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Do You Speak Delrin? Introduction Outstanding Attributes List of Grades Low Wear, Low Friction Series Key Properties Table Stiffness & Strength
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Radii Creep Resistance Stress Relaxation Fatigue Resistance
Delrin
Acetal resins
Performance
Typical Applications
39 41 43 45 47 49 51 53 55 57 59 61 63 65
Uniform Wall Thickness Ribs Design Basics Bosses Threads Snap Fits Rapid Prototyping Stockists/Machinists Colours Processing
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DuPonts registered trademark
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? 9 k Delrin u Spea Do Yo 11 n oductio Intr utes Attrib 13 anding Outst s 17 Grade Series List of iction w Fr 19 ear, Lo Low W rength s Table ss & St 21 Stiffne opertie Key Pr tance 23 ep Resis Cre xation Rela 25 Stress nce Resista 27 Fatigue tance 29 ct Resis Impa e ance sistanc 31 Perform UV Re ture ra 33 Tempe e sistanc ical Re 37 Chem
Delrin
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v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v v
Use the colour coded bars to help you flick through to the relevant section and data
resins Acetal
Radii
Basics Design
yping Protot Rapid hinists sts/Mac Stocki rs Colou sing Proces cycling d & Re Regrin ng Marki Laser ns licatio al App Medic g Readin rther Fu es Sampl
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This handbook makes basic information easily available to designers and others and gives a quick reminder of the impressive range of Delrin properties. It is illustrated with a selection of photographs showing some of the enormous variety of applications for which Delrin has already been successfully used.
ts DuPon
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. . . Are you up to speed with all the new grades including Low Wear, Low Friction, UV Resistant and the Eleven Series? . . . Do you know where Delrin is used and why? Have you heard of Delrin but dont know what it feels like? . . . This Delrin phrase book will help you brush up on your acetal knowledge until it becomes your first language.
Delrin versatility: snap fits to ski bindings, clips to conveyors, buckles to bicycle parts
the automotive, appliance, construction, hardware, electronics and consumer goods industries. Trade name: Delrin Generic name: acetal Sub class: homopolymer Abbreviation: POM (polyoxymethylene) Structure: highly crystalline polymerized formaldehyde
Typical examples of Delrin applications appear throughout this handbook
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It has a well balanced profile of mechanical properties, environmental resistance and processability at moderate cost. Delrin acetal resins provide substantial strength, stiffness and creep resistance. Delrin has gained widespread recognition for reliability of performance in many thousands of engineering components all over the world. Since its commercial introduction by DuPont in 1960 it has been used in
Delrin acetal homopolymer was introduced by DuPont in 1960. Copolymer acetal followed somewhat later, around 1962.
Delrin versatility: skate parts, ski bindings, speaker grilles
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This unique balance of properties makes Delrin suitable for many metal replacement projects
Delrin versatility: coloured lighters to carousels, pumps to pegs
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500 Medium viscosity 500P Medium viscosity, easy processing 511P Medium viscosity, easy processing, improved stability 900P Low viscosity, easy processing 911P Low viscosity, easy processing, improved stability 1700P Very low viscosity, easy processing, improved stability
Toughened
100ST Super tough, high viscosity 100T Toughened, high viscosity 500T Toughened, medium viscosity
UV
127UV 527UV 927UV 1727UV 107 507 High viscosity, best UV Medium viscosity, best UV Low viscosity, best UV Very low viscosity, best UV High viscosity, UV Medium viscosity, UV
Glass Reinforced/Filled
510GR 525GR 570 577 10%GR 25%GR 20%GF 20%GF, UV resistant
Delrin 100 = high viscosity 500 = medium viscosity 900 =low viscosity
Delrin: whether standard or specialised, a grade for every application
RESIN SELECTOR DELRIN AGAINST METAL Level 2 Requirements: how can I avoid...? Level 3 Solution: appropriate grade of Delrin
Delrin with low specific wear rate, ws
Wear Delrin 100/500/900
! ew N
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Delrin 500CL Delrin DE9152/DE9156 Delrin 500AL Delrin 100KM Delrin 520MP Best Delrin 500AF
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LOW WEAR, LOW FRICTION SERIES THE FACTORS A FFECTING WEAR AND FRICTION A Choosing Delrin is a good RE: * Pressure of contact starting point for applications in * Relative velocity which wear and friction are major * Temperature * Geometry of motion issues. Unmodified Delrin has * Frequency of motio low friction and wear against steel * Nature and finish ofn surface as can be seen from the chart * Lubrication below.
