Metal Replacement Forum 2014

an event organized by
5|6 JUNE 2014 Sheraton milan malpensa airport hotel
Metal
Replacement
Think
Forum
2014
pl astics!
Metal Replacement Forum 2014
is a two-day event devoted to the design (Design for)
and production (Production for) of components
and products made from engineering
polymers and composites as replacements
for aluminium and metal alloys.
www.eriseventi.com
Milano, 5/6 giugno 2014
Metal Replacement :
Opportunities and Challeges
with Special Polyamides
By Erico SPINI
(Radici Plastics MKT & Application Development Manager)
1
RADICIPLASTICS WORLDWIDE
EUROPE PRESENCE
France
Radici Plastics France SA
Germany
AMERICAS
Radici Plastics GmbH Brazil
Radici Plastics Ltda.
Italy
Radici Novacips SpA USA
Villa d’Ogna Radici Plastics USA Inc.
Radici Novacips SpA

Chignolo d’Isola
Spain ASIA
Radici Plastics Iberica SL China India
Radici Plastics (Suzhou) Co., Ltd.
Ltd. Radici Plastics Modi P. Ltd.
UK
Radici Plastics UK Ltd
RadiciGroup | Plastics
WORLDWIDE POLYMER BRANDS
PA6, PA6.6, High Temperature PA, PA6.12 and PA,

PA, PET and PBT flame-
flame-retardant grades used
64% renewably sourced PA6.10 polymers and copolymers used for injection and extrusion in all applications where fire
for injection,
injection, extrusion and blow-
blow-moulding in all industry resistance is required, especially in the electrical/electronics
sectors and automotive sectors.
Thermoplastic semi-
semi-crystalline PBT and PET A line of thermoplastic elastomers based on
for injection moulding SEBS, SBS and co-
co-polyesters; used for injection and blow
moulding.
Eco-
Eco-sustainable range of materials mainly coming Long fibre polyamides for injection
from RadiciGroup’s polymerization, fibres and compound moulding.This material family represents a major step
plants scraps forward in metal replacement due to its exceptional impact,
creep and fatigue properties.
properties.
POM acetal copolymers for injection

moulding applications
Radici Plastics Innovation Proposal
An outstanding range of specialities
Market Requirements Radici’s Answer

Lightweighting, low CO₂₂ Specialty PA designed for metal
emission, NVH vehicles replacement :
comfort, productivity, cost -High performance PA66
PA66--GF
reduction -High performance and high flow PA6
PA6--GF
- LGF polyamides Radistrong®
Smaller and more powerful High temperature range of polyamides :
auto engines, insulation -Radilon® HHR family
properties at high temperature -Radilon® XTreme family
in the EE sector, LFS technology
Better chemical resistance, Two families of long chain polyamides :

improved dimensional stability, -Radilon® D range of PA610 compounds
improved hydrolysis resistance -Radilon® DT range of PA612 compounds
Safety, technical performances, An outstanding range of flame retardant

respect of environmental materials including red ph and halogen free
standard and productivity for families :
the electrical/electronics - Radiflam®
apparatus
Materials Selection Criteria :
Functional and
Environmental Analysis
Functional Analysis : understand the needs of the
application ranking them in order of importance
Radici Plastics
Design Approach
Philosophy
Define the application in terms of required

functions by an in-depth exchange between
customers tech departments and Radici Plastics
technicians
Define any additional features that can make

the application even more attractive in
comparison with the existing solution
(competitive advantage)
Functional Analysis : translate customer needs into
product properties
A process in three "steps”
Assign a “factor of importance” for each function

associated with life period of the item
Translate the functional requirements into

properties (often measurable) associated with the
material to be proposed
Decide whether to use an existing formulation or

proceed with a request for a new material
Functional analysis: the functions of the
application are described by identifying the “needs”
related to the life period of the item to be designed
• Transformation (injection, blow

Phase 1 molding, extrusion, etc)
• Post processing operations

Phase 2 (assembly, welding, painting, etc)
• Usage
Phase 3
• End of life (recycling, incineration)

Phase n
Example of redesign die-cast aluminum to plastic:
under the hood bracket for car
RadiciGroup | Plastics * Low importance **** High importance

Example of redesign die-cast aluminum to plastic:
under the hood bracket for car
Based on input from functional

analysis was chosen an innovative
material already present in the
Radici Plastics product range
Approved material :
Radilon® A RV500RW 339 Ner

(special PA66-50% GF, heat
stabilized , improved tensile
strength at break, deformation at
break and impact, higher
mechanical resistance in the
presence of welding lines)
Development time : 8 months

approx
RadiciGroup & Sustainability
Radici has introduced recognized and
certified methods for the 'analysis of LCA
studies
the environmental impact of its
materials from "cradle" to “gate” or
even to disposal or recovery. This
approach is an integral part of the
Radici Group's policy aimed at
improving the "environmental
performance" of its products and GRI Certified R&D for
Sustainability Sustainability sustainable
processes Report products
Radici adheres to the GRI (Global

Reporting Initiative) international
standard.
The function provided by the product

PCR-EPD
to compare, the data and metrics, are approach
governed by the Product Category
Rules (PCR) and reported into
Environmental Product Declaration
(EPD) applying the methodology and
performing measures in accordance
with LCA RadiciGroup | Plastics
Environmental Impact Analysis
Radici Plastics has obtained Environmental

Statements of the main products Radilon ®
certified by an independent body
(EPD, Environmental Product Declaration)
Objective :
Connect the technical performance to that of
the environment, choosing between different
alternatives formulation and / or process that
can lower environmental impact
Environmental Impact Analysis : example of LCA
indicators comparison
LCA Indicators - EPD model

PA Grade 1 PA Grade2
100 100 100 100 100 100

95
93
81 80
66
63
Global Warming Ozone Layer Photochemical Acidification Eutrophication Non

(GWP 100) Depletion Oxidation renewable, fossil
Comparison of the indices of environmental impact between two grades

of polyamides with similar mechanical properties
Environmental Impact Analysis : example of LCA
indicators comparison
Method : EPD (2008) V1.04
Die-cast aluminum replacement : all EPD’s indicators are in favor of Radilon®

A RV350RW
RadiciGroup |339
Plastics bk (PA66-GF35 Radici’s high performance grade for engine
brackets)
Evolution of polymeric materials
characterization for advanced design
State of the Art and new Opportunities
Which Future for

Engineering
Plastics ?
Metal substitution by engineering plastics on demanding

applications started successfully about 30 years ago
There are still big opportunities fuelled by the increasing

lighweighting demand even on parts that were never considered
for metal replacement
Automotive new regulations on CO₂ emission limits
The new challenges on metal substitution required more

sophisticated materials as well as more evoluted design approach
Engineering plastic supplier are requested to provide high

performance materials but also more materials properties
information
RadiciGroup | Plastics including short and long term data (creep, fatigue,
media ageing, etc)
Advanced Design Material Characterization
Properties of engineering plastics, like modulus
and strength, are influenced by several parameters
or factors :
Modulus E ≈ f (↘, T, RH, MA, Cr)

Strength at break σ ≈ f (↘, T, RH, MA, F, Cr) where :
↘ = fibres orientation
T = temperature
RH = relative humidity
MA = Media ageing
F = fatigue
Cr = creep
Metals, in general, are considered isotropic with some

mechanical properties unaffected by RH and
temperature (at least until 200-250 °C)
Enhanced performance
Radilon® (PA66-GF50)
Stress-Strain Curve Comparison at Different Speeds Fatigue Behaviour Wöhler Diagram - Sinusoidal
(23°C, DAM, ISO 527) Displacement, 5hz, R= min stress/max stress =0.1
350,00
23°C - RH50 (water content 1.24 %)
300,00
120
250,00 Rad A RV500RW : 1 mm/sec 100
S max (Mpa)
Stress (Mpa)
200,00 Rad A RV500RW : 100 mm/sec 80

150,00 PA66-GF50 : 1 mm/sec 60
Stress-Strain Curves Comparison
40
100,00
(23°C, DAM) ISO 527 Double Injection
PA66-GF50 : 100 mm/sec
120 20
50,00
0
0,00 100
2 3 4 5 6 7
Stress (Mpa)
0,00% 0,50% 1,00% 1,50% 2,00% 2,50% 3,00%

80
Strain (%)
Cycles to Failure (Millions)
60
40
20
0
0,00% 0,20% 0,40% 0,60% 0,80% 1,00% 1,20% 1,40%
Strain (%)
Instant properties and long term properties are essential ingredients for
a correct design with engineering polymers
High performance
Radistrong® (PA66-LongFibers)
Creep Behavior (140 °C, 60 Mpa) Impact Resistance

3,50 50 10
Charpy Notched Puncture Energy (J/mm)
45 9
3,00
40 8
2,50 35 7
Charpy Notched (KJ/m2)
Puncture Energy (J/mm)

Deformation (%)
30 6
2,00
25 5
PA66-GF50
1,50
Radistrong® A LGF50W 20 4
1,00 15 3
10 2
0,50
5 1
0,00
1 10 100 1000 10000 0 0
Radistrong® A PA66-GF50 Radistrong® S PA6-GF50
Time (hours) LGF50W LGF50W
Instant (impact) and long term properties like creep are very often requested
as basic information that allow a correct engineering plastics parts design for
metal replacement
High Heat Resistant

Radilon® HHR & Radilon® XTreme
Tensile Modulus Vs Temperature Heat Ageing in Air at 220 °C

20000 120
Tensile Strength at Break retention (%)

18000 Radilon XTreme RV350HHR
100 PA*-GF35
Tensile Modulus (ISO 527 Mpa)
16000
PA46-GF40
14000
80 PPA-GF45
12000
Radilon A RV350HHR
10000
Radilon A RV500HHR 60
8000 50%
Retention
6000 40
4000
2000 20
0
-40 10 60 110 160 210 260
0
Temperature (°C) 0 500 1000 1500 2000 2500 3000 3500
Time (h)
The graphs in this case show some typical characteristics required for these
materials resistant to high temperatures: the trend of the tensile modulus as a
function of temperature and tensile strength at break evolution in case of heat
aging at 220 °C until 3000 h
Long Chain
Radilon® D and Radilon® DT
(PA610 and PA612)
The graphs show the evolution of some mechanical properties after

immersion in gasoline containing ethanol. For these types of material is
required a higher chemical resistance even in the case of contact with other
fluids such as solutions of zinc chloride and calcium
Projects criteria : from a “classical”
to an “advanced approach”
Projects Criteria : classical virtual analysis
Process Simulation & Optimization
Flow analysis
Packing analysis
Cooling analysis
Shrinkage & Warpage
Gas assisted injection molding
Structural Simulation as the tool for part design

optimization. Materials are considered isotropic
Static linear and non-linear analysis

