MetaltoPlastic UPP V3

SOLVAY ADVANCED POLYMERS
Designing with Ultra Polymers

Practical Guidelines for Metal-to-Plastic Conversions
July 25, 2007
MO RE PL AST ICS WIT H MO RE PERFO RMANCE

2007 Solvay Advanced Polymers, LLC
Topics Introduction to Solvay Advanced Polymers Description of Ultra Polymers Metals vs. Plastics Simulation Technology Case Study
Solvay Advanced Polymers

Headquartered in Alpharetta, Georgia (US) with manufacturing, R&D sites and affiliates in NA, Europe and Asia Formed in 2001 when the Solvay Group acquired BP Amocos high-performance plastics business Dates back to 1974 and the inception of high-performance plastics production at Amoco and Union Carbide Recently acquired Mississippi Polymer Technologies and Gharda Polymers in Panoli, India 14 distinct product families which include Sulfone Polymers, Aromatic Polyamides and SolvaSpire Ultra Polymers
Solvay Offers More Plastics with More Performance Than Any Other Company in the World
Plastics Performance Pyramid

PrimoSpire
self-reinforced polyphenylene
Ultra Polymers
Exceptional thermal properties Excellent mechanical properties Superior chemical resistance Outstanding flame resistance Un-matched wear resistance
Applications - PrimoSpire SRP

Why PrimoSpire SRP?
Superior strength and stiffness without reinforcements Excellent chemical resistance Superior surface hardness Ease of machinability
Orthopedic Fixation Device
Semiconductor Test Sockets
Fasteners
Stock Shapes
PrimoSpire SRP Comparison with Unfilled Plastics

Tensile Properties
250 200 150
10
Strength, MPa
Strength Modulus
Modulus, GPa
8 6
100 50 0 PrimoSpire PR-120 PrimoSpire PR-250 PPS PI PEEK PEI
4 2 0
PrimoSpire SRP is the Stiffest and Strongest Unreinforced Plastic in the World
PrimoSpire SRP Comparison with Metal

Specific Tensile Strength
(MPa/g/cm3)
250 200 150 100 50 0
PrimoSpire PrimoSpire Aluminum, Aluminum PR-120 PR-250 Heat 6061-T4 Treated Die Casting, 296 Carbon Steel, C1018 Magnesium Stainless AE42-F Steel, 301 Titanium 62-4-2
PrimoSpire SRP has Properties Similar to Metals On a Strength-to-Weight Basis

Topics Introduction to Solvay Description of Ultra Polymers Metals vs. Plastics Simulation Technology Case Study
Metals vs. Plastics

Reinforced Polymers Metal
Fiber-Reinforced Polymers
Flow Direction
STRESS
STRESS
PrimoSpire SRP
Unfilled Polymers ELONGATION
Transverse Direction
ELONGATION
PrimoSpire SRP has Exceptional Strength and PrimoSpire SRP has Exceptional Strength and Stiffness Without Reinforcements Stiffness Without Reinforcements
Material Strength in Molded Part Several Factors Affect Strength Fiber orientation Weld line Gate location Processing
WELD LINE GATE
OR IE ON ATI NT
GATE
10
Metals vs. PrimoSpire SRP

Tensile Strength (MPa) Metals Aluminum Die Cast Zinc Magnesium Self-Reinforced Polymers PrimoSpire PR-120 PrimoSpire PR-250 207 152 8 5 1.2 1.2 320 280 225 70 70 40 2.8 6.6 1.8 Youngs Modulus (GPa) Specific Gravity
11
Equivalent Stiffness
METAL PLASTIC
W T/3
x
T
x
W = 2T
W
x x
For Same Deflection: Tensile Modulus (E) x Moment of Inertia (I) for metal and plastic should be the same With Same Area: Moment of Inertia of plastic cross section is approximately 12 times the Moment of Inertia of metal cross section along the x-axis
Difference in Modulus Can Be Compensated By Difference in Modulus Can Be Compensated By Geometrical Stiffness Without Increasing the Volume Geometrical Stiffness Without Increasing the Volume
12
Stress vs. Strain

Linear
30% GF Polymer
Tensile Stress, MPa
250 200 150 100 50 0
Non-linear
23C 50C 70C 80C 100C 120C 130C 150C 180C 200C
Latch Assembly
Strain (%)
Ultra Polymers Offer Higher Strain and Ultra Polymers Offer Higher Strain and Strength at Higher Temperature Strength at Higher Temperature
13
What is Creep? Creep Is Deformation Under Constant Load

1
Elastic STRAIN Viscoelastic Relaxation Elastic
2
TIME
TYPES OF INSERTS 1. Molded in 2. Ultrasonically assembled 3. Press fit

14
What is Tolerance?
Tolerance is a Combined Effect of Variations in Tool dimension Shrinkage Process parameters Optimize Tolerance in Part Design Design for plastics Make Certain CPk is Achievable
Plastic has advantage of lower modulus
Interference Fit
Metal
Plastic
Tight Tolerance Represents Poor Plastic Design Tight Tolerance Represents Poor Plastic Design