PROTOTYPE
1000 Countersurface = steel
13
Best
Delrin 100/500/900 Delrin DE9156/DE9152 Delrin 500CL Delrin 500AL Delrin 100KM Delrin 520MP Delrin 500AF
TESTING IS IMPORTANT
ABS
v
PPOv For metal as a counter surface, the harder the surface the better the wear and friction behaviour of the system. Aim for a hardness of greater than 50 HRc
100
PBTv POM v
(Delrin)
v PA66
($$$) Delrin 100/500/900 ($) Delrin DE9152/DE9156 ($$) Delrin 500CL ($$) Delrin 500MP ($$$) Delrin 500AL ($$) ($$$$) Best Delrin 500AF High wear resistance against aluminium
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vPOM+20%PTFE
1 0.00 (Delrin) 0.10 0.20 0.30 0.40
aluminium
wear
PV= pressure velocity
Dynamic coefficient of friction, The natural lubricity of Delrin means it may be found unlubricated in many gear and bearing applications
RESIN SELECTOR DELRIN AGAINST DELRIN Level 1 Tribological system Level 3 Solution: appropriate grade of Delrin
Non-squeaking grades of Delrin Delrin 500SC@10% ($) Delrin 500AL ($$) Delrin 900SP ($$) Delrin 120MP/520MP ($$$) Delrin 500AF ($$$$) Delrin with low specific wear Wear Delrin DE9156/DE9152 Delrin 500SC @ 5% Delrin 500AF Delrin 500AL Delrin 900SP Delrin 500SC @ 10% Best Delrin 120MP/520MP rate, ws ($$) ($) ($$$$) ($$) ($$) ($) ($$$)
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LOW WEAR, LOW FRICTION SERIES . . . continued Quieter too! Cer When two parts are in contact in a wear
situation it is normal to choose dissimilar materials (eg Delrin acetal and Zytel nylon). Factors such as dimensional stability may make such a choice impossible, in which case the new Low Wear, Low Friction grades of Delrin may be suitable. The table below shows the improvement in wear and friction compared to standard grades.
10000 New Grades
15
tain grades (squeak) dram reduce noise atically with standard compared grades
squeak
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wear
external lubrication
Friction
friction
Best
Delrin DE9156/DE9152 Delrin 500AF Delrin 520MP Delrin 120MP Delrin 500AL Delrin 500SC @ 5% Delrin 900SP Delrin 500SC @ 10% Delrin toughened grades (external lubrication needed) Delrin 100T Delrin 500T Delrin 100ST
1000 100
100Pq DE 9152q
Standard Grades Countersurface = Delrin 0.30 0.40
external lubrication
q900SP
10 1 0.10
q500AL q520MP
0.20
optimise design
Dynamic coefficient of friction, Please refer to the grades list for details of Low Wear, Low Friction Resins
K E Y P R O P E RT I E S TA B L E
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Yield stress
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71 25 70 2800 12 8
Fo r see grap sec nex hs tio t n
Yield strain Strain at break Flexural modulus Izod notched impact strength @ 23C @40C
Temperature of deflection under load C 115 Melt temperature C 177 Flammability HB Shrinkage 1,9 to 2,2 % Melt Flow Index 2,2 g/10 min Chemical Resistance outstanding 3 Density 1,42 g/cm
Delrin 100 is the toughest unmodified acetal available with a unique combination of elongation and stiffness
Delrin: stiff, strong, tough, chemically resistant
PERFORMANCE
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19
80
-20C
60
23C
3 2 1 0
20 0 20 40 60 80 100
Stress (MPa)
40
90C
20
10
Strain (%)
Stress v Strain at 20C, 23C and 90C
Temperature (C)
Youngs modulus of Delrin as a function of temperature
To judge the stiffness and springiness of Delrin ask your nearest DuPont Engineering Polymers office for test bar samples.
Material chosen and why Delrin 100 was chosen for its unique balance of stiffness and strength
The exceptional elongation coupled with stiffness makes Delrin suitable for snap fits
PERFORMANCE
Creep
Creep is defined as time dependent strain, resulting from stress.
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Isochronous stress/strain D e l r i n 1 0 0 @ 2 3 C
h 100 0h 50 00 h 10 00 0h
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20
1h 10 h
100
Stress (MPa)
10
10
00
15
Delrin Acetal Resins have extremely good creep resistance for an unreinforced polymer
Always try to design parts so that they are not permanently loaded
Upon removal of a 14 MPa deforming stress, Delrin immediately recovers 40% of the imposed strain
PERFORMANCE
Stress relaxation
Stress relaxation is defined as decrease of the stress required to maintain constant strain.