Thermal analysis
Structural-thermal analysis
Natural frequency calculation
Dynamic response
No links between
process simulation and
structural analysis
Projects Criteria : classical virtual analysis
Radici CAE service:
structural analysis – classical approach
• Metal replacement of an aluminium bracket
Aluminium part Redesign for PA66-GF50 Structural analysis - VM stress
Iteration
Force
Design validation by FEA
Projects Criteria : advanced virtual analysis
Radici CAE service:
Structural Advanced Simulation
Advanced approachconsider the material properties linked to process
• Anisotropy induced by fiber orientation and local material properties can
be taken into account in an integrated, non-linear analysis, which use
process simulation data do build up a macromechanic model with local
anisotropic material properties
• Step 1) Material characterization by cutting specimens

from plaques at different angles for structural materials
Anisotropic macroscopic properties
Radilon® A RV500RW 339 BK
Stress-Strain Curves versus orientation (DAM)
Stress (Mpa)
Strain (%)
• Step 2) Moldflow analysis on the part – eventually

exploring different possibilities as per gate location, process
parameters etc. – and exports the filler orientation
tensor map
• Step 3) The material macroscopic properties and fibre

orientation data must be calibrated and mapped over a
structural mesh using specific programs.
The output consists in a structural mesh with mapped
element by element anisotropic material properties
that can be used by many FEA programs to perform
structural analysis.
Metal replacement examples with
special polyamides designed to
specification
Case 1
Component : industrial valve actuation
plate
Activity : aluminum substitution
Key requirements :
•mechanical + fatigue performance
•low deformation
•tolerances respect
Material : Radilon® A RV500RW 339 BK
Advantages vs metal :
•cost saving 40%
•No machining needed
•Raduced assembly time
•Better surface aspect (improved
membrane life time)
Case 2
Component : auto turbo duct resonator
Activity : metal substitution
Key requirements :
•mechanical + fatigue performance
•heat ageing in contact with air at high
temperature (up to 210 °C)
•attitude to vibration welding, weld strength
Material : Radilon® A RV350 HHR (high

temperature PA66-GF35)
Advantages vs metal :
•cost saving 20 to 40 %
•Reduced assembly time
Case 3
Components : window fittings, thermal
breakers
Activity : metal substitution
Key requirements :
•suitable for powder electrostatic painting
•excellent surface aspect
•good painting adhesion
•excellent mechanical properties
•excellent thermal stability
Materials : Radilon® A X7351 BK (injection

molding experimental) & Radilon A
ERV2503CW BK (extrusion experimental)
Advantages vs metal : cost saving up to 50%
Milano, 5/6 giugno 2014
Thanks for Your

Attention
33
ing. Walter Carraro
Hot Runner systems for engeneering

1 polymers in the Metal Replacement
Long fibers?
Reinforcements up to 70% ?
•Thermostability limited to 20°C ?
•Processing temperatures up to 400°C ?
PPS PA46
PET
LCP PPA
PEI
2 •I canali caldi per i tecnopolimeri nei Metal Replacement

How do you process them?

Traditional solution with sub-runner
• Problems of waste and re-use of scraps

•Economic disadvantage on expensive materials
•Less pressure available in the cavity

Solution with Hot Runner
•Higher pressure available in the cavity
•Tight tollerance when valve-gated
•Shorter cooling cycles time

Mold-Masters technology
•1 Uniform heated nozzles
•2 2 pieces brazed manifolds
•3 High wear resistant gate seals’ materials
Gate seal Heater element
Nozzle
Manifold
Terminal end
Backplate
Locating ring
1 Nozzles: Brazed Heater Technology
 Optimized heater winding prevents thermal degradation
 Embedded heater element outlasts conventional replacement heater sleeves
 Heater is in precise location – cannot move like a clamp on heater

1 Nozzles: Heaters comparison Thermal profile
Brazed nozzle heat profile
Brazed nozzle heat profile

1 Nozzles: Temperature Control
 Thermocouples designed for ease of installation and replaceability
 Front-mounted thermocouple
 Thermocouples are in close proximity to the gate for optimal
temperature reading

2 Manifolds
Patented 2-piece brazed manifold technology
 Optimized runners for highly reinforced
and abrasive materials
 Large channels for low pressure fill
 30mm standard thickness is 25% less than

competitive systems
 Runners are carefully milled and polished,

with no sharp corners or dead spots
 Balanced filling

2 Manifolds, balancing
•Flow path dynamic viscosity

3 Gate Seal

•3 Gate Seal: Core Ring Gate
1. Mold closed, 2. Pin forward,

gate closed gate open

PPS 70% mixed glass fiber/mineral
•Socket Philips
•32 cavities mold
•Tip gate
•Weight: 0,6 gr.
•Gate Seal: tungsten carbide

PPS 70% mixed glass fiber/mineral
•Socket Philips
•4 cavities mold
•Tip Gate
•Weight: 8 gr.
•Gate Seal: E-Type

LCP 30% g.f.
•Masque Toyota YARIS

•4 cavities mold
•Mixed injection
•Weight: 13 gr.
•Custom Gate seal

PA66 33% g.f.
•Automotive part
•4 cavities mold
•Tip gate
•Weight: 20 gr.
•Gate Seal: F.Type

PPS 40% g.f.
•Electrical pins
•4 cavities mold
•Valve gate
•Gate Seal: Hot Valve

PPA 50% g.f.
•2 cavities mold
•Valve gate
•Weight: 16 gr.
•Gate Seal: B-M Cylindrical valve

PA12 50% g.f.
•1 cavity mold
•Valve gate
•Weight: 16 gr.
•Gate seal: Hot valve

Why Mold-Masters?
• Expertise on more than 130.000 applications with highly reinforced
and flame retardant materials
• Brazed heaters, since more than 30 years produced in Canada, need
20% less energy than traditional ones
• 10 years warranty when hot runner system is sold together with
temperature control and hot halves
• Multinational company with technical support all over the world

METAL REPLACEMENT
SUCCESS STORIES:
REAL WORLD CHALLENGES &
SOLUTIONS
David Sánchez
Product Manager EM Europe
PolyOne
About Us: PolyOne Corporation (NYSE: POL)
 A leading global provider of specialized polymer materials,

services and end-to-end business solutions
 2013 annual revenues of approximately $3.8 billion
 Headquartered in northeast Ohio, USA
 Operations in North America, South America, Europe, Africa and Asia
 PolyOne serves more than 10,000 customers globally and offers

more than 35,000 polymer solutions
 PolyOne has more than 7,600 associates worldwide in:

— More than 80 manufacturing and distribution facilities
— Over a dozen Labs and Innovation Centers
— Sales and service locations on five continents
PolyOne Corporation Page 2

Why replace metal with plastics?
Primary reasons for metal replacement Key Benefits of plastics

System optimization • Higher performance-to-weight ratio
• Light weighting • Less material to reach similar performance
• Improved overall performance • No corrosion, withstand most chemicals
• Reduced total costs
Design freedom
• Miniaturization
• More complex shapes
• Part consolidation and function integration
• Differentiated look
• Outstanding surface aspect
• Integration of functions
Production improvement
• Need of versatile processes • In-process recyclability
• Eliminate secondary operations • Lower scrap rates
• Ease of handling • In-mold color versus painting
Regulation changes
• Brass (drinking water)
• Compliance with regulations
• RoHS (heavy metals)
• End Of Life vehicles, CO2 emissions

Project work method
 Full understanding of the project requirements

 Analysis of Economic feasibility
 Analysis of Technical feasibility
FEA simulation
 Initial calculation based on existing geometry
 Material pre-selection
 Geometry redesign / optimization
 New calculation
MoldFlow® study
 Helps to optimize design and manufacturing
 Final material selection

 Support for the molding trials

STRENGTH ! (mechanical properties)

Case study
Sailboat rigging block
NEEDS SOLUTION
▪ Maintenance – free solution ▪ Integrated lubrication (maintenance free)
▪ Corrosion resistance to saltwater ▪ Extended lifetime (better weatherability)
▪ High mechanical performance at ▪ Improved maneuverability (lower friction)
extreme weather conditions ▪ Lighter assembly
▪ Weight reduction ▪ Improved cost solution
▪ Cost effective solution
Solution – OnForce™
Lifespan 40% increased
Weight reduction 30% reduction
Overall cost saving 10% savings

Long fiber reinforced solutions,
features & applications
Polymer Mix
Glass Creels Pultrusion Pelletizer Finishing/

Wet Bath Puller
Block Packaging
PULTRUSION FIBER LENGTH PROCESSING

Excellent fiber impregnation In Pellet  7 – 25 mm Standard equipment
Fibers: glass, carbon, basalt.. In Part  2 – 4 mm Minimize shear, keep fiber length
Fillers: lubricants, FR, color.. 3D skeleton of fibers
STIFFNESS + IMPACT EXTREME TEMPERATURE

Good impact at high stiffness Stable properties at high temps.
Integrity retained after impact High performance at sub-zero
CREEP and FATIGUE ISOTROPY

x2-3 lower deformation Skin-Core effect
Improved structure stability Homogeneous mechanicals
x2-3 better fatigue resistance Homogeneous shrinkage
Extended lifetime

WEIGHT ! (density)

Case study
High quality kitchen knives
NEEDS SOLUTION
▪ No discoloration ▪ Color stability
▪ Same feel as aluminum ▪ Same weight & touch as alum
▪ Automatic process ▪ No secondary operations
▪ Innovative design ▪ Greater design possibilites
▪ Cost efficient ▪ Reduced overall system cost
Solution – Gravi-Tech™
Lifespan 30% increased
Manufacturing costs 20% reduced

High density solutions,
DENSITY FOOD CONTACT

2 – 11 g/cc EU and FDA
CONDUCTIVITY
Thermal conductivity 1-2 W/mK FERRO MAGNETIC
Electrical conductivity 105 Ω Attractable by magnet
FINISH RADIATION SHIELDING

Electroplating Same as lead (35 KeV – 1332 KeV)
Vacuum metallization Non toxic
Coloration (pre-color, master)
VALUE PERCEPTION FUNCTIONALITY PROTECTION

Weight of metal Precision Radiation Shielding
Cold touch of metal Counter - weight Lead free
Look of metal Noise shielding Design & Manufacturing
SPARK ! (electrical conductivity)

Case study
Fan wheel in gas heater
NEEDS SOLUTION
▪ Avoid tribocharging electrification ▪ Dissipative solution
and subsequent explosion ▪ Surface resistivity <107 Ohm
▪ Weight reduction ▪ Lighter fan
▪ Mechanical performance at 8000rpm ▪ Excellent mechanical and dimensional
▪ Automated manufacturing process performances
▪ Cost reduction ▪ No secondary operations
Solution – Stat-Tech™
Weight reduction 60% reduction
Manufacturing time 65 sec in Stat-Tech vs. 4 min in Metal

Electrically conductive solutions,
FILLERS
ELECTRICAL
Polymer systems
Electrical conductivity / resistivity
Surface / Volume resistivity Carbon (amorphous / crystalline)
Fibers (carbon, metal)
RANGES
PERCOLATION CURVE
Anti-static (1011 - 108 Ω)
Filler vs. Conductivity
Dissipative (108 - 105 Ω) Threshold filler content
Conductive (<105 Ω)
ESD ATEX PAINTING EMI SHIELDING

Tribocharging ESD + Oxygen + Fuel Conductive paint & part Effectiveness (80-100dB)
Static electricity Risk of explosion High quality EMI frequency
Electro-static discharge Need to dissipate ESD Cost effective Part thickness

HEAT ! (thermal conductivity)

Kruunutekniikka – Company
 Production design from start to finish, mold design through to shipment
 Coolics® : Customized LED cooling solutions, replacing metal with

specialty thermoplastics (www.coolics.fi)
 Offer customers added value by combining our deep technical

knowledge with an innovative, flexible team
We welcome your heat dissipation challenges!

