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DuPont Superstructural Web Seminar

PUSHING BACK THE BARRIERS TO METAL REPLACEMENT

February 28, 2006

DuPont Superstructural Web Seminar


PUSHING BACK THE BARRIERS TO METAL REPLACEMENT

The information and suggestions provided in this on-line seminar are based on data believed to be reliable, but the DuPont Company makes no warranties express or implied as to their accuracy and assumes no responsibility or liability arising out of its use by others. Further, the information and suggestions are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a particular material for a particular purpose. DuPont makes no guarantee of results and assumes no obligation or liability in connection with the use of the information or suggestions provided in this seminar.

Pushing Back the Barriers to Metal Replacement


Presented by:

Bob Tabasko
Superstructural Market Development Leader

Gary Kozielski
Technical Consultant Superstructural Products

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary

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The Introduction to Superstructural


Family of resins with exceptional structural properties
Potential to provide: ultra high, consistent stiffness and strength capability
outstanding impact performance excellent creep resistance structural performance at elevated temperatures

Based upon: Zytel HTN high performance polyamide technology (greater than 35% glass reinforced)
Long glass fiber reinforced Zytel HTN and PA66 resins Rynite glass-reinforced polyester

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The Introduction to Superstructural

Less than 4% of metal applications have been converted to engineering plastics.

Superstructural grades open up a host of new metal replacement opportunities!

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary

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Pushing Back the Barriers to Metal Replacement


Steel

Zn Al

Tensile Strength

Reinforced Standard EP Resins

Unreinforced

Tensile Modulus

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Pushing Back the Barriers to Metal Replacement


Steel

Zn Al

Tensile Strength

Reinforced Standard EP Resins

Superstructural

e tur Fu

Unreinforced

Tensile Modulus

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Superstructural Key Grades


Reinforcement Type Standard Fiber Length Filler Level Zytel HTN51 51G45HSL Zytel HTN52 52G45HSL Zytel HTN53 Zytel HTN54 Zytel PA66 Rynite PET Rynite 545

45

50

53G50HSLR

54G50HSLR

Rynite 555 (55% glass)

60

70G60HSL

Long Length

40

75LG40HSL

50

51LG50HSL

75LG50HSL

60

75LG60HSL

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Key Features of the Zytel HTN Product Families


Superstructural
Ultra Stiff High Strength Excellent Creep Resistance HTN51 Series
Outstanding retention of properties with moisture Improved dimensional stability Retains high level of stiffness up to 140C PPA resin

HTN52 Series
Highest melting point and deflection temperature Moldable in water heated tools PPA resin

HTN53 Series
Highest stiffness/strength at ambient temperatures Good toughness Outstanding surface finish Water heated tools

HTN54 Series
Good toughness High burst pressure and knit line strength Retention of properties with moisture Retains high level of stiffness up to 110C Water heated tools PPA resin

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary

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What is Zytel HTN


Zytel HTN high performance polyamides are partially aromatic nylons. Most, but not all, Zytel HTN resins fall within the narrower family of polymers known as PPA (Polyphthalamide), within which they offer perhaps the best combination of highest performance and ease of processing.

Di-amine

Aromatic Di-acid

O
-C-

[- NH-(CH

) 6 - NH - C-

]n

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What is Zytel HTN


Due to its Aromatic Ingredient, Parts Made With Zytel HTN Have Excellent Chemical Resistance, and High Temperature Performance Polyamide
Aromatic (Partially) PPA 55% or More
HTN51 HTN52 HTN54 Other PPAs

Aliphatic
Aromatic Di-Acids

Aromatic (Partially)

Aromatic (Fully) Aramid 100%


KEVLAR NOMEX

0%
Examples: Zytel PA66 Zytel PA6 Zytel PA612

Less Than 55%


HTN53 PAMXD6 PA66 + PA6I/6T

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Superstructural: LFRTs Long Fiber Reinforced Thermoplastics