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Te n s i l e s t r e s s r e l a x a t i o n o f D e l r i n 1 0 0 a n d 5 0 0 @ 2 3 C
100 80
% of initial stress
40
20
Stra in 0 ,3% . 17
Hours
Material chosen and why Delrin 100P was chosen for its good friction properties and a balance of impact and creep resistance with high dimensional stability
Stress free mouldings may be obtained by annealing Delrin at 160C for 45 mins
PERFORMANCE
Fatigue
When materials are stressed cyclically at high levels of stress in relation to their tensile strength, they tend to fail at levels of stress below their ultimate tensile strength. This phenomenon is termed fatigue failure.
50 40 30 20 10 0 10 3 10 4 10 5
24
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25
Stress (MPa)
10 11 15
32
Stress (MPa)
Cycles to failure
10 6 10 7
Material chosen and why Delrin 100 was chosen for the best balance of stiffness and strength coupled with flex fatigue resistance needed for the spring fingers of the tool gripper
Delrin Acetal Resins have extremely high resistance to fatigue failure from 40C to +80C
PERFORMANCE
Impact Resistance
Impact resistance is defined as the ability to withstand a sudden blow rather than a slowly applied load.
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26
Impact strength, kJ/m2
60 50 40 30
-20 0 20 40 60
Temperature, C
27
20 10
500
500T
100
100T
100ST
Material chosen and why Delrin 100ST was chosen for the best combination of stiffness and impact resistance at low temperature, combined with good mouldability
Delrin acetal maintains its high toughness down to very low temperatures
PERFORMANCE
UV Resistance
Colour ed offer so Delrin resin s m protect e UV io of carb n. High levels on blac ka an effec tive UV ct as for non s -critical creen applicat outdoo r ions
Colours
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Acetal resins, like most polymers, are affected by light, particularly sunlight which includes ultra-violet radiation of wavelength 290-400 nm.
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Typical values for Delrin grade 527UV compared with other grades.
500
1000
1,0
500
1000
x27UV BK
1,0
UV Stabilised
Sta
Relative Gloss
0,5
x07
K
BK
0,5
nda
rd
x0 0B
Exposure, kJ/m
Exposure, kJ/m2
Material chosen and why Delrin 127UV was chosen for its excellent balance of mechanical properties combined with good UV resistance
The Delrin UV family of resins are well suited for sporting goods and other items which are used outdoors but stored indoors
PERFORMANCE
Temperature
The highly crystalline nature of Delrin means it is suitable for short-term exposure to temperatures close to the melting point of 177C.
Key The Charac rmal teristic s Proper ty C Melt te mperat ure Vicat So 177 ftening 10 N 50 N 174 Relative 160 Therma l Index ( w/o im pact) HDT (1 90 ,8 MPa) Ball Pre 115 ssure Te st 165 Specific Heat Therma 0,35 l Conduc tivity 0,30 (W/m to K) 0,37
If you need higher temperature resistance, consider DuPont Zytel nylons , Crastin and Rynite polyesters or Zenite LCPs.
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31
100
After 1 year at 100C Delrin retains 80% of its tensile strength
75
50
10
Exposure time in years for which tensile strength in excess of 55 MPa is retained
Material chosen and why Delrin 100 was chosen for its good thermal stability combined with a low coefficient of friction and superior impact resistance
The thermal stability of Delrin means it finds use in applications from 50C to +90C
PERFORMANCE
Chemical Resistance
g affectin factors ance are: The l resist hemica c
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CHEMICAL Acetic acid (5%) Acetic acid (50%) Acetone Air (all pressures) Alcohol (all types) Ammonia (10%) Aniline Benzene Bleaching fluid (10% chlorine) Brake fluid Butane Calcium chloride (10%) Carbon dioxide Carbon monoxide Chloracetic acid (10%) Chlorine gas Chlorinated water < 0,5 ppm Chloroform Chromic acid (10%) Citric acid Cyclohexane Detergents Diesel fuel Ethanol Ethyl acetate
BEHAVIOUR resistant unsatisfactory resistant resistant resistant unsatisfactory limited resistance resistant unsatisfactory resistant resistant resistant resistant resistant unsatisfactory unsatisfactory resistant limited resistance unsatisfactory resistant resistant resistant resistant resistant resistant
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14 Alkali
0 Acid
Material chosen and why Delrin 500P was chosen for its excellent wear properties, chemical resistance, snap-fit ability and dimensional stability
Delrin has excellent resistance to moisture, gasoline, lubricants, solvents and many neutral chemicals
PERFORMANCE