Kruunutekniikka – Application & Needs
LED lighting market is growing very rapidly: durability, lifetime

operating cost, reduced environmental impact and legislation all are
driving the transition
 Design differentiation is critical for lighting manufacturers to
profitably compete in this tough global market
 LED lights can last many years (sustainable vs. halogen lamps;
30% - 80% energy savings) but are sensitive to heat. Managing the
heat generated by LEDs is critical to maintaining useful life and energy
efficiency
 Aluminum is the established material for drawing heat from the LED
lamp, but…
Metal limits design options, is costly to form, we don’t control the
supply chain…

Kruunutekniikka – Material solution
▪ Thermal Conductivity in plane up to 20 W/mK

THERMAL ▪ Thermal Conductivity through plane up to 5 W/mK
PERFORMANCE ▪ Differences coming from the additives structure
▪ Electrically conductive grades (<10E4 Ohm)

ELECTRICAL ▪ Electrically isolative grade (>10E12 Ohm)
PERFORMANCE ▪ Different additives / different thermal performance
▪ Broad range of polymers available

WORKING ▪ from PP (90 – 100 ºC)
TEMPERATURE ▪ to PEEK (240 – 260 ºC)
▪ Flame: HB to V0/0.8mm
OTHER ▪ HDT (1.8 MPa) up to 260 ºC
FEATURES ▪ Coloration: light colors possible (electrically isolative grades)

Kruunutekniikka – Collaboration & Benefits
Replacing metal with the Therma-Tech™ solution helped

Kruunutekniikka effectively manage heat while also providing the design
flexibility, reduced weight and processing ease of conventional
thermoplastics
 Formulation experts from PolyOne proposed two customized
Therma-TechTM grades, which are 37% less dense than the die-cast
aluminum they replace (one grade for overmolding)
 Currently LEDs account for about 10% of the entire lighting market,
but this is expected to increase to 80% in the next five years. Innovation
will separate winners from me-too participants
 We control our supply chain, we have more design options, and we
are in good position to continue to benefit from demand growth for LED
lighting.
Thank you! Jari.Kanervisto@kruunutekiikka.fi

PolyOne, your partner for metal replacement
Metal properties PolyOne EM Specialty Solutions
OnForce™ Edgetek™ ThermaTech™ Stat-Tech™ Gravi-Tech™ LubriOne™
Stiffness +++ ++ + + = +
Impact +++ ++ = + = +
Heat resistance +++ +++ + + + +
Thermal Conductivity = = +++ + ++ =
Creep & fatigue +++ + = = = =
Electrical conductivity ++ = + +++ ++ =
EMI Shielding ++ = + +++ ++ =
Radiation Shielding = = = + +++ =
Wear resistance + + = + = +++
Noise/Vibration Harshness + + = = ++ =
Perceived quality ++ = + + +++ =
Color-ability ++ ++ = + = +
Legend : = medium, +++ best

Thank You!
David Sánchez
Product Manager
Specialty Engineering Materials
PolyOne Corporation
Mobile: +34 626 790 458

E-mail: david.sanchez@polyone.com
Web: www.polyone.com
© 2014 PolyOne, All Rights Reserved

From brass to specialty
polyamides in contact with water,
pressure and heat!
Francesco Martina Technical Project Manager EMS-CHEMIE (Italy)
Curzio Scheurer Key Account Manager I&C EMS-CHEMIE (Germany)
MR FORUM_ Dall’ottone alle PA speciali in contatto con acqua pressione e calore _ 06.06.14 _ Pag.: 1.
I dati e le informazioni qui riportate si basano sull'esperienza e conoscenza ad oggi acquisite. L'utilizzo, integrale e/o parziale, delle presenti informazioni non comporta alcuna responsabilità da parte di EMS-GRIVORY.
Content
• What is brass?
• Positioning and approvals of the
materials "FWA"
• Challenges for the robust design
• Guidelines for the correct material
selection
• Examples of applications and news
• Conclusions
Brass
• Highly resistant and robust alloy for flushmounted installations
• Material of excellence broadly used and well-known by plumbers
• Alloy Copper (Cu) - Zinc (Zn) à 5 to 45% Zn
ücasting à 33 to 42% Zn
üforging à 5 to 45% Zn
• For better machinability à lead (Pb) up to 3%
• Other elements are present to improve performance (e.g. As (0,15%)
and Sn (1.0%) to reduce the risk of dezincification)
• Alloys with Zn > 15% undergo risk of
stress-cracking
Weaknesses of brass alloys
• Density: high transport cost
• High cost / volume
• Costly material, risk of theft
• Limited processability for the realization of complex parts in
“one shot”
• Raw materials prices instable
and fluctuating over time
• High concentration of lead and
other heavy metals
Standards for drinking water
• Directive 98/83/EC related to the quality of drinking water for
human consumption
• From December 2013 maximum content of:
ü Pb < 0.010 mg/l
ü As < 0.010 mg/l
ü Ni < 0.020 mg/l
• Introduced in 2003 in Germany with DIN 50930-6
(guidelines for brass selection)
Applications Pb - content As - content
Fittings ≤ 3.5% ≤ 0.15%
Fittings + Pipe Connectors ≤ 2.2% ≤ 0.10%
Regulations and norms for drinking water approval
EU- Directive 202/72/EC FDD
F
aappppr AA
USA - FDA regulations CFR 21 roovve
edd
FR Norm AFNOR XP P 41-250
USA Norm NSF/ANSI Standard 51 and 61
DE - KTW Federal Office for the Environment
DE - DVGW W270, assessment of microbial growth
UK - Testing method: BS 6920:2000

BE - www.belgaqua.be
IT – DM 174/2004
EMS specialty polyamides “FWA”
• Grivory GV: PA 66 + PA 6I/X

• Grivory HT1: PA 6T/6I
• Grivory HT3: PA 10T/X
• Grilamid LV / LBV: PA 12
• Grilamid TR: amorphous PA
Approval's list for the contact with drinking water
KTW DVGW WRAS ACS NSF 61
W 270
Grivory GV...FWA 30°C ü 30°C ü 30°C
Grivory HT1V...FWA 85°C ü 85°C ü 82°C
Grivory HT3V-40 FWA 85°C ü 85°C ü 82°C
Grilamid LV...FWA 60°C ü 85°C ü 60°C
Grilamid LBV...FWA 85°C ü 85°C ü 82°C
Grilamid TR90 (LS) 85°C ü 85°C compliant
82°C
Grilamid TR55 85°C ü 85°C compliant
82°C
Strategic segment for EMS-GRIVORY
Water distribution, heating and domestic plumbing
Faucets and
cartridges for
kitchen and
bathrooms
Water distribution
Heating
applications
Water meters and filters

Milestones EMS in the sanitary segment
1995: realisation of the first filter housing in Grivory GV
1997: realisation of the first shower cartridge in Grivory HT
1999: realisation of the first water meter housing in Grivory GV
2001: installation of testing bench for circulating hot water
2004: new design for the water meter housing with OVALIX
2005: start hydrostatic test according to ISO 9080
2006: OVALIX patent granted
2007: realisation of distribution valves in Grilamid
2008: installation of an additional testing bench with chlorinated and oxygen-rich water
Challenges in the development
morphology
uncertainty of the design over
real service life time lifetime
conditions
creep
thermal shock feasability ??
interaction with fatigue
other elements
residual stress
water uptake
misuse processing
ageing
Expected lifetime and/or requirements
plumbing equipment
water meter
passenger car
standby
operation
mobile phone
lifetime
0 10 20 30 40 50 60
years
Sanitary: up to 50 time longer lifetime expectations
Pressures in the sanitary segment
operation
specification PN16
long term burst pressure
water hammer
short term
0 20 40 60 80 100
Pressure [bar]
Up to 100 bar for the part's approval
Design: example of stress reduction
Stress concentration
100%
72%
56%
notch
It is important to use large radii / blend edges

Sharp corners can triplicate the nominal stress
Design: example of stress reduction with Ovalix
148 MPa 150 -
without Ovalix 125 -
Pressure 90 bar 54 MPa 100 -
i g n 75 -
s
de
93 MPa 50 -
100 -
e d
t 80 -
25 -
t en 154 MPa
0-
Pa 60 -
MPa
54 MPa 40 -
20 - Stress reduced by 40% !

95 MPa
with Ovalix 0-
MPa
Design: example of stress reduction with Ovalix
Burst pressure with and without OVALIX
for Grivory HT1V-5 FWA
Burst pressure (bar)
round + 64 %
Ovalix
Increase of the transversal strength
Specimen "Tulip", 210 bar hydrostatic pressure at 23 °C
4500
4000
3500
Tempo [h] 3000
+ 400 %
2500
2000
1500
1000
500
0
GV-5H GVX-6H
Anisotropy of reinfoced compound
Fiber orientation in the weld lines
notch
loa d
Most of the fibers is oriented orthogonally to the load

How to increase the resistance in the weld lines
Polymers reinforced 40% glass fibers
100
Impact Charpy (KJ/m^2) ISO 179/1eU
Grilamid LBV
90
Grivory HT3
80
70 Grivory HT1
60
PPS
50
40
30
20
0 1 2 3 4 5 6
% elongation at break ISO 527
Selection guideline for FWA products
Grivory Grivory Grivory Grilamid LV /
HT1V HT3V GV LBV
Thread strength lll lll ll l
Creep resistance lll lll ll ll
Ductility l ll lll lll
Dimensional stability ll lll l lll
Water uptake *
Processing l ll ll lll
Water contact
cold both-sided both-sided one-sided both-sided
warm one-sided one-sided - both-sided
Max. wall thickness 5 mm 5 mm 6 mm 15 mm
(*) suitable for moving parts
“Tested” lifetime for sanitary applications
Development area
Temperatues [°C]
80
HT1, HT3, LBV
60
HT1,LV
30
GV, HT1, LV LV
10 50
Life time [years]
Verification by part testing necessary.

