at the STASSKOL site
Lan / 28.08.09
slide 2 / 73
⇒ Polymers – material of 21st century
Production volume from 1950 to 2002
kt
180.000 Worldwide
Worldwide
Production 2002:
Worldwide*) 194.000 kt
140.000 Western Europe 51.000 kt
Germany 16.500 kt
=> 2010: appr. 260.000 kt
100.000
60.000 Western
WesternEurope
Europe
20.000
Germany
Germany
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000
*) including adhesives, paints, dispersions, fibres, etc. Origin: BASF

Lan / 28.08.09
slide 3 / 73
⇒ New Materials – market rules of polymer production
one special application:

many
piston compressor
applications
polymer commodities sealing

sealingmaterial
material
Margin
Margin small
small large
Number
Number of
of applications
applications very
very large
large key
keyfact:
fact:polymers,
polymers, very small
but
buttotally
totallydifferent
different
Scale
Scale of
of production
production very
very large
large very small
market
marketrules
rules
Turnover
Turnover potential
potential high
high low
Optimized materials for compressor sealings are not available from

traditional polymer suppliers like BASF, Evonics, GE, etc.
Need for material optimization by the supplier of compressor sealings! Lan / 28.08.09
slide 4 / 73
⇒ New Materials
Benefits
• Reduction of material costs
• Products with optimized properties
• Better quality control
• Independence from suppliers
• Lower delivery times
Lan / 28.08.09
slide 5 / 73
⇒ New Materials
Requirements
Evaluation of raw materials
Development of
PTFE processing
Development of
characterization methods
Material development
Sealing materials for Sealing materials for

lubricated applications dry-running appl.
Lan / 28.08.09
slide 6 / 73
⇒ Outline
Lan / 28.08.09
slide 7 / 73
⇒ Development of polymer processing
Steps from the powders to the semi finished product
PTFE Additives Lubricants
Homogeneous Powder Mixture
Compression
Molding
Semi finished product

Lan / 28.08.09
slide 8 / 73
Mixing of PTFE and Additives
Mixing procedure
Creating the Cooling down the

Recipe pre-mixture pre-mixture
Transfer of the
mixture in the
mixing device
Mixing device
4200 rpm
10 l Volume Executing the
Programmable
mixing program
Lan / 28.08.09
slide 9 / 73
Molding of PTFE compounds
Rotational axis
Plunger
Core
Shell
PTFE
PTFE
Base plate Pressure plates
Efficient and modular tool concept

Highly reproducible material properties Parameters
Short setup times Pressure, Pressure duration
Large variety of outer and inner diameters Temperature,
Duration of Sinter Process
Tool with further optimizations for hot compression
molding Lan / 28.08.09
slide 10 / 73
⇒ Characterization of sealing materials
1. Material composition & processing

Pressure
Pressure
pre-
form
PTFE
bush-
powder
ing
Cold preforming pre-heated tool Sinter process

under pressure
Pressure free
sinter process complex
(8 h @ 380 °C) temperature profile
- easy process - time consuming process

- average mechanical - excellent mechanical
properties properties
- average wear resistance - high wear resistance Lan / 28.08.09
slide 11 / 73
Test 1 First tool for hot compression

12.09.07 No homogeneous temperature profile
Problems at the ejection of the
bushing
Improved temperature homogeneity

Test 2 Problems at the ejection by
20.09.07 fretting of the tool components
Optimized pressure plate

Test 3 Optimized temperature profile
24.09.07 Small crack caused by
inhomogeneous pressure distribution
Further improvements needed
Lan / 28.08.09
slide 12 / 73
STASSKOL – laboratory
Process steps:
5 WB
4 1 – Mixing of the
Oven
Hydraulic components
Tools
press 2 – Freezing
WB 3 – Homogenization
4 – Pressure application
5 – Sintering
3 1 H
H = Hood
WB M
F = Freezer
2 F
M = Mixing device
B = Bench for
handling
Rack for matrix materials and fillers
Lan / 28.08.09
slide 13 / 73
⇒ Outline
Lan / 28.08.09
slide 14 / 73
⇒ Development of polymer characterization
Basics about tribology
• Origins from the greek word for friction (→tribos).