BEHAVIOUR resistant resistant resistant unsatisfactory resistant resistant resistant resistant resistant unsatisfactory unsatisfactory resistant unsatisfactory unsatisfactory resistant resistant resistant resistant limited resistance limited resistance limited resistance resistant resistant unsatisfactory
CHEMICAL Nitrous acid Nitrous oxide (dry) Oils (food) Oils (mineral) Oleic acid Palmitic acid Paraffins Perchloric acid (10%) Phosphoric acid (30%) Phthalic acid Potassium hydroxide (10%) Propane (liquified gas) Sodium chloride (10%) Sodium hydroxide (10%) Sodium hypochlorite (5%) Sulfur dioxide Sulphuric acid (30%) Tetrahydrofuran Toluene Trichloroacetic acid Trichloroethane (1,1,1) Turpentine / white spirit Urea (5%) Vinegar
BEHAVIOUR unsatisfactory unsatisfactory resistant resistant resistant resistant resistant unsatisfactory unsatisfactory resistant unsatisfactory resistant resistant unsatisfactory unsatisfactory unsatisfactory unsatisfactory resistant resistant unsatisfactory resistant resistant resistant resistant
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Hexane Hydrochloric acid (10%) Hydrofluoric acid Hydrogen peroxide (1%) Hydrogen peroxide (30%) Hydrogen sulphide Insecticides Isoctane Jet fuel / kerosene Lubricating oil Methyl chloride Methylene chloride Methyl ethyl ketone Mineral oil Motor oil Nitric acid (10%)
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Material chosen and why Delrin 500P was chosen for its good petrol resistance, good mechanical properties and ease of moulding
T Y P I C A L A P P L I C AT I O N S Do it in Delrin . . .
Ski Bindings
Lighters
Gears
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Zips
Conveyors
36 Clips
Door Handles
37 Fuel Systems
Fasteners
Chemical resistance
Speaker Grilles
Economical, toughness
The exceptional balance of properties has led to a diverse use of Delrin around the world
DESIGN BASICS
Radii
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38
Stress Factor
P
3,0
39
2,0
T
2,0
Usual
1,5
Always use radii at rib junctions and stressed areas but also consider thread terminations, knurled inserts and surface textures
R/T
Material chosen/Design comment Delrin 111P was chosen for this application. Radii lowers stress concentration when parts are put under load
Delrin like many plastics, is notch-sensitive but unlike other resins it has high impact strength at low temperatures
DESIGN BASICS
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rinkage Even sh tortion * less dis set-up * Even ickest moulding qu cycle terial Less ma st * low co
Material chosen/Design comment Delrin 500P. Low distortion and cost efective part ensured by use of even wall thickness
Even wall section will greatly benefit highly crystalline polymers such as Delrin
DESIGN BASICS
42
way ffective are an e rigidity of Ribs ve the to impro arts. p moulded , ribs should be rin For Del e general wall th 2 1 2 to / 3 to 1 / with / 4 ickness, le per side. th t ang 1 2draf /
Sink marks caused by ribs may be hidden by use of textured surface or suitable interruption in the area of the sink.
Material chosen/Design comment Delrin 100P enables increased stiffness to be achieved by use of ribs without compromising surface finish
* Save material and weight * Shorten moulding cycle * Eliminate voids in thick sections
43
If ribbing is unacceptable, Delrin 510GR and 525GR offer significant increase in stiffness
DESIGN BASICS
Bosses
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44
Bosses are used for for mounting purposes or les. ound ho reinforcement ar As a rule the outside ould be diameter of a boss sh le 2 to 3 times the ho diameter. Heavy sections may be e boss avoided by stepping th off the adjoining wall. ns. Use radii at all junctio
Material chosen/Design comment Delrin 511P. Boss and linking rib design provides accurate hole centres
* * *
Boss Design Hole dia = 0,75 x nominal dia of screw Boss dia: 2 to 3 times hole dia Hole depth 2 x nominal screw dia minimum
Always use screws designed for plastics when considering assembly. These may be single or twin-start threaded or trilobular screws. Repeated assembly and disassembly is possible with Delrin.
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Weld lines should be avoided in bosses. Delrin being generally unreinforced, has excellent weld line strength
DESIGN BASICS
Threads
When required, threads may be automatically moulded into the part, eliminating the need for mechanical threadforming operations. For external threads, it may be possible to locate the parting line on the centre of the thread. For internal threads, an automatic unscrewing device is used in the tool.