Lifetime depends on design, stress, temperature profiles, processing, etc.
Grivory GV: tested and reliable in cold water
• High strength and stiffness

• Robust, high impact resistance
• High creep resistance
• Limited to one-side water contact
• Use restricted to cold water (max. 30 °C)
• Wall thickness up to 6 mm
• Grivory GVX for higher burst pressure
Typical applications:
ü Water meters
ü Filter housings
ü Lids for pressure reducers
Grilamid LV / LBV: best performance profile
• Best hydrolysis resistance
• Good dimensional stability (for moving parts)
• Very high tenacity and ductility
• Wall thickness up to 15 mm
• Suitable for both-sided water contact
• Easy processing
• Grilamid LV for cold water / Grilamid LBV for hot water
ü Thick valve housing
ü Threaded housing for faucets
ü Robust water meters
Grivory HT: for cold and hot water
• Highest strength and stiffness (threads)
• Very high creep resistance
• Cold water contact: both-sided
• Warm water contact: one-sided contact
• Restricted to wall thickness up to 5 mm
• Good price / performance ratio
Grivory HT3: superior hydrolysis resistance and ductility
ü Water meters for cold and hot water
ü Parts in heating applications
ü Parts of pumps
ü Valves for boilers
New developments: Grivory HT1VX-5 FWA
0,6
Shrinkage 2 mm thickness (24h) 0,52

0,5
0,4 0,37 0,37
0,3 0,26
0,2
0,15
0,11
0,1
longitudinal transversal difference

HT1VX- 5 FWA HT1V-5 FWA
New developments: Grivory HT1 HHR
Hydrostatic pressure at 45 bar, hot water 80°C
Material Time to failure [h]
HT1 HHR GF40 >1000

PPA GF40 85
Impressive increase of the hydrolysis resistance !!
New developments: Grivory HT1
HT1VX-5 FWA HT1 HHR
ü Ideal for the contact with ü Ideal for the contact with
foodstuff and drinking water foodstuff and drinking water
ü high flowability for thin wall ü exceptional hydrolysis stability

thickness ü unique physical-mechanical
ü better isotropic properties performance and of long term
ü low warpage ü for applications not accessible

until today
Conclusions
• Brass can be replaced despite of
demanding technical requirements
• .. reducing costs and eliminating the
presence heavy metals
• EMS offers a broad range of products
approved and tested since a decade
• Support during development guaranteed
• We never stop, new products even more
powerful developed!
Metal replacement – same goal, different ways ….
METAL REPLACEMENT FORUM 2014
THINK PLASTICS!
5th/6th June 2014 Welcome

Sheraton Milan Malpensa Airport Hotel
Welcome
Dipl.-Ing. (FH) Mario Wörle
Welcome
Agenda
1. A. Schulman – Who are we?
2. High stiffness & high heat compounds
3. Heat conductive compounds
4. Processing technologies
2
Agenda
1. A. Schulman – Who are we?
3
Metal replacement – same goal, different ways
A. Schulman – who are we?

A. Schulman Inc. Akron (Ohio/USA)
recycling of scrap rubber into usable materials
Start of compounding (USA)
A. Schulman Europa (Germany, France and England)
Start of distribution (Germany)
Start of masterbatch production (A. Schulman Belgium)
Alex Schulman
is born in Minsk A. Schulman becomes a public corporation
(Russia) Start of EP production in Germany
A. Schulman Indonesia
A. Schulman China
A. Schulman India
Acquisition of Delta Plast
Acquisition of ICO Polymers
and Mash Compostos Plasticos
A. Schulman Middle East, Ras Al Khaimah
Acquisition of Elian SAS, France
Opening A. Schulman Academy
1897 1928 50 52 60 62 70 77 97 04 05 07 10 11 12
4

One of the largest independent compounders worldwide
Five Business Units

• Engineering Plastics
• Masterbatch MBS
• Masterbatch CMP
• Distribution Services
• Specialty Powders – ICO Polymers
5

Key figures
• 37 manufacturing plants
• 3,500 employees
• >500,000 tons of compounding and powder capacity
• >1 million tons of thermoplastic sales per year
• 2.2 billion US $ turnover
6

A. Schulman worldwide
7
One question at the beginning…
Why metal replacement…?
efficient…? lighter…?
ecological…?
safer…? resistant…?
8
One question at the beginning…
Why metal replacement…?
9
Agenda
1. A. Schulman GmbH – Who are we?
10
High stiffness & high heat compounds

Key figures Possible material groups
• 37 manufacturing
® PPA plants
Schulamid PPA
• 3,500 employees
Schulamid® XM PA
• >500,000 tons of compounding and powder capacity
Schulamid® XT PA
• >1 million tons of thermoplastic sales per year
Schulamid® PA6; PA66; PA612; PA610
Schuladur® PBT; PET; PBT/PET
Schulatec® PPS
Schulatec® PEEK
IXEF® MXD6
11

Schulamid®
• Schulamid 6 GF 65 65% glass fibre
• Schulamid 612 GF 65 GID 65% glass fibre
Schuladur®
• Schuladur A1 GF 50 PBT/PET 50% glass fibre
• Schuladur PCR GF 45 PBT/PET Rec 45% glass fibre
Schulatec®
• Schulatec PPS GF 40 40% glass fibre
IXEF®
12
• IXEF 1022 PA MXD6 50% glass fibre
13
14
15

summary
• Cost savings on short- and mid term base is possible
• Function integrated metal replacement is feasable
• Only the right material can bring you the benefit, you need to substitute metal
• Know how conflation is needed
16
Agenda
17
Heat conductive compounds
Schulatec® HC
• Heat conductive & electrical neutral
Schulatec® HC 3000
• Heat conductive & electrical conductive
18

Thermal conductive filler systems
• Electrical conductive fillers
• Metals e.g. copper, iron and their alloys
• Graphite, carbon fibres, carbon nano tubes (CNT´s)
•…
• Electrical isolating fillers
• Ceramics, e.g. boron nitride and aluminium nitride
•…
19

Why termal conductive materials?
• Miniaturisation
• Hermetic housing
• Bad heat transfer (convection) because of small installation space
• More and more electrical components
• Higher energy density, because of increasing heat
thermal conductive plastics with a specific heat conductivity of

λ 1 – 20 W/mK are available
but..!!
20
21

Heat conductivity [W/mK]
metals 15 (stainless steel) – 150 (aluminum) - 360 (copper)
plastics 0.25
Schulatec® HC up to 4
Schulatec® HC 3000 up to 5
22

summary
• Cost savings on mid- and long term base is possible
• Function integrated metal replacement is feasable
• Combination of mechanical properties and thermal conductivity is given
• High material costs

• Know how conflation is needed
23
Agenda
24
Processing technologies
Hybrid construcions
• Metal – Plastic structures Source: KEM
Organosheets
• Woven fabrics (GF and/or CF) which are embedded in a
thermoplastic martrix system
• Injection of reinforcements & functional elements
Source: Träger
WIT, GIT CIT, PIT

• WIT – Water injection technology
• GIT – Gas injection technology
• CIT – combination of water and gas injection technology Source: HALE
• PIT – projectile injection technology
25 2K WIT
One bullet point at the end…
The real beginning of metal substituion,

is the recognition of potentials
and the willingness
to challange established systems …
26
Thank you for your attention.
Thank you.
Thank you.
Metal replacement
General overview LGF
Injection Molding
6th June 2014

Valerio Franzetti
Plastics, what is true?
• Plastics do not have enough strenght / modulus for metal

structural applications
• Thermal resistance of plastics is limited
• Plastics can not dissipate heat because they are an insulator

plastic
• Plastics are not conductive and are not suitable for EMI/RFI
applications.
• It is difficult to powder coat plastics
Hystorically it is correct….
But materials development and design are changing
the scenario
Possible solutions
• Stiffness
LNP TM THERMOCOMP TM compound - GF and other reinforcements
LNP TM VERTON TM compound - long glass fibers reinforced - E = 20 GPa
• Temperature resistance and thermal management

EXTEM TM resin - Tg up to 310 °C
LNP TM KONDUIT TM compound - thermal conductivity from 1 a 10 W/m °K
• Electrical conductivity
LNP TM FARADEX TMcompound - 40-60 dB (30 – 1000 MHz)
LNPTM STAT-KON TM compound - Surface resistivity from 100 to 10^12 Ohm/sq
• Powder coating
NORYL GTX TM resin - conductive for powder coating
LGF vs. SGF
Long glass fibers Normal glass fiber Long glass fibers

not dispersed dispersed dispersed
TM TM
LNP VERTON resin
Different properties
Long glass fibers

not dispersed
Free fibers
Polymer
Long glass fibers

dispersed
Coated fibers
Typical properties
LNP TM VERTON TM resin
• PA 6, PA66, PPA based polymers
• Granulate lenght about 11 mm
• Higher rigidity, higher modulus, higher impact properties

vs. SGF materials
• Improved mechanical properties at high temperatures
• Better creep performances

«Keeping» glass fibers lenght
Molded part in
VERTON TM resin
Same part after combustion

of the organics components
Safety belt component
Material feeding - slow speed (in case of automatic feeding)
Injection point - depends on part

0,7 x max thickness
minimum 2,5 mm
NO tunnel gate
location max thickness
Runners - avoid 90° sharp connection

use generous radius
Hot runners - possible

manifold externally heated
free flow nozzle externally heated
L/D ratio : 19-21

Lead P : D
Three zone screw
Section 'a' : 20%L = 4D

Section 'b' : 20%L = 4D
Section 'c' : 60%L = 12D
Screw with short feed section
not recommended - min 50% Sections 'a' e 'c' have
constant depth, section 'b'
variable depth
Screw - three zone standard

NO mixing elements
NO barrier screw
min. 50 mm. diameter
Injection speed - low / medium
Back pressure - low
Screw speed - 30 – 60 rpm
Regrind - avoid for critical applications

10% max for normal applications
Application
Mantenimentoexamples
della lunghezza delle fibre di vetro
Agricultural Vehicle Seat Pan
• Stiffness
• Fatigue resistance
• Aesthetics
• Chemical resistance Chair components
Goal: Cost-Out, Equivalent Performance
• Heavy Truck Side Fairing Support Structure
Original Assembly Included 9 Parts One piece molded structure

• 2 Die-Cast Aluminum Stabilizers Fastening Clips, Releasing Handles and
• 2 Fiberglass Extruded Frame Bars Locking
• 1 Painted Stamped Steel Brace Savings = € 42 and 4 kg per Truck
• 4 Painted Stamped Steel Brackets
• Labor Intensive Assembly
confidential
Cost reduction
TM TM TM
Butterfly valve – NORYL THERMOCOMP VERTON
Steel valve Tear down

Thermoplastic valve
Concept
Cost reduction and weight out
Gear shifter bracket Mini in LNP™VERTON™
Requirements
Temperature
Loads
Displacements
Natural frequency
Functions
Design space
Results
Weight savings ca. 1 Kg = 40% (2.5->1.5)
Cost savings 20%
Better Mechanical performance
Better gear change feeling
STAMAX™ resin
PP LGF
Instrument panel retainer - STAMAX 30YK270
Mantenimento della lunghezza delle fibre di vetro
2014 Jeep Cherokee
Optimized Instrument Panel for Mass Reduction:
• North America’s First IP at 2.0 mm LGF PP
• 27% Mass Reduction / 0.8 kg/car
• Potential 30% Molding Cycle Time Reduction
• Piece Cost Reduction
• Advanced Fiber Orientation Prediction

Application examples at Fiat Group
Mantenimento della lunghezza delle fibre di vetro
IVECO
Structural Front Panel
(aesthetical front grille)
STAMAX 30YM243
PP-30%LGF UV Stabilized
Unpainted, Class A surface
IVECO Stralis
Exterior mirror
FIAT Ducato
Exterior mirror
STAMAX ™ resin - door modules: ALFA Giulietta
• Concept highlights
– Very light plastic parts (800 gr)

– Semi structural window rail
– First PP-LGF carrier for Alfa
rear door
confidential
STAMAX ™ resin – other application
FIAT GRANDE PUNTO
FEM ALFA ROMEO MITO

STAMAX 30YM240
PP 30%LGF
In development FEM
JEEP B-SUV 520rear
& FIAT
doorB-SUV 334
confidential
Together we will find
the solution.
Thanks for the attention.
Distributor for Italy
www.tecnosrl.biz
SABIC and brands marked with ™ are trademarks of SABIC or affiliates.