• Interdisciplinary part of mechanical engineering
• Combination of engineering, material science, physics and chemistry
• Scientific description of friction, wear and lubrication
• Development of technologies for optimization of friction behavior.
Economic importance:
About 5 % of the gross products of the industrial nations are getting lost by
friction and wear
This means for Germany: 35 Billion EUR/Year
[Origin: Society of tribology; 2007].
Lan / 28.08.09
slide 15 / 73
• Tribology is always a system property and never a material property!
Temperature,
Pressure,
Polymer matrix 1. Material
Material 2. Service Gas,
Fillers composition
composition parameter Dew point,
Lubricants Counter surface,
Roughness of CS,
etc.
3. Testing
equipment
Test rig design
Direction of
Movement,
sample geometry,
Samples can be very wear resistant in one system etc.
and they can fail in systems
with other operational conditions.
A material testing procedure close to the compressor is needed!
Lan / 28.08.09
slide 16 / 73
PTFE – A long history of an innovative material
1941 – Patent of PTFE under the

brand name Teflon® by DuPont.
1946 – Use of PTFE for machine parts at
industrial and military applications
1960 – Start of the career as anti-stick coating for
frying pans
Roy Plunkett, 1938
PTFE as „accident“...
• Today:
Broad product family based on PTFE
(coatings, films, powders, sheets,
grades for injection molding, etc.)
Distribution under a large variety of product names
• Usage in a broad spectrum in the industry
from aerospace to pharmacy
• Distribution of PTFE in over 40 countries
Lan / 28.08.09
slide 17 / 73
Basic properties of native PTFE
• Outstanding resistance against light and weather
• Outstanding chemical resistance but

no resistance against fluorinated gases (e.g. cooling agents)
• No detectable water absorption
• Lowest friction coefficient of all commercial polymers
• High cold flow (poor mechanical properties)
• Extremely high wear rate (not suitable for compressor sealings)
Fillers and lubricants have to be added to overcome the

high cold flow and high wear rate
Lan / 28.08.09
slide 18 / 73
Fillers (mainly improving the mechanical properties)
• Glass fibers und Glass pearls

• Metal powders (e.g. bronze or steel powder)
• Carbon fibers
• Carbon black (hard and/or weak)
Lubricants (mainly improving the tribological properties)
• Graphite
• Molybdenum disulfide
Lan / 28.08.09
slide 19 / 73
Optimization of the wear properties
• Despite its excellent properties, the wear rate and the cold flow of PTFE
are to high for engineering applications.
These properties can be improved considerably by adding suitable fillers.
mechan. friction chemical expansion thermal

parameter cold flow wear
properties coefficient resistance coefficient conductivity
virgin
PTFE
PTFE +
Fillers
anorg./org
trends: blue: no effect
red: negativ The choice of the fillers and lubricants

and the right concentrations are responsible
green: positiv
for matching the application requirements
Lan / 28.08.09
slide 20 / 73
Temperature,
Pressure,
Polymer matrix 1. Material 2. Service
Service Gas,
Fillers composition parameter
parameter Dew point,
Roughness of CS,
etc.
3. Testing
equipment
Test rig design
Direction of
Movement,
sample geometry,
A material testing close to the compressor is needed!
Lan / 28.08.09
slide 21 / 73
Tribological System
Operation conditions (Temperature, velocity, etc.)
Structure of the tribological system

intermediate
Sample system
(gas and/or
Counter lubricant)
suface
Structural changes of the surface friction coefficient, wear rate

(visual effects) (measured properties)
Tribology is always a system property and never a material property!