Fiber length in granules12 mm

Fiber length in molded parts are typically 34 mm versus 0.3 mm for standard glass fiber resins
Component design plus processing conditions govern average fiber length and therefore part performance Knit line strength of LFRTs may also be an issue for certain designs

Specific guidelines are available from DuPont for both of these points

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Ultra High Strength and Stiffness


260
Glass fiber reinforced engineering polymers

Polyamides conditioned to 50% RH

240 220
ISO 527

200 180
PA46 50% GF PA66 43% GF PPS 40% GF PBT 50% GF PPS 50% Long Glass

Stress at Break (MPa)

160 140
PP 50% Long glass

120 100 8 10 12 14
ISO 527

16

18

20

Tensile Modulus DAM (GPa)

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Ultra High Strength and Stiffness


260
Glass fiber reinforced engineering polymers

Polyamides conditioned to 50% RH

240 220
ISO 527

DuPont EP Superstructural standard glass fiber reinforced products

Zytel HTN51G45HSL

Zytel HTN53G50HSLR Zytel HTN52G45HSL

200 180
PA46 50% GF PA66 43% GF Zytel 70G60HSL

Zytel HTN54G50HSLR Rynite 545 Rynite 555

Stress at Break (MPa)

PPS 40% GF PBT 50% GF

160 140
PP 50% Long glass

PPS 50% Long Glass

120 100 8 10 12 14
ISO 527

16

18

20

Tensile Modulus DAM (GPa)

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Ultra High Strength and Stiffness


260
Glass fiber reinforced engineering polymers

Polyamides conditioned to 50% RH

240 220
ISO 527

DuPont EP Superstructural standard glass fiber reinforced products DuPont EP Superstructural long glass fiber reinforced products

Zytel HTN51G45HSL Zytel HTN51LG50HSL Zytel HTN53G50HSLR Zytel 75LG60HSL Zytel HTN54G50HSLR

Zytel 75LG50HSL Zytel HTN52G45HSL Zytel 75LG40HSL Zytel 70G60HSL PA46 50% GF PA66 43% GF

200 180 160

Rynite 545

Rynite 555

Stress at Break (MPa)

PPS 40% GF PBT 50% GF

PPS 50% Long Glass

140
PP 50% Long glass

120 100 8 10 12 14
ISO 527

16

18

20

Tensile Modulus DAM (GPa)

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Long GlassHigh Notched Impact Strength and Modulus


70
Glass fiber reinforced engineering polymers DuPont EP Superstructural standard glass fiber reinforced products

Polyamides conditioned to 50% RH

ISO 179

60

50

Notched Charpy Impact Strength (kJ/m2)

40

30

PA46 50% GF PP 50% Long glass

20

PA66 43% GF Zytel 70G60HSL

Zytel HTN53G50HSLR Zytel HTN54G50HSLR Rynite 545 Rynite 555

10

PPS 40%GF

Zytel HTN51G45HSL

0 6 8 10 12 14
ISO 527

16

18

20

Tensile Modulus (GPa)

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Long GlassHigh Notched Impact Strength and Modulus


70
Glass fiber reinforced engineering polymers

Polyamides conditioned to 50% RH

ISO 179

60

DuPont EP Superstructural standard glass fiber reinforced products DuPont EP Superstructural long glass fiber reinforced products

Zytel 75LG60HSL Zytel 75LG50HSL

50
Zytel 75LG40HSL

Notched Charpy Impact Strength (kJ/m2)

Zytel HTN51LG50HSL

40

30

PA46 50% GF PP 50% Long glass

20

PA66 43% GF Zytel 70G60HSL

Zytel HTN53G50HSLR Zytel HTN54G50HSLR Rynite 545 Zytel HTN 51G45HSL

10

PPS 40%GF

Rynite 555

0 6 8 10 12 14
ISO 527

16

18

20

Tensile Modulus (GPa)