DISTRIBUTION OF THERMOPLASTIC RESINS
PRODUCTION OF THERMOPLASTIC POWDERS
PRODUCTION OF MASTERBATCHES AND ADDITIVES
DISTRIBUTION OF PRIME AND OFF-GRADE

THERMOPLASTIC RESINS
PRODUCTION OF POLYAMMIDE COMPOUNDS
BUSINESS DIVERSIFICATION
Arcoplex Group 2
Distribution of thermoplastic resins.
Market leader since 1958.
Partner and distributor of prestigious international producers: Arkema,

Basf, Carmel Olefins, Kolon Industries, Repsol, Samsung, Solvay, Total, Versalis.
Change oriented company with a strategic long term vision.
Strong moral and ethical values and great professional skills towards any
party: partners, customers, suppliers, institutions.
Arcoplex Group 3
OUR TERRITORY COVERAGE
WAREHOUSE 5 8
STOCK 5.000 Tons 7.000 Tons
ACTIVE CUSTOMERS 2.250 3.500
SALESMEN 16 14
SALES AGENTS 16 18
TECHNICIANS 4 2
Arcoplex Group 4
CONSULTIVE APPROACH
Arcoplex is active in the world of plastics by adding to the commercial activity

consultancy and technical assistance.
Competence, training, products portfolio and logistic service as strenghts.
Specialized in engineering plastics, constantly investing in the R&D area.
Arcoplex Group 5
RELATIONSHIP WITH THE PRODUCERS
Arcoplex is the joining link between the main worldwide producers of

thermoplastic resins and a global market always more demanding and diversified.
Because of that financial and structural investments have been aimed to the
spread and knowledge of plastics and their right use.
Arcoplex Group 6
The meaning of:
Search for the satisfaction of needs of a market requiring always

increasingly complete solutions.
A cutting-edge laboratory of analysis, where both producer and transformer can

test the experience and the skills of Arcoplex in achievement of their projects.
The target is to ensure top competiveness to customers that can find in Arcoplex
the answers to their operational needs to protect the technical and culturale
legacy that stil exists in Italy.
Arcoplex Group 7
A REAL SUPPORT TO CUSTOMERS AND TRANSFORMERS
A technical laboratory able to provide free analysis aimed to the characterization
and determination of polymers from granule to finished product.
CHARPY-IZOD IMPACT STRENGTH
TENSILE MODULUS AND FLEXURAL MODULUS
ELONGATION AT YIELD AND ELONGATION AT BREAK
VICAT
HDT
DSC
MELT FLOW INDEX
DENSITY-SPECIFIC GRAVITY
SELF-EXTINGUISHING UL-94
GLOW WIRE
COLOUR SPECTROPHOTOMETRY
SHORE HARDNESS A AND D
ASHES
FT-IR SPECTROMETRY
Arcoplex Group 8
THE ROLE OF A TECHNICAL DISTRIBUTOR
IN METAL REPLACEMENT
Source of continuous and updated information from the market
to the producers.
Qualified consultant and expert for his customers with a complete range
of innovative solutions.
Consultancy and technical service during the whole process:

from project to production to the final product.
Link between producers ,end user and transformers.
Arcoplex Group 9
WHAT POLYMER AND WHY?
POLYMERS
SAN PMMA
SBS PA 6.10
PS PA 10.10
HI PS PA 10.12
PP OMO PA 6
PVC POM
PP COPO PC
HD PE SEBS
EVA PA 6.6
LD PE PEI
ABS PSU
ASA PES
PPO PPS
PBT PA 11
PC-ABS PA 12
TP LCP
PET-G LNP Application examples
Arcoplex Group 10
WHAT POLYMER AND WHY?
1 EASY IMPLEMENTATION
AND PROCESS
2 WEIGHT REDUCTION
3 COST REDUCTION
Arcoplex Group 11
THE IMPORTANCE OF SYNERGY
Arcoplex Group 12
THE ROLE OF ARCOPLEX
Added value in more directions
Business relationship with many international producers,

with a wide and complete range of products.
Technical office with 4 people and a fully equipped laboratory:

Axtrolab.
Complete coverage of territory thanks to the sales network of Arcoplex

Group.
Continuous supply and direct relationship with 3.500 customers: wide

range of case histories of applications and solutions.
Arcoplex Group 13
THE ROLE OF ARCOPLEX
Added value in more directions
Thanks to all this:
PRODUCERS TRANSFORMERS
Is a benchmark for
END USER DEVELOPERS
Arcoplex Group 14
THE IMPORTANCE OF PARTNERSHIP
Longlasting relationship and strategy.

Constant, complete and accurate exchange of information.
Technical integration
Complete collaboration.
Arcoplex Group 15
Arcoplex e Solvay EP a
winning combination
04/03/2013
SOLVAY EP DISTRIBUTION
Despite the efforts of all the biggest manufacturers of plastic material, being so
present is extremely complex and expensive without the help of our distributors,
especially in a market so big and diverse.
Being the best is not enough anymore, you need to work with the best too.
Solvay EP has always considered its distributors true partners with whom we can
and must work together on projects that have common goals.
Tools provided by Solvay:

- Innovative products
- Technical support training
- Technical assistance at customers' at any stage of the project
Trasparency, fairness e mutual trust

are the elements that make the difference and allow the success
of the ARCOPLEX-SOLVAY team
Arcoplex Group 17
FROM THE PROJECT TO THE OBJECT
TECHNYL A 218 W30

Safety valve for heating system
Target
Reducing weight and cost
Basic Requirements
• Dimensional stability
• Certification WRAS - KTW - ACS
• Thermal Resistance
Innovative Features
• Better surface appearance of the building
• Excellent mechanical performance
Arcoplex Group 18
TECHNYLSTAR SX 218 V50

Grid drain
Target
Basic Requirements
• Stiffness
• High performance mechanical
• High aesthetic
Innovative Features
• Good processability
• Good chemical resistance
Arcoplex Group 19
TECHNYL A218 W V50 BK FA

Hydraulic Counter
Target
Basic Requirements
• Certification WRAS - KTW - ACS
• High mechanical performance up to 90bar
Innovative Features
• Good aesthetic
• FDA certification
Arcoplex Group 20
TECHNYLSTAR SX218 V50

Forklift
Target
Basic Requirements
• Stiffness
• Mechanical performance
• High aesthetic
• Water resistance
Innovative Features
• Low environmental impact
• It does not require painting
• Easy to recycle
Arcoplex Group 21
TECHNYLSTAR C 548 B black

Fuel Tank
Target
Basic Requirements
• Impact resistance
• Blow moulding
Innovative Features
• Lightness
• It does not require painting
Arcoplex Group 22
Esperienze e conoscenze al servizio della
sostituzione metallo (Le fibre carbonio)
Lehmann&Voss&Co. Un partner Globale
Dati:
Fondata nel1894
Azienda familiare giunta alla 4a generazione
382 dipendenti*
7 business units
Fatturato di 297* millioni di Euro
* 2013 LEHVOSS Group without joint ventures
Sede centrale LuV

Nella città di Amburgo
Production sites for LUVOCOM 1907: Primo laboratorio per

l‘industria della gomma e
dei cavi
Pawcatuck, CT Hamburg, Incheon,

USA Germany South Korea
Divisione LUVOCOM®- La storia
1983 Registrazione del marchio LUVOCOM®
1985 Svuluppo della famiglia prodotti LUVOCOM® ELETTRO-CONDUTTIVI.
1985 Sviluppo di uno dei primi compound tribologici in PEEK al mondo :

LUVOCOM® 1105/CF/10/GR/10/TF/10, oggi ricetta di riferimento.
2004 Sviluppo della famiglia prodotti LUVOCOM® TERMO-CONDUTTIVI
2005 Sviluppo della tecnoclogia LUVOCOM® XCF, fibre carbonio ad alto

modulo, resistenza a trazione e impatto.
2013 Sviluppo della famiglia prodotti LUVOCOM ® LF (Fibre Lunghe), e

Sviluppo LUVOCOM ® SCF (con alta compatibilità al Teflon)
2014 Sviluppo Fibre carbonio ALIMENTARI e per ACQUA POTABILE

Il mercato LUVOCOM
CF +
PTFE +
Nano +
Additives
Richieste tecniche
delle „cariche“
Special-
Compounders
CF
Produttori di polimeri
standard compounders
GF
PP PA PEEK
Richiste tecniche del polimero

Introduzione
COMPOUND:
Sono granuli plastici composti da:
•una base polimerica
•un complesso di additivi cariche e rinforzi ed
•una tecnologia di estrusione atta a inglobare i suddetti in modo omogeneo.
Polimero RINFORZI e ADDITIVI

Richieste tecniche - carbon fibre - silicone oil - flame retardents
- graphite - impact modifier
del cliente PEEK PPA - glass fibre
- laser pigments
PPS PA66 - glass spheres- nano additives
- aramid fibre - ceramic - release agents
PA46 PBT - UV-stabilisation
- mineral fibre - carbon black
... - CNT - metall - flow improvement
- PTFE - colour - other
Il compound LUVOCOM® è sviluppato in modo che il

materiale risultante massimizzi le specifiche caratteristiche.
Introduzione
Tecnologia di Compoundazione
Gli ingredienti non si fondono l’uno nell’altro, ma si mescolano

fisicamente più o meno bene.
L’efficacia meccanica di un composto polimero–fibra dipende da:
•la percentuale in peso degli ingredienti nella base polimerica ,

•il diametro e la lunghezza media degli spezzoni di fibra,
•le forze d’adesione fra la fibra e la base polimerica.
Le ultime due differenziano dalla prima perché sono metodologie del

compoundatore per fornire al mercato un prodotto dalla proprietà ben
definite e definibili: CONOSCERE COME!!!
Macchine Viti Granulazione

Esempio di adesione delle fibre di carbonio / polimero
LUVOCOM®
PEEK Fibra
Carbonio
LUVOCOM®
PEEK Fibra
Carbonio
Le famiglie prodotto LUVOCOM®
Le FIBRE di CARBONIO
Principali caratteristiche delle fibre carbonio:
• Aumento delle proprietà meccaniche ( creep – strenght - modulo)