Samples can be very wear resistant in one system and
they can fail in systems with other operational conditions.
Lan / 28.08.09
slide 22 / 73
Tribological system of a piston compressor
Parameters:
• Material of the sealing ring (composition)
• Material of the piston rod or cylinder (with or without coatings)
• Lubrication (intermediate substance)
• Surrounding media (e.g. gas type)
• Temperature
• Dew point of the gas
• Roughness of the piston rod or cylinder
• Pressure of application
• Velocity of the piston rod or piston
Changing one parameter can change the tribological material behavior!
Lan / 28.08.09
slide 23 / 73
Service parameters – Classification of the gas system
Gas
oxidizing inert reducing

(air, O2) (N2) (H2, CH4)
Humidity
wet dry bone-dry
Major focus of actual developments: dry and bone-dry gases.

Improvements against competitor materials
The other parameter (T, p, etc.) have also be close to the application Lan / 28.08.09
slide 24 / 73
Temperature,
Pressure,
Polymer matrix 1. Material 2. Service Gas,
Fillers composition parameter Dew point,
Roughness of CS,
etc.
3. Testing
Testing
equipment
equipment
Test rig design
Direction of
Movement,
sample geometry,
A material testing close to the compressor is needed!
Lan / 28.08.09
slide 25 / 73
Wear measurement
Measurement of the wear rate by a pin/disc tribometer
p (pressure of application)
sample pin
counter surface
Parameters
• Continuous measurement of
friction coefficients,
wear rates and temperature
v (velocity of rotation)
• Sample velocity of up to 6 m/sec
The absolute wear [mm] is proportional to the pressure (p in N/mm2), • Variable contact pressures
to the friction velocity (v in m/sec) and to the test duration (t in sec) • Controlled temperature of
the counter surface up to 150°C
wear
This means: wear rate k = [mm3/Nm] • Different gaseous media
pvt (N2, H2, CH4...)
Friction coefficient: µ = FR/FN • Dew point: below - 80°C
• Exchangeable counter surfaces
(X20,GG, Repcoat, Ni-Resist...)
But: Is it comparable to oscillating movement?
Lan / 28.08.09
slide 26 / 73
Comparison of tribological behavior under

rotational and oscillatory movement
material rotation oscillation c. surf.

k-fact. temp. time k-fact. temp. time
Comparison between the results of tribological characterization
The tribological properties under rotational movement are not corresponding

to the tribological properties under oscillatory movement
The results of rotational tribology can not be converted to the test compressor
A oscillatory tribometer comparable to the compressor is needed!
Lan / 28.08.09
slide 27 / 73
Wear measurement under reciprocating movement
Principle of measurement
Pressure load p = FN / A Test duration ∆t
Frictional Direction
Sample
force FF of movement
∆l (speed v)
Counter surface
Two major responses:
a) Friction coefficient: µ = FF / FN Temperature
b) Wear rate: k = ∆l / (p v ∆t) Life-time (Reliability)

Lan / 28.08.09
slide 28 / 73
Oscillating Tribometer – Requirements
• Continuous measurement of friction coefficients,

wear rates and temperature
• Stroke of 130 mm
• Average sample velocity of up to 6 m/s
• Normal force to counter surface: 50 N to 500 N (pressures of 10 bars to 100 bars)
• Simultaneous test of 4 samples
• Controlled temperature of the counter surface up to 200°C
• Different gaseous media (N2, H2, CH4...)
• Dew point: below - 80°C (adjustable)
• Exchangeable counter surfaces of different materials
(X20,GG, Tungsten carbide, Repcoat, Ni-Resist...)
Drive train and working principle of the tribometer has to be

comparable to a piston compressor
Transferability of the results

Lan / 28.08.09
slide 29 / 73
Oscillating tribometer – time line
Project start: 20.08.2007
Validation of measuring unit: 25.10.2007
Complete drawings for

the drive train: 11.01.2008
Completion of tribometer
construction: KW18
Test runs at the supplier: KW18 - KW22
Tribometer at STASSKOL: July 2008
Status: Tests on reproducibility