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Long GlassResins Increase Multiaxial Impact Performance


Zytel Long Glass resins not only offer higher drop weight impact and notched impact resistance, but the nature of the break is more contained
25

Energy to Max Load


20

Total Energy

15

Joules

10

0 PA66 50% GR BK Zytel 75LG50L NC010

DAM ISO 663 3 mm Disc

PA66 50% GR BK

Zytel 75LG50L NC010

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Benefits Through Mechanical Properties


Zytel HTN Superstructural grades provide an excellent balance of strength, stiffness and impact performance compared to other glass fiber reinforced polyamides. Very low moisture effects give a major advantage Stress at Break (MPa)
300 20 18 250 16 14 12 150 10 8 100 6 4 2 0 HTN51G45HSL PA66 43%GR DAM HTN51LG50HSL 50% RH PA46 50% GR 0 HTN51G45HSL PA66 43%GR DAM HTN51LG50HSL 50% RH PA46 50% GR

Tensile Modulus (GPa)

200

50

ISO 527

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Extending Temperature Extremes


Long glass fiber increases the deflection temperature, allowing higher loads as temperatures heat up.
285 280
Standard Glass Long Glass

ISO 75

275 270 265 260 255 250 245 240 235

DTUL, C

66 PA

G 50 %

el Zyt

L 0HS G5 5L

SL SL 50 H 45 H G 51G 51L TN TN H H

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary

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Superstructural: Key Benefits


The Superstructural family offers a superb combination of stiffness, strength and impact resistance coupled with specific grades that are able to deliver a high temperature capability. They Can Provide
The opportunity to enjoy the benefits of replacing metals in high performance components that were previously unable to be made in standard engineering polymers The possibility of producing plastic components with superior performance or alternatively with thinner section thereby reducing total cost and weight of parts

We will look at these areas more closely

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Pushing Back the Barriers to Metal Replacement

DuPont Superstructural grades offer many major benefits versus metals.

Lets remember the key advantages...

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Major Weight Savings Opportunities


Lighter weight provides savings in many different ways:
Easier handling of parts Reduced shipping costs Automotive fuel efficiency
Increasing weight per component
Density (g/cc) 10 9
COPPER

8 7 6 5 4 3 2 1 0

BRASS STEEL CAST IRON

DIECAST ZINC and ZA ALLOYS

ALUMINUM ALLOYS MAGNESIUM ALLOYS SUPERSTRUCTURAL POLYMERS

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Benefits Through Light Weight Strength


40% => m ith inu um ings w gth ! Al v sus ht sa stren ver eig ble w ara p com

Superstructural Polymers Magnesium Alloy Aluminum Alloy Mild Steel Zinc


0

up to 163 133 95

52 34
50 100 Specific Tensile Strength (MPa/s.g.) 150 200

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Time and Cost Saving Through Reduced Number of Processing Steps

6 steps 6 Steps

6 Steps
Diecasting
Granules

Sheet metal construction

Injection Molding Metal Finished part Ingots

Finished Part

Finished part Sheet metal

Painting

Meltdown cold chamber

Painting

Stamping

Injection molding
Finishing Molding Assembly

Only 3 Steps

Drilling Cutting Bending

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Cost Savings Through Much Longer Average Tool Life

Beware: when replacement costs of


Number of Shots (k)
1,200 1,000

diecast tools are amortized into your part cost, the expense can really add up!

1000 k
800 600 400 200

450 k 150 k
Aluminum

300 k
DuPont Superstructural Engineering Polymers

Magnesium

Zinc

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Other Major Benefits versus Metals

Opportunity for cost saving and functional benefits through part integration

Potential for highly innovative new designs

Higher corrosion resistance

Better surface finish with integral colors

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Other Major Benefits versus Other High Performance Polymers

DuPont Superstructural grades offer key benefits over some other polymers that you may consider...