• Riduzione del coefficiente di espansione termica (CTE)
• Aumento della conducibilità termica
• Composti elettricamente conduttivi
• Miglioramento delle proprietà tribologiche (CoF e Usura).
• In colori scuri limitati
• Basso allungamento %
Le fibre carbonio LUVOCOM®
LUVOCOM® utilizza moltissimi tipi di fibra carbonio, talvolta

sviluppate insieme ai nostri fornitori e sempre trasformate con precisi
processi produttivi per l’ottimizzazione delle caratteristiche proprie.
Caratteristiche tipiche delle fibre carbonio usate nei LUVOCOM® :
• Aumento ulteriore delle proprietà meccaniche verso GF e dei CF

(serie XCF)
•
•
LUVOCOM® XCF
Tensile
Impact
E- Strenght ( (GPa
Resistance
Modulus MPa)
KJ/m2
) )
Comparazione GF/30 - CF/30 – XCF/30
PEEK
PEEK-GF-30
1105/CF/30/EM
1105/XCF/30
1105/XCF/30
PEI
PEI-GF-30
1106-8133
1106/XCF/30
1106/XCF/30
PPS
PPS-GF-30
1301-0824
1301/XCF/30
1301/XCF/30
PPA
PPA-GF-30
20-0659
20/XCF/30
20/XCF/30
PA46
PA46-GF-30
19/CF/30
19/XCF/20
19/XCF/20
PA66
PA66-GF-30
1/CF/30
1/XCF/30
1/XCF/30
0 00 10 5
50 20
100 10 30 150 40
15 200 50 20 250
60 2570
300 8030
350 90 35 100
400
LUVOCOM® XCF
Applicazione: Supporto dei vani porta
bagaglio a mano.
OEM: AIRBUS A320 (ora su tutti I modelli)

LUVOCOM® XCF
Requisiti:
Riduzione costi (replacement of
magnesium an carbon fibre composite)
600 kg Leggerezza
Requisiti fuoco e fumi per aereomobili.
Alta resistenza meccanica (fatica e 16G)
00
LUVOCOM® XCF
Scelta del Materiale:
LUVOCOM® 1301/XCF/30
PPS con 30 % fibra carbonio XCF
Verniciabile
LUVOCOM® utilizza moltissimi tipi di fibra carbonio, talvolta sviluppate
insieme ai nostri fornitori e sempre trasformate con precisi processi
produttivi per l’ottimizzazione delle caratteristiche proprie.
•Ottimizzazione delle proprietà TRIBOLOGICHE

LUVOCOM® Tribologici
Wear Factor (x 10E-6)
3
PEEK stessa 1 PEEK stessa

formulazione: formulazione:
CF/GF/Nano CF/GR/TF
0
150 °C 1105-
150 °C 1105-
100 °C 1105-
150 °C 1105-
1105-7373
1105-7678
1105-7185
1105-7185
(different
Influenza delle fibre carbonio e Influenza delle fibre carbonio
(different
7678 VP
CF)
VP
7373
7185
7185
nanoadditivi
CF)
0,4
0,3
CoF
0,2
0,1
0
Applicazione: Palette pompe vuoto
Preparazione degli studi preventivi per la
OEM: Produttori auto definizione dei materiali più idoneei.
Richieste: Ottima resistenza usura, e CoF

Condizioni: dipendono dal tipo di Pompa
Universal tribometer
Temperature of test
100°C
chamber
Counter surface AlMg3, wet-sanded 400-grit paper
4 m/s – parallel to the direction of melt
Sliding speed:
flow in the part
Load applied: 0,2 MPa
Force 3,2 N
diagram 1: wear
PEEK
TRIBO PEEK (competitor)
PA66
PPS
PA66
PEEK
LUVOCOM® PEEK in USE
Friction
CoF* Usura Specific wear rate
Materiale Polimero Usura [µm/km]
coefft.
[µ] [µ] [µm/km] ks*10-8 [mm3/Nm]
LUVOCOM 1-VAP 10 PA6.6 0,03 0,17 92
LUVOCOM 1-VAP 05 PA6.6 0,06 0,09 46
LUVOCOM
PEEK 0,05 0,03 18
1105/CF/10/GR/10/TF/10-2 Axial
LUVOCOM 1105-8000 PEEK 0,06 0,35 191
LUVOCOM 1301-7449 PPS 0,08 0,12 73
LUVOCOM 1105-VAP 10 PEEK 0,05 0,02 11
LUVOCOM 1105-VAP 05 PEEK 0,10 0,04 20
* I coefficenti di attrito sono confrontati su valori medi a 800 km e 1440 km.
Table 4: summary of results – friction test

Luvocom® serie SCF (Superior
Sliding
Superimpact)
PPA + CF + TF
PPA + SCF + TF
Resistenza a Trazione (MPa) E-Modul (GPa) Charpy (kJ/m2)

• Ottimizzazione delle proprietà conduttive – ATEX e/o ALIMENTARE.

LUVOCOM® Conduttivi
Curva di percolazione di due compound LUVOCOM ® (PA 6.6, CF, colored).
Performance elettriche ottenute tramite differenti tecnologie.
Alcuni colori disponibili su LUVOCOM® 1-8068.
1016
1012
ROB 1010 - 1012 Ω - Antistatic Additives
1010
1-0889-5/RD
ROB 106 - 1010 Ω, Area for antistatic compounds
ROB 20 % CF
- Ex areas, protection against distruptive discharge
Ω 106-9 Ω
- Slow electrostatical discharge for electronic applications
106
ROB 103 - 106 Ω, ESD area (Electric Static Dissipative)
1-8068/RD
10 % CF - For fast electrostatical discharge
< 103 Ω - For grounding contacts
103
ROB 100 - 103 Ω
- High electrical conductivity
- Shielding of electromagnetic fields of high frequencies
100 - Current conduction in mA area
10 % 20 % 30 % 40 %
- EMI/RFI shielding
Weight % carbon fibers
LUVOCOM Conduttivi
Applicazioni Raschiatore alimentare
LUVOCOM®-1-8818//RD/L
• PA 6.6 Fibra carbonio antistatico,
PERSONALIZZAZIONI tecniche aggiuntive : • Idoneo al contatto alimentare.
• Rosso
FOOD (antistatico e alimentare)
ATEX ( conduttivo / Antistatico e resistenze

meccaniche per zone esplosive )
ACQUA POTABILE (secondo KTW, WRAS e ACS) Sistema Pompa

Dosatrice
LUVOCOM® 1301-8724 (PPS)
Girante e guarnizioni POMPA ACQUA • Stabilità dimensionale
LUVOCOM® 1301-8956 e 1105-9020/T • Resistenza Chimica
PPS PEEK • ATEX
• Stabilità dimensionale • Idoneo al contatto con aliementi.
• Resistenza usura
• Bassi Coefficenti di Frizione (minor energia)
• Idonetà al contatto con acqua potabile.
• Fibra Carbonio Lunga.

LUVOCOM Fibre lunghe carbonio
Migliore resistenza a flessione/fatica VS standard LGF e vs standard GF
Tensione (Mpa)
Materiali condizionati:
50 % umidità relativa
PPA 50%LGF PA66 50%LGF PA66 50%LCF

Co-engineering LUVOCOM®
Mechanical
Thermal analysis
Rheology
Optical methods
IR-spectroscopy
Chemical determination methods DSC Pin on Plate
Thermal conductivity
Tribology
Mold flow
Emission and smell
Cytotox
Special investigations (e.g. UL 94)
TGA Hot Disk

Il vostro Partner
30 anni di esperienza nei compound TAILOR MADE

Azienda indipendente
Co-Engineering dal disegno alla produzione
Conoscenza competente delle applicazioni tecniche
Rete di vendita e produttiva globale
Ampia gamma clienti con collaborazioni decennali
PER MAGGIORI INFORMAZIONI ABBIAMO LO STAND QUI AL
METAL REPLACEMENT FORUM
LUVOCOM®
Solutions
Compounded
Individually
GRAZIE PER L‘ATTENZIONE

Headquarters Americas Asia Asia
Lehmann & Voss & Co. LEHVOSS North America, LLC LEHVOSS (Bejing) Chemical Co. Ltd LEPS Compounds Korea
Alsterufer 19 185 South Broad Street 606 Diyang Tower 8 Lot, 130 Block
20354 Hamburg Pawcatuck, CT 06379 No.H2 Dongsanhuan North Road 695-7 Gojan-dong, Namdong-gu
Germany USA 100027 Bejing Incheon, 405-310
Tel +49 40 44 197-250 Tel +1-855-681-3226 China Korea
Fax +49 40 44 197-487 Fax +1 860 495 2047 Tel +86 10 6297 0425 Tel +82 10 3775 6567
Email: luvocom@lehvoss.de Email info@lehvossllc.com Email info@lehvoss.cn Email info@lehvoss.cn
Any recommendations made for use of Seller's materials are made to the best of Seller's knowledge and are based upon prior tests and experience of the Seller believed to be reliable; however,
Seller does not guarantee the results to be obtained and all such recommendations are non-binding – also with regard to the protection of third party's rights –, do not constitute any
representation and do not affect in any way Buyer's obligation to examine and/or test the Seller's our goods with regard to their suitability for his Buyer's purposes. No information given by the
Seller is to be construed in any way as a guarantee regarding characteristics or duration of use, unless such information has been explicitly given as a guarantee.
Milan, 5th and 6th June 2014
Metal Replacement:
VESTAKEEP (PEEK) &
VESTAMID HTPlus (PPA)
Uwe Kannengießer
5th of June 2014
1
Evonik solutions
for Metal Replacement
Agenda
1. Evonik’s Industries Scope
2. Megatrends
3. HP innovation fields
4. Our key competences
5. Process capability
6. Polymer solutions of High Performance Polymers (HPP)

Evonik Industries - Chemicals
Chemical Site Marl
Turn-over > €10.0 billion
Workforce > 30 000 employees
C4-Chemistry / Care & Surface Specialties / Specialty Acrylics /

Building Blocks Superabsorber Coatings & Colorants
Industrial Consumer Coatings &

Chemicals Specialties Additives
Aerosil & Silanes / Feed Additives / Exclusive High Performance

Adv. Fillers & Pigments Synthesis & Catalysts Polymers / Methacrylates
Inorganic Health & Nutrition Performance

Materials Polymers
Technology Consumer Specialty

Specialties Solutions Materials
Performance Polymers
Key Figures 2013
Performance
Polymers
Parsippany
Headquarters Darmstadt,
Germany
Sales €1.81 billion
more than Darmstadt