and transferability
Material development
Lan / 28.08.09
slide 30 / 73
Oscillating Tribometer – Operating @ STASSKOL site
Oscillating tribometer under process gas

with temperature controlling units
Tribometer head in detail Lan / 28.08.09

slide 31 / 73
The STASSKOL-COMPRESSOR for close-to-service testing
Lan / 28.08.09
slide 32 / 73
Lan / 28.08.09
slide 33 / 73
Highlights:
a) variable length of packing
b) Cooled / uncooled packings
c) Various systems of packings
d) Monitoring the pressure and temperature
of each packing chamber
e) Monitoring of packing´s leakage
f) Various rod diameters
g) 250 bar final pressure for non lube application
h) Cooled rod
i) Applied gases: N2, H2, CH4, AIR, CO2
Lan / 28.08.09
slide 34 / 73
Layout of the piston rod packing
Sealing ring pair

Measurement of the
Leakage gas sealing chamber temperature
Measurement of the
gas temperature
Pressure
breaker
Pressure measurement
Determination of the working principle of the piston rod packing Lan / 28.08.09
slide 35 / 73
⇒ Outline
Lan / 28.08.09
slide 36 / 73
⇒ Material development at STASSKOL
Development process
“real-Testing” (FPM)
Mixing
Test planning
Product (Field)
Analysis Finding the right mix
Parameters
• Material composition
• Processing parameters (p, T, ...)
• Testing conditions
(p, T, v, t, gas)
Semi finished Characterization •...
product (tribological,
mechanical, etc.)
Efficient chain for a quick development of custom-made materials!

Lan / 28.08.09
slide 37 / 73
⇒ Material development at STASSKOL
STASSKOL – Development Database
Raw materials Lot no., sample, etc.
Mixing
Mixture Mixture no., sample, etc.
Molding
Bushing Bushing no., etc.
Machining
Sealing ring Tribometer Pins Tensile test

Bushing no..
samples
Database for material processing and handling

Documentation of all steps for 100% traceability Lan / 28.08.09
slide 38 / 73
⇒ Material development
Properties of STASSKOL materials for lubricated applications
Density Modulus Elongation k-factor* µ-

Material Additives
[g/cm3] [MPa] at break [%] [10-7mm3/Nm] factor*
Competitor 1 2,22 970 147 2,3 0,07 GF
Competitor 2 2,24 1104 300 2,5 0,07 GF
STASSKOL 2,24 1278 232 0,6 0,06 GF + CP
GF = Glass fibers, CP = Color pigment, * = rotating, X20CrMo13
STASSKOL materials can be colorful

Higher modules of STASSKOL materials
Lower friction coefficients of STASSKOL materials
Lower wear rates of STASSKOL materials
Higher time of service is expected
Lan / 28.08.09
slide 39 / 73
Properties of STASSKOL materials for lubricated applications
Morphology of STASSKOL Materials by Scanning Electron Microscopy
Sample 1:
Material composition:
PTFE + glass fiber + color pigment
x 20
magnification
Homogeneous distribution and good bonding of filler

particles Lan / 28.08.09
slide 40 / 73
Development goal: dry Hydrogen applications
Gas

reducing
(air, O2) (N2) (H2, CH4)
Humidity
wet dry
dry bone-dry
Development of a sealing material for dry Hydrogen applications
Lan / 28.08.09
slide 41 / 73
Development of a substitute of FOF-315
Measuring unit 1 2 3 4
Bushing no. 20080514-1 20080514-2 20080514-3 20080514-4
Filler & Carbon black Carbon fiber Carbon black Carbon fiber
Processing (cold comp.) (cold comp.) (hot comp.) (hot comp.)
Counter surface GG 30 GG 30 GG 30 GG 30
Contact force 50 N 50 N 50 N 50 N
Temperature - - - -
Velocity 2,7 m/sec 2,7 m/sec 2,7 m/sec 2,7 m/sec
Gas Air Air Air Air
Test duration: 12 hours
Tribometer test run no. 389

Lan / 28.08.09
slide 42 / 73
Oscillation tribometer – test run no. 389 vs. compressor run B15
Wear k-Factor Wear k-Factor

Wear Wear Wear Wear
Σ Ch1, Ch2 V389 Σ Ch1, Ch2 V389
Packing Material CR Ch1 SR Ch1 CR Ch2 SR Ch2
absolute absolute normalized normalized
[mm] [mm] [mm] [mm]
[mm] [mm3/Nm] [a.u.] [a.u.]
1 H20080514-1 0,083 0,210 0,083 0,123 0,499 2,08E-5 12,5 11,1
2 H20080514-3 0,147 0,300 0,143 0,177 0,767 2,54E-5 19,2 13,6
3 H20080514-4 0,000 0,000 0,010 0,030 0,040 1,87E-6 1,0 1,0
4 FOF-315 0,120 0,367 0,097 0,090 0,674 - 16,9 -
Differences: CR = cover ring

SR = sealing ring
Counter surface, temperatures, gas, dew point Ch = chamber
Results of STASSKOL compressor and oscillating tribometer

were comparable
Two STASSKOL materials did have lower wear than FOF-315
Further development was done to improve the performance Lan / 28.08.09

slide 43 / 73
SK-404 – performance comparison versus FOF-315
a) Results from the oscillating tribometer 900
800 wear of the test specimen

wear rates: vs. ∆s
700
time
FOF-315: 600
∆t
wear [µm]
k = 5.6 10-7 Parameter: ∆s
500
∆t
• hydrogen gas
H20080714-4: • velocity: 2,7 m/sec
400
k = 4.2 10-7 • pressure: 26 bar 300

• X20WC count. surf. FOF-315 (Garlock)
200
unit: • temp.: 100 °C H20080714-4 (STASSKOL)
100
mm3/Nm 0 5 10 15 20 25 30 35 40 45 50 55 60 65
test duration [h]

b) Results from the test compressor
Test run no. Packing Material Total wear [mm] Pressure work [Nsec/mm2] Wear rate [mm3/Nm]
B15 4 FOF-315 0,68 1,97 106 12,8 10-7
B17 4 H20080714-4 0,43 3,19 106 6,2 10-7
Better performance of SK-404 on both – osz. tribometer and test-compressor

Next step: Field experience to verify the results Lan / 28.08.09
slide 44 / 73
Field test of SK404 - parameters of operation
Suction pressure: 4,7 bar (68.2 psi)

Discharge pressure: 9,7 bar (140.7 psi)
Suction temperature: 22 °C (71.6 °F)
Discharge temperature: 92 °C (197.6 °F)
Speed: 441 rpm
Stroke: 230 mm
Mean piston speed: 3,4 m/sec
Piston rod diameter: 80 mm
Analysis of the host gas
Average molecular weight: 7.411 g/mol Lan / 28.08.09

slide 45 / 73
Design of packing A – single sealing ring design out of FOF 315
Lan / 28.08.09
slide 46 / 73
Design of packing B – traditional design out of SK404
Lan / 28.08.09
slide 47 / 73
Sealing ring designs Traditional design
Advantages of the single sealing ring design
• Less space required

• Lower frictional energy Gap
• Homogeneous pressure distribution
• Lower wear of the ring segments
• Higher service life-time
Gap
Single sealing ring design Spring Ring segments
Gap
Flow
channel
Outer groove Inner groove Lan / 28.08.09

slide 48 / 73
Last report on packing’s operational conditions (April 24th 2009)
Lan / 28.08.09
slide 49 / 73
Measurement report on packing A (FOF315 – single sealing rings)
Every single sealing ring has still some gap left for adjustment
Buffer gas system is in a very good condition

Lan / 28.08.09
slide 50 / 73
Measurement report on packing B (SK404 – tangential cutted rings)
Only 1 ring pair and 1 cover ring are still operational
Buffer gas system is in a “like-new condition”

Lan / 28.08.09
slide 51 / 73
Result of the SK404 field test
• Good performance of the new material
• Material will be used at Polysilicon applications
• Also general permission to use the material at other hydrogen applications

(Dew points down to – 50 °C)
• Actual production volume: ~ 30 bushings / week
• Actual possible dimensions: up to 200 mm (outer diameter)
• Future developments: The material will be tested after processing by

hot compression molding
Lan / 28.08.09
slide 52 / 73
Development goal – dry Nitrogen applications
Gas

(air, O2) (N2) (H2, CH4)
Humidity
wet dry bone-dry
Major focus for actual developments are on dry Nitrogen
Lan / 28.08.09
slide 53 / 73
Development of SK-701 (V1)
a) Test at the STASSKOL oscillating tribometer
Parameter: • Temperature: 100 °C

• Pressure: ~ 30 bar
• Test duration: 15 hrs
• Stroke: 130 mm
• Velocity: 2.7 m/sec
• Hydrogen gas (Td < - 50 °C)
• CSF: steel with TC coating
Materials
H20090107-4 H20090107-5 SK-404 (V1) SK-801 (V1) H20090211-1 SK-701 (V1) Comp. mat. 1 Comp. mat. 2
STASSKOL STASSKOL STASSKOL STASSKOL STASSKOL STASSKOL Competitor Competitor

Pricing Pricing Pricing Pricing Pricing Pricing Pricing Pricing
Experiment Experiment Commercial Commercial Experiment Commercial Commercial Commercial
Lan / 28.08.09
slide 54 / 73
wear rates of the
wear rate [mm3/Nm]

investigated materials
RELIABILITY!
friction coefficients
of the investigated materials
actual:
Compressor-Test
Lan / 28.08.09
SK-701 Optimum of performance & pricing & Field-Test
slide 55 / 73
Field test of SK-701 (V1)
Compressor is running at Air Liquide WOB since 6th of march 2009 Lan / 28.08.09
slide 56 / 73
Development goal – bone-dry Hydrogen applications
Gas

reducing
(air, O2) (N2) (H2, CH4)
Humidity
wet dry bone-dry

bone-dry
Major focus for actual developments are on dry and bone-dry Hydrogen
Lan / 28.08.09
slide 57 / 73
Material of the 1st approach
Density Modulus k-factor*

Material µ-factor*
[g/cm3] [MPa] [10-7mm3/Nm]
M20070903-2 1,951 2254 0,6 0,05
SK 801 1,875 1778 0,1 0,03

CPI 184 1,826 1651 0,8 0,10
PTFE + thermoplastic polymer + carbon + lubricants
Processed by using an optimized tool

Processed by using optimized pressure and temperature profiles
Compact material with a high density and a high modulus
Characterization of tribological properties in progress
Lan / 28.08.09
slide 58 / 73
Test runs at the compressor
Exp. Packing Material Total wear pSuct Leakage Gas Td [°C]

no. no. [mm] [bar] [m3/h]
D15 1 SK 801 0,27 30 10,3 CH4 - 91
D15 2 M20070903-2 0,21 30 3,1 CH4 - 91
A18 1 SK 801 0,48 27 0,0 N2 - 91
A18 2 M20070903-2 0,42 27 0,0 N2 - 91
A19 1 CPI 184 0,30 32 2,0 N2 - 92
A19 2 M20070903-2 0,33 32 2,0 N2 - 92
B14 1 CPI 184 0,52 32 2,0 H2 - 95
B14 2 M20070903-2 1,25 32 2,0 H2 - 95
duration: 210 h
New STASSKOL material has similar wear under nitrogen geometry: 3/3tlg.
Further developments are necessary
Further testing under hydrogen is necessary

Long runs are necessary Lan / 28.08.09
slide 59 / 73
Test of the 1st material at the oscillating tribometer
1400 Parameter:
wear rates: 1300 wear of the specimen vs. time • hydrogen gas
1200 • velocity.: 2,7 m/sec
CPI-184: 1100 • pressure: 26 bar
k = 5 10-7 1000 • X20WC counter surface
• temperature: 100 °C
wear [µm]
900
800
M20070903-2:
700
k = 20 10-7 600 M20070903-2
CPI-184
500
unit: 400
mm3/Nm 300
200
0 2 4 6 8 10 12 14 16 18 20 22 24
test duration [h]
Further improvements are necessary in order to beat CPI-184 Lan / 28.08.09

slide 60 / 73

• Stroke: 130 mm
• Hydrogen gas (Td < - 50 °C)
H20080620-1 H20080627-1 H20080620-3 H20080620-4 H20080620-5 H20080620-6 H20080620-7 H20080620-8

Filler A Filler A Filler A Filler A Filler B Filler B Filler B Filler B
Lubricant A Lubricant B Lubricant C Lubricant D Lubricant A Lubricant B Lubricant C Lubricant D
Wear Resistance is significantly based on Material Composition!

Lan / 28.08.09
slide 61 / 73

-6
Parameter:
1,6x10
-6
• hydrogen gas
1,4x10 H20080620-1 • velocity.: 2,7 m/sec
-6 H20080627-1 • pressure: 26 bar
1,2x10
wear rate [mm /Nm]

H20080620-3
• X20WC counter surface
-6 H20080620-4
wear rates of the 1,0x10
H20080620-5 • temperature: 100 °C
investigated materials 3 8,0x10
-7 H20080620-6
H20080620-7
6,0x10
-7 H20080620-8
CPI-184
Comp. mat.
-7
0,50 4,0x10
-7
0,45 2,0x10
H20080620-1
friction coefficient µ [a.u.]
0,40 H20080627-1 0,0

H20080620-3
0,35
H20080620-4
0,30 H20080620-5
H20080620-6
0,25
H20080620-7
0,20 H20080620-8
CPI-184
Comp.
0,15
mat. friction coefficients
0,10
0,05
0,00
Lan / 28.08.09
Next step: test runs at the compressor under hydrogen gas
slide 62 / 73

• Stroke: 130 mm
• Hydrogen gas (Td = - 80 °C)
Materials at the test:
SK801 Version 1 SK801 Version 2 Comp mat 1 Comp mat 2 Comp mat 3
Commercial Newly developed Commercial Commercial Commercial
STASSKOL STASSKOL Competitor Competitor Competitor
Highest wear resistance at SK801 Version 2

Lan / 28.08.09
slide 63 / 73
Development of SK-801 (V2) Parameter:

• hydrogen gas
• velocity.: 2.7 m/sec
• pressure: 20 bar
• CSF: steel with TC coat.
wear rates of the • temperature: 120 °C
investigated materials
RELIABILITY!
friction coefficients
Lan / 28.08.09
Better performance than Competitor materials / Actual: Compressor run
slide 64 / 73
Roadmap 1. Further developments for the

replacement of competitor materials
2. Long runs
under service conditions
at our test compressor
3. Tests in the field at

selected customers
Lan / 28.08.09
slide 65 / 73
⇒ Outline
Lan / 28.08.09
slide 66 / 73
⇒ Material production site
New building is planned

only for production of
semi-finished products Border
(bushings of sealing materials) (+ 3 m Space)
Mischraum
(abgesaugt)
Two big advantages: 5,0 m
a) Independent from expensive

Produktionshalle
2x2m
material from competitors Büro

WC
4x4m
b) Shorter delivery times

8 m distance between buildings
Flaschenlager
Test bedPrüfstand
Lan / 28.08.09
slide 67 / 73
Map of the ground floor ABL

s) D HV HV HV HV
(Ga
N 2
HV HV
Small room HV HV
creating powder mixtures Ofe

n
R7
n
Ofe
Tisch
R6
Large room R5
Presse
ppe
bushing production Tre
D D
Ofen
Tisch
ch Ofen
Tis
Presse
M1
D R1 Ofen
GS M2 Presse
GS Mixing room Tisch