47
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Round threads
46
To avoid squeak on heavily loaded threads, consider the Low Wear, Low Friction grades of Delrin
v
ttress Use of a bu ill w type thread ssary nnece avoid u s on radial force rt pa the mating
Material chosen/Design comment Delrin 500P. Moulded thread form avoids machining
The dimensional stability of Delrin makes it very suitable for the moulding of accurate thread forms
DESIGN BASICS
L
Snap Fits
Snap Fits are a cost effective way of assembling parts together without the use of special tools. Usually the parts are at rest before and after assembly and pass through a stressed condition as the snap fit is made to work.
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48
* * *
s long Make L a as possible p fit lug Taper sna at root Use radii
Delrin is also excellent for circular and spherical snap fit designs
With Delrin, a single use snap fit may be stressed up to 8% strain (Delrin 100). For a frequently used one refer to the fatigue stress graph
v
49
Material chosen/Design comment Snap fit in Delrin 500 gives strong, rattle-free connection
The combination of stiffness and elongation makes Delrin very suitable for snap fits
Shoehorn prototype
RAPID PROTOTYPING In order to test parts in the actual material it is normally necessary to mould them. Due to the ease of machining of Delrin, it may be possible to prototype parts by NC machining, utilising the CAD data which describes the part geometry.
1
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* *
2
ed ing m minimu achining to a m Suppor t and lon thin walls g parts Be awa r effect o e of the notch f machin parts ing
3
CAD Data
Modify Geometry 50
Test Parts
Hand Finish 51
6 7
Mould Parts
STOCKISTS/MACHINISTS
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Contact your DuPont representative for detailed information on your local Delrin stockist
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53
Details of companies experienced in machining Delrin acetal resins are also available from your DuPont representative
Always ask for Delrin by name
Custom colo urs are available as fu lly compounded product from DuPont or by masterbatch from pigment supp liers
Ideally any masterbatch should be acetal based
Shrinka
g e v. C o lour
BK
BL
54
GY
RD
SHRINKAGE
1,7
NC
WT
YL
55
GN
COLOUR
PROCESSING
The most important variables in producing good parts by injection moulding are:
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* Melt temperature * Injection speed * Hold pressure * Screw forward time * Mould temperature
Above all, a good quality homogeneous melt is required. Typical set-up conditions for Delrin 100 are shown below.
Melt Temp (C) Mould Temp (C) 90 Hold Pressure (MPa) 100
Grades based on the P stabilisation syst em are suitable for hot runner to ols, these include 100P, 500P, 900P, 1700P 127UV, 527UV, 92 7UV, 1727UV, 111P, 511P, 911P.
Always dry toughened grades for 4 hours at 80C
Hold Pressure Time (s/mm) 8 Max Hold Up Time (min) 30 Shrinkage (%) 1,9 - 2,2 57
56
215
Material chosen and why Delrin 927UV was chosen for its excellent mouldability and impact resistance. Its resistance to UV and easy colourability are additional assets
For specific processing information ask for the free booklet Delrin Moulding Manual
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58 Material chosen and why Delrin100 regrind was chosen for the shank. Capable of withstanding high impact, it provides the correct rigidity
59
It is important to use analytical techniques in part design to reduce the impact of recyclate on the environment
LASER MARKING
Laser marking is particularly suitable when the batch sizes are small and marking variability is required (e.g. serial numbers or different languages). A range of colours specially optimised for laser marking is available in Delrin. Tested with several Nd:YAG laser systems, these colours provide high contrast markings with almost no engraving
ication by ight Amplif n L ASER = L of Radiatio mission imulated E St
Advantage s
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ut and cha racter type No surfac e no solvent, pre-treatment, no ink High durab ility of the marking
60 Material chosen and why Delrin 500LM BK-L01 was chosen for its clarity of laser marking plus its mechanical properties
61
M E D I C A L A P P L I C AT I O N S
CAUTION
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&
DuPont makes no representation, promise, express warranty or implied warranty concerning the suitability of these materials for implantation in the human body or in contact with internal body fluids or tissues.
Do not use DuPont materials in medical applications involving permanent implantation in the human body or permanent contact with internal body fluids or tissue. Do not use DuPont materials in medical applications involving brief or temporary implantation in the human body or contact with body fluids or tissues unless the material has been provided directly from DuPont under a contract which expressly acknowledges the contemplated uses.
For food contact or pharmaceutical applications, regulatory compliance statements are available, please contact your local DuPont representative for details.
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Technical Information
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To access further information concerning any topic covered in this binder, please contact your local DuPont office
wide DuPont has a terature selection of li ific covering spec eas application ar ances, such as Appli Electrical, Automotive, , Furniture etc. ha together wit n Principles General Desig ich covers all handbook wh eering resins DuPont engin
The general brochure covering all DuPont engineering polymers is called From concept to commercialisation
64 A wealth of experience available in various formats 65
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