Employees 3,500 Marl
Production sites Austria

China
Germany
Japan
Russia Shanghai
Taiwan
United Kingdom
USA
HP – growth target industries and
applications serve Megatrends
Megatrends
Makrotrends
Demographics Target
industries & applications
Ø Increasing medical demand for HP
Ø Senior adapted goods
Medical
Ø Energy efficiency/ alternative
Climate & energy Electronics
Resources
Ø Light weight construction
Alternative energy
Ø Green products – Photovoltaic & Solar
Ø Miniaturization – Wind energy
Globalization – Geothermic
Ø Mechantronics
Ø Increasing / alternative mobility • Lightweight Mobility
− Automotive
Ø Increasing security demand
− Aerospace
Ø Increasing communication
technologies • Industrial energy saving
The knowledge
society Ø New media & virtual reality
HP continuous product development for
exploration of new business opportunities
PA12 Building
PA612 Blocks
PA610 Resins,
PA1010 Blends and
Compounds
PEBA
VESTAMID TROGAMID VESTAKEEP VESTENAMER
CoPA
PEEK Powders
PPA
VESTOSINT VESTAMELT VESTAKEEP P84
PI
Fibres
TOR Films
Foams
PMMA
Stock shapes
PMI PLEXIGLAS TROGAMID VESTAKEEP ROHACELL
HP fields of innovative expertise
Polymer Design Adhesion & Bonding
Compounding Light Weight
Processing Testing
Our key competences overview
Assistance in design
o (CAE- / CAD- Moldflow – Studies)
o Technical calculations
Support in processing issues

o Colour matching of customer molds
o Injection moulding (One Shot, Two Shot, Composite)
o Extrusion
(Multi Layer Technology / Corrugated Tubes a.s.o.)
o Blow moulding
Advisory service for thermoplastic HPP- materials

o Selection of appropriated plastics depending on
requirements
o Tailor made products
Processing Capabilities
Mixing
Compounding
Injection Molding
Extrusion
Injection molding
Rod Extrusion
Film Extrusion
Multilayer Extrusion
Compounding
Extrusion
HP Polymer Competencies –
Providing solutions to gain new goals
Medical Automotive & Vehicle Design Hybrid Structures
Oil & Gas Pipe Industry Sports & Leisure Resource Efficiency
Seite | 11
1. Dental Dosing Device
Application
Dental Dosing Device
Grade
VESTAKEEP 4000G
Process
Injection molding
Requirement for parts

• High purity, plate able
Added value
• Reduction in weight compared to metal
• Low friction handling and warm hands
• Better sterilization and a longer service life
than titanium.
Seite | 12
2. Spinal Cages
Application
Spinal Cage
Grade
VESTAKEEP Care
Process
Injection molding

• High purity, plate able
• Similar properties to human bones / cartridge
Added value
• Bio-compatibility
• High impact strength
VESTAKEEP Spinal Cage • Individual part design by CNC machines
• Radiolucent for x-rays
Seite | 13
3. Real Accu Driller
Application
Surgery driller
Grade
VESTAKEEP 2000G
Process
Injection molding

• Sterilize by hot steam and radiation
• Low weight for better handling
Added value
• High ductility (+20%)
• Impact resistance (+25%)
• Injection moulding support for warpage free
parts
Seite | 14
3. Lotus Exige – Charge air conduct
Application
Charge air conduct
Grade
VESTAMID HT Plus M1033
Process
Injection molding

• Weight reduction
• Temperature resistance
• Chemical resistance (oil, fat, fuel, etc)
Added value
• Reduction of weigh (50%)
4. Seat car shaft adjustment shaft
Application
Seat car shaft adjustment shaft
Grade
VESTAMID HTplus M1035
Fig.1: Original splined steel tube
Process
Injection molding

• Torsion stiffness
Fig.2: Light weight construction optimized
for injection molding • Functional integration
Added value
• Equal stiffness and 30% lighter part design
• Integration of the shaft lock down device direct
in the injection moulding and design of the part
• Reduction costs for the assembling
Seite | 16
5. Seat car shaft adjustment shaft
Application
Seat car shaft adjustment shaft
Grade
Process
Injection molding

• Bending stiffness
• Functional integration
Added value
• Equal stiffness and 50% lighter part design
• Integration of the shaft lock down device direct
in the injection moulding and design of the part
• Reduction costs for the assembling
Seite | 17
6. Hybrid Träger (Erlanger-Traeger)
Application
Front-end
Grade
Process
Injection molding

• High stiffness
• Functions integration
Added value
• 20% lighter
• Higher stiffness, higher performance K higher
safety
• Better in the crash test 30%
Seite | 18
7. Connecting rod (Pleul Stange)
Application
Steering stabilizer
Grade
VESTAMELT X1333
VESTAMID HTPlus M1033
Process
Injection molding

• Functional integration
• Same transformation of torque
Added value
• Plastic rubber bonding
• Constant properties under conditioning minimum
50% better than competition
• Corrosion protection by VESTAMELT
Seite | 19
8. Turbocharger wheel
Application
Turbocharger wheel
Grade
VESTAKEEP 2000 CF30
Process
Injection molding

• Chemical resistance
• Thermal resistance
• Reduction of process cost for milling
Added value
• Easier and cost efficient production compared
to metal
• Less scrap during production
• Efficient use of material (recycling)
• Fuel saving by lower moment of inertia and
faster acceleration Seite | 20
9. Electronic and aerospace industry
VESTAKEEP in Electronics
Application
Connectors fixing
Grade
VESTAKEEP AR 1212
Process
Injection molding

• Flame resistance
Added value
• Flow ability
• Out standing flame resistance
10. Gas stream connection
Application
Gas Stream connection
Grade
VESTAKEEP 4000G
Process
Injection molding

• Chemical resistance (exhaust gases e.g.
sulfuric acid)
• Thermal resistance (200°C)
• Bonding to rubber
Added value
• Weight reduction of appr.75%
• Better corrosion resistance of PEEK in
comparison to stainless steel
• Shows lowest plastic deformation Seite | 22
11. Oil Adapter for brake system
Application
Oil Adapter for brake
Grade
VESTAKEEP L4000G
Process
Injection molding

• High mechanical conditions
Added value
• Long-term behavior under pulsating internal
pressure of 100 bar and a continuous use
temperature of 110 ° C
Seite | 23
12. Oil Pipes liner (Flexible)
Application
Oil Pipes Liner
Grade
VESTAKEEP 5000G
Process
Extrusion

• Thermal resistance (up to 160°C)
Added value
• Weight reduction (20%)
• Corrosion protection
• Highest performance at evaluated
temperatures
• Higher ductility compared to others PEEKs
(20%) Seite | 24
13. Water Meter
Application
Water Meter
Grade
Process
Injection molding

• Approval for drinking water (up to 90°C)
• Operation pressure up to 16 bar
Added value
• Reduction of processing cost compared to
brass
• Option for integration of plastic and rubber
sealings
Seite | 25
14. Bicycle bearing
Application
Bicycle bearing
Grade
Process
Injection molding

• Torsion stability in comparison to
aluminum
Added value
• Weight reduction and similar mounting like aluminum
• Higher mechanical performance in comparison to
other polymers
• Longer lifetime (30% higher safety factor against
cracking of all considered polymers solution)
Seite | 26
15. Solar Panel
Application
Solar Panel
Grade
VESTAMID HTplus X1000
Process
Extrusion

• Electrical non-conductivity
Added value
• Good UV-resistance
• Welding-waterproof material bonded
connection
Seite | 27
16. Press fitting for tank lip
Application
Press fitting for tank lip
Grade
VESTAKEEP 4000G
Process
Injection molding

• Chemical resistance (special to
hydraulic oils and fuels)
• Dimension stability (swelling)
• Creep resistance
Added value
• VESTAKEEP shows lower grip to ensure a
long-term pressure of 20MPa
Seite | 28
17. Metal insert in a locking device
of a filler cap
Application
Metal insert in a locking device of a
filler cap
Grade
VESTAKEEP 2000 GF30
Process
Injection molding

• Wear resistance
Added value
• One step process (cost savings in
assembling, min. 50%)
• Higher ductility
Seite | 29
Thanks you for your attention
Seite | 30
Gharda solutions for Metal

& Sintered Carbon
replacement
Mr. Bernard Lanham – Gharda Chemical Ltd
Dr. De Fazio Massimo – Resp. Sviluppo prodotti

Daire Chemicals S.p.A
1
Content
Gharda Chemicals presentation
Daire Chemicals presentation
Metal Replacement solutions
Sintered carbon replacement
2
Gharda Chemicals Ltd.

US 250 MN company
Started in 1964
>2500 Employees
4 Production Plants with ISO certification Producer
of Agrochemicals,
High Performance Pigments & Polymers
Central R&D & Design-Mumbai
Exports to >25 Countries.
3
Research & Application Development Centre

Gharda Institute of Science and Technology (GIST), Mumbai, Maharashtra, INDIA
4
11 NATIONAL AWARDS FOR

GHARDA POLYMER SBU
• SIR P. C. RAY AWARDS FOR TECHNOLOGY DEVELOPMENT: 1998, 2001,
2005, 2012.
• PLASTICON AWARDS FOR PRODUCT DEVELOPMENT: 1999, 2002, 2005,
2012.
• FICCI AWARD FOR NOVEL PRODUCT DEVELOPMENT: 2005
• MINISTRY OF CHEMICAL & FERTILIZER INNOVATIVE PRODUCT AWARD:
2012, 2013
5
GHARDA POLYMERS MANUFACTURED
G-PAEKTM
(PEK- Polyether Ketone)
GAPEKKTM
(PEKK- Polyether Ketone Ketone)
GAZOLETM
(AB-PBI- Polybenzaimidazole)
6
Thermoplastics Pyramid
ABPBI
PEKK
PEK
SSP PEEK
PES
Temperature
LCP
Resistance
Performance
PPSU
PSU PPS
PEI
PC PA
PPE POM
ABS PET/PBT
PMMA PS LLDPE HDPE

PVC LDPE
AMORPHOUS CRYSTALLINE
7
Daire Chemicals S.p.A

• Estabilished in 1982
• Privately owned company
• Partner for the producer and for the end user showing
all feagures of materials for new applications
• Partner for the molders , resolving technical problems and looking also
for saving solutions
• Exclusive Gharda Distributor for all Italian market
8
Daire Chemicals spa

Engineering Polymers Distribution & Technical Assistance
9
Content
Metal Replacement Solutions for high
temperature requirements
10
G-PAEKTM & GAPEKKTM
11
STRUCTURE & PROPERTIES
PEEK PEK PEKK

Glass Melting Initial
H Polymer Transition Temp. Decompositi
N Temp. (Tm) °C on Temp.
(Tg) °C (IDT) °C
N n PEEK 143 343 560
PBI PEK 152 372 570
PEKK 176 396 581
PBI 467 NA 625
12
PEK (Polyether Ketone) &PEKK (PolyetherKetone Ketone)

advantages
• High heat resistance up to 300 °C

• Low Creep and Retention of mechanical properties at
elevated temperature
• Outstanding chemical resistance
• Outstanding wear resistance (2 times that of standard)
• Outstanding resistance to hydrolysis
• Outstanding thermal properties
• Excellent mechanical properties
• Very good dielectric strength, volume resistivity, tracking
resistance
• Excellent radiation resistance
13
Glass Transition Temperature