(Air filter system) D D
AZ
32 m2 213 m2
Tisch
Tisch
N2
W
+
Dusche WC
R2
R3 R4
+
Presse
+
10 m2 10 m2
S S S S W W W W Elektro S +
ABL ABL
Lan / 28.08.09
slide 68 / 73
Map of the 1st floor
reppe
T
+
Office for administrative stuff
+
HRA
S S
Archive for collecting
• order documentation Tisch Office
• mixing reports 19 m2
• reports of bushing production
Tisch S
• samples of raw materials
• samples of powder mixtures
Archive
19 m2
Lan / 28.08.09
slide 69 / 73
Some figures of the material production
• Planned capacity of 100 kg of powder mixture per day
• Planned capacity of 80 bushings per day (cold compression molding)
• Planned capacity of 8 bushings per day (hot compression molding)
• Largest outer diameter of a bushing: 1000 mm
• Total stuff at maximum capacity: 6 to 7 people
• Beginning of construction: September 2009
• End of construction: January 2010

Lan / 28.08.09
slide 70 / 73
⇒ Summary
• Virgin PTFE is not suitable for compressor applications
• Fillers and lubricants have to be added
• The new STASSKOL oscillating tribometer

is the key to success!
• The efficient development process at STASSKOL

enables short optimization times for custom-made materials
• STASSKOL will produce the bushings at its own site
Thank you very much for your attention!

Lan / 28.08.09
slide 71 / 73

NEA - Materials

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

NEA - Materials

Transféré par

Droits d'auteur :

Formats disponibles

Research & Development

• New Materials: why, who and how?

• Development of polymer processing

• Development of polymer characterization

• Material production at the STASSKOL site

Production volume from 1950 to 2002

*) including adhesives, paints, dispersions, fibres, etc. Origin: BASF

one special application:

polymer commodities sealing

Optimized materials for compressor sealings are not available from

• Reduction of material costs

• Products with optimized properties

• Better quality control

• Independence from suppliers

• Lower delivery times

Sealing materials for Sealing materials for

• New Materials: why, who and how?

• Development of polymer processing

• Development of polymer characterization

• Material production at the STASSKOL site

Steps from the powders to the semi finished product

PTFE Additives Lubricants

Homogeneous Powder Mixture

Semi finished product

Mixing of PTFE and Additives

Creating the Cooling down the

Molding of PTFE compounds

Efficient and modular tool concept

1. Material composition & processing

Cold preforming pre-heated tool Sinter process

- easy process - time consuming process

Test 1 First tool for hot compression

Improved temperature homogeneity

Optimized pressure plate

• New Materials: why, who and how?

• Development of polymer processing

• Development of polymer characterization

• Material production at the STASSKOL site

Basics about tribology

• Origins from the greek word for friction (→tribos).

Basics about tribology

• Tribology is always a system property and never a material property!

PTFE – A long history of an innovative material

1941 – Patent of PTFE under the

Basic properties of native PTFE

• Outstanding resistance against light and weather

• Outstanding chemical resistance but

• No detectable water absorption

• Lowest friction coefficient of all commercial polymers

• High cold flow (poor mechanical properties)

• Extremely high wear rate (not suitable for compressor sealings)

Fillers and lubricants have to be added to overcome the

Fillers (mainly improving the mechanical properties)

• Glass fibers und Glass pearls

Lubricants (mainly improving the tribological properties)

Optimization of the wear properties

mechan. friction chemical expansion thermal

trends: blue: no effect

red: negativ The choice of the fillers and lubricants

Basics about tribology

• Tribology is always a system property and never a material property!

Operation conditions (Temperature, velocity, etc.)

Structure of the tribological system

Structural changes of the surface friction coefficient, wear rate