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Zytel HTN53G50HSLR versus PAMXD6

HTN53 Series Advantages


Versus PAMXD6 (Polyarylamide)
Significantly better impact and elongation to break values Lower density (2.5% with 50% glass level) Mold tool temperature of 90C compared to 140C plus Less flash

Customer Benefits
Components with much better toughness and overall balance of properties Opportunity for reduced volume cost Reduced processing costs

Faster set up (crystallization rate)

Reduced cycle time leads to higher production rates

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Zytel HTN54 series versus other PPA Resins

HTN54 Series Advantages


Versus Other PPA Resins
Higher overall toughness (impact and elongation to break) Water heated mold capability

Customer Benefits
Components with greater durability in high abuse situations Easier molding and potential for reduced cost

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Zytel LFRTs versus Long Fiber Reinforced PP

Zytel LFTR Advantages


Versus Long Fiber Reinforced PP
Significantly higher strength (>70% increase)

Customer Benefits
Opportunity to have higher performance parts or thinner section components with same performance Components with greater durability in high abuse situations or new markets Parts with extended performance capability or opportunity to open up new markets Ability to develop components for more demanding environments. Greater reliability of part performance

Much higher notched impact strength (>65%increase)

Higher stiffness particularly at elevated temperatures

Vastly improved thermal properties (DTUL at 1.8 MPa for 75LG50HSL is 260C versus 160C for Long Fiber PP)

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary

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Applications

The benefits of DuPont Superstructural products in action...

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Tractor HingeZytel HTN53

High rigidity, impact resistance and tensile strength Lower cost versus aluminum

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Brake BoosterZytel HTN51

High strength and low warp Lighter weight due to reduction in wall thickness (60% lighter than thermoset)

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Spline for Auto Arm Rest Retractor Mechanism Zytel HTN53

The spline can be subject to high loads and abuse situations Previously made from machined diecast metalheavy and costly Zytel HTN53 series offers high modulus, strength and very good impact properties Lighter weight and lower cost than metals, and the parts require no finishing

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Structural Parts for Mobile Telephones Zytel HTN53

The main frame of a mobile phone is required to hold the sophisticated electronics firmly in place, protect them if dropped, be dimensionally stable and resist exposure to household chemicals Zytel HTN53 offers high stiffness, very good impact resistance, and outstanding surface finish. Zytel HTN53 can be molded to close tolerances using water heated molds

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Windowlift Motor Gear Housing Zytel HTN51

Previously cast aluminum Weighs 30% less than cast aluminum housing Higher efficiency Excellent retention of stiffness and strength at elevated temperatures, chemical resistance, low warpage and low shrinkage

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Boat PropellerRynite 555

The stiffness and strength of Rynite 555 is a key factor in limiting blade deflection and preventing deformation during fast starts and high-speed running. Higher performance Cost advantage No corrosion Engine protection Easy mounting

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Agenda

1 2 3 4 5 6

Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Other Plastics Applications Summary

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Summary
Outstanding Strength
Rigidity Toughness High Temperature Capability

Allowing you to enjoy the benefits of Polymers in highly demanding application areas weight saving, anti-corrosion, part cost, colors, integration New Superstructural Pushing Back the Barriers to Metal Replacement!

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Thank you for joining us today. Please send in any questions using the Q&A function.
We will be answering questions for the rest of the hour. Depending on demand, we may not be able to answer your question straight away. All questions will be logged and any questions unanswered at the end of the session will be followed-up via email. Alternatively, please contact your local DuPont representative or log on to plastics.dupont.com and click on the Contact Us button. For questions about our products and how to use them, call us at the following numbers: 800-441-0575 or International 302-999-4592 Or visit us at: plastics.dupont.com

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Copyright 2006 DuPont or its affiliates. All rights reserved. The DuPont Oval Logo, DuPont, The miracles of science, Rynite, Zytel, NOMEX, and KEVLAR are registered trademarks or trademarks of DuPont or its affiliates.