500 467
450
Glass Transition Temperature (°C)
400
350
300
250
200 176
143 152
150 120
80 85
100
50
0
PA 46 PPS LCP PEEK PEK PEKK PBI
14
Melting Point
500 467
396
373
400 343
Temperature (°C)
300
Tm Tm Tm Tg
200
100
0
PEEK PEK PEKK PBI
15
Compressive Strenght
160
140
Compressive Strength (MPa)
120
100
80
60
40
20
0
GAPEKK PEKK
Pyramid PEKK PEKK
KEPSTAN PEKK
OXPEKK Gharda PEK Standard
3200G Competitor
KK827H-BK Competitor
8001 Competitor
MG200 1200G PEEK
16
Compressive Strenght
G-PAEK 1100 (PEK) GAPEKK 3100 (PEKK)

(Compression tested) (Compression Tested)
Compressive Strength
@ 10% Yield Ultimate value
MPa MPa
G-PAEK 1100 (PEK) 120 135
GAPEKK 3100 (PEKK) 135 150
17
Limiting Oxygen Index (%) of different

Engineering Plastics
45
40
35
30
LOI (%)
25
20
15
10
5
0
PAI PEKK
PEEK 450G PEK 1200G PSU Polyimide
18
Flammability as per UL-94 for Engineering

Plastics
Polymer UL-94 Specimen Thickness
PI V-0 3.17 mm
PPS V-0 1.5 mm
PEI V-0 1.5 mm
PES V-0 0.8 mm
PTFE V-0 1.5 mm
PEEK V-0 1.5 mm
G-PAEK 1200G V-0 0.8 mm
GAPEKK 3200G V-0 0.8 mm
19
Smoke Emission of Different Engineering

Plastics
Specfic Optical Density (Ds)
800
700
600
500
400
300
200
100
0
20
Creep Test for G-PAEK 1200G
If we continue the test till 1020 hours i.e. ~1016 years G-PAEK 1200G will show
extension (% strain) of 3.5%, this is strain at yield point for this specimen
21
PEKK & PEK Applications

• Off-Shore Application
– Refining
– Cracking
– Oil Drilling
• Submersible Pumps
– Dewatering/ mining/ high depth pumps
• Friction & Wear parts
• Automotive
• Nuclear
• Food Industries
• Semicon
• Textiles
• Etc…
22
PEKK & PEK

Off-Shore Applications
• Valve Plates, Valve rings and , Seals
– 30% CF and 30% GF PEK & PEKK grades
are used
– PEKK supersids PEK due to higher Tg and
temperature resistance.
– High strength and temperature
resistance.
23
PEKK & PEK

Off-Shore Applications
• Piston Rings & Bushings
– High pressure, High
temperature, corrosive
gasses and chemicals
– Lubricated and wear grades
of PEKK/PEK used.
24
PEKK & PEK

Valve seats & seal rings
Improved compressive
Strength.
Improved heat resistance
Low creep
Excellent chemical resistance
25
PEK Stock Shapes

Rods & Plates
26
PEK- Compression Moulded & machined Parts
27
PEK- Photocopier machine parts
28
PEK for Nuclear Applications
29
Content
Sintered Carbon replacement
30
GAZOLETM 6000
PEK/ABPBI Blends
31
GAZOLE - PEK/PBI alloys

(grades)
• GAZOLE 6200
6200
• GAZOLE 6300
• GAZOLE 6400 6300
PBI Dimensional
Stability
• GAZOLE 6500 content
Hardness
• Carbon Fiber filled 6400 Wear resistance
COF
• Glass Fiber filled
• Lubricated 6500
32
GAZOLE 6000 (PEK/ABPBI alloys)

ADVANTAGES
• Melt Processable thermoplastic alloys
• High Temperature Resistance & Superior Mechanical Performance at elevated
temperatures up to 300 °C, similar to Sintered Carbon parts
• Lower CTE & negligible warpage.
• Low Sloughing, Excellent Wear resistance with very high limiting PV of 18.6 Mpa.
• Low COF values of 0.12 making it Inherently lubricious with a very smooth surface
finish.
APPLICATIONS
• Petrochemical – Thrust pads, bushings, bearing
cages, valve seats, seals
• Industrial – Conveyor belt hinges, Glass handling
equipment parts, compressor piston rings etc.
33
Sintered Carbon vs competing polymers

Properties Unit Standard GAZOLE ® Sintered PI PBI
6230FC Carbon Graphite Competitor
Density g/cc 23°C 1.42 1.8 1.51 1.41

Flexural Strength MPa ASTM D 150 66 82 158
790
Modulus of Elasticity GPa ASTM D 22.5 23.0 4.0 13.70
638
Compressive MPa ASTM D 180 195 133 123
Strength 695
Max. Temperature °C UL 746 300 260 280 280
34
DMA Analysis GazoleTM Vs Sintered Carbon

GAZOLE 6230 FC
SINTERED CARBON
PI Graphite
35
Stribeeks Curve Dry Run
PI Graphite
Sintered Carbon
Gazole 6230FC
36
Stribeeks Curve Wet Run

20% Sand (<60Micron)+ 80% Water mix
Gazole 6230FC
PI Graphite
Sintered Carbon
37
Coefficient of Friction & abrasion data

comparisation
Grade COF @ 2900 rpm Taber Abrasion
& 25 N load loss (mg) @
5000 cycles
GAZOLE 6230FC 0.04-0.05 39
Sintered Carbon 0.28-0.29 59.3
PI Graphite 0.17-0.18 113
38
Wear Data For Gazole Grades
GAZOLE PBI G-PAEK G-PAEK PAI PAI PI

Wear Compounds Unit 6430FC Lubricated 1230FCT 1230FC Lubricated Graphite
Max. PV MPa.m/s 62.91 55.93 41.94 32.62 27.97 18.64 3.5
Specific Wear m/s

Rate K0 at PV (m3/Nm
limit X 10-16) 2.31 2.98 2.67 6.09 1.48 3.84 2.1
Coefficient of
friction µ at PV
limit - 0.05 0.11 0.1 0.17 0.07 0.14 0.12
39
PEK/PBI alloys Applications

END APPLICATIONS
• Plasmas torches
• Conveyor belting, tilt pad bearings
• Glass handling Pumps
• Turbines & Compressors parts.
• Seals, Seats & Thrust washers
• Bushings
• Bearing cages
• Balls
• Electrical insulators
• Soldering tools
• Wafer transportation and chamber parts in spin coating, etching, PVD
• Lifting pins, screws, bushings
AS COMPOSITES
• PEEK/PBI blend is used as matrix for Thermoplastic composite prepegs made of CF, GF or
aramid fibres- for metal replacement applications.
40
GAZOLE –PEK/PBI Blend Applications

Submersible Pump for down-hole applications
Thrust Bearings , Thurst Pads
- Very High Friction and Wear resistance for Thrust
pads
- High pressure resistance down-hole & High Tg is a
key need.
41
GAZOLE PEK/PBI Blend Applications

Industrial
• Seals, Bearing Cages, Bushings
– High PV limit grades
– Excellent wear resistance properties
42
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OFFENDING COMMAND: ~
STACK:
L’ALIMENTAZIONE SENZA FILTRI
GIORGIO SANTELLA - PIOVAN

…obiettivi
Elimina Risparmia Migliora

• usura da abrasione • costi di manutenzione • pulizia del reparto
• linee intasate • costi di esercizio • efficienza di trasporto
• problemi di polvere • costi di installazione • produttività
• pulizia filtri • costi di ricambi • profittabilità

…principio di funzionamento
la separazione del materiale dall’aria avviene
senza l’ausilio di filtro
La velocità dell’aria è
inferiore al 10% del
minimo necessario per
muovere materiale

…tipologie di contenitori

contenitore tradizionale con

ingresso materiale diretto

contenitore tradizionale con

ingresso materiale tangenziale


…capacità di alimentazione
un filtro sporco genera una considerevole perdita di

carico al passaggio dell’aria di trasporto, con una
inevitabile diminuzione della capacità di alimentazione

…perchè
• efficienza di separazione aria materiale > 99.99%
• la migliore resistenza all’abrasione
• nessun costo di manutenzione
• nessun consumo di aria compressa
• la più alta efficienza di trasporto, nessuna perdita di carico
• assenza di tubi intasati
• assenza di parti di ricambio
• utilizzo semplificato, niente da manutenere
• costi ridotti

…applicazione in camera bianca

…sicurezza e costi

…la gamma


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an event organized by

5|6 JUNE 2014 Sheraton milan malpensa airport hotel

Radici Novacips SpA

PA6, PA6.6, High Temperature PA, PA6.12 and PA,

POM acetal copolymers for injection

Market Requirements Radici’s Answer

Better chemical resistance, Two families of long chain polyamides :

Safety, technical performances, An outstanding range of flame retardant

Define the application in terms of required

Define any additional features that can make

A process in three "steps”

Assign a “factor of importance” for each function

Translate the functional requirements into

Decide whether to use an existing formulation or

• Transformation (injection, blow

• Post processing operations

• End of life (recycling, incineration)

RadiciGroup | Plastics * Low importance **** High importance

Based on input from functional

Radilon® A RV500RW 339 Ner

Development time : 8 months

Radici adheres to the GRI (Global

The function provided by the product

Radici Plastics has obtained Environmental

LCA Indicators - EPD model

100 100 100 100 100 100

Global Warming Ozone Layer Photochemical Acidification Eutrophication Non

Comparison of the indices of environmental impact between two grades

Method : EPD (2008) V1.04

Die-cast aluminum replacement : all EPD’s indicators are in favor of Radilon®

Which Future for

Metal substitution by engineering plastics on demanding

There are still big opportunities fuelled by the increasing

Automotive new regulations on CO₂ emission limits

The new challenges on metal substitution required more

Engineering plastic supplier are requested to provide high

Modulus E ≈ f (↘, T, RH, MA, Cr)

Metals, in general, are considered isotropic with some

200,00 Rad A RV500RW : 100 mm/sec 80

0,00% 0,50% 1,00% 1,50% 2,00% 2,50% 3,00%

Creep Behavior (140 °C, 60 Mpa) Impact Resistance

Charpy Notched (KJ/m2)

Puncture Energy (J/mm)

High Heat Resistant

Tensile Modulus Vs Temperature Heat Ageing in Air at 220 °C

Tensile Strength at Break retention (%)

The graphs show the evolution of some mechanical properties after

Structural Simulation as the tool for part design

Static linear and non-linear analysis

Design validation by FEA

• Step 1) Material characterization by cutting specimens

• Step 2) Moldflow analysis on the part – eventually

• Step 3) The material macroscopic properties and fibre

Activity : aluminum substitution

Material : Radilon® A RV500RW 339 BK

Activity : metal substitution

Material : Radilon® A RV350 HHR (high

Activity : metal substitution

Materials : Radilon® A X7351 BK (injection

Advantages vs metal : cost saving up to 50%

Thanks for Your

Hot Runner systems for engeneering

•Thermostability limited to 20°C ?

•Processing temperatures up to 400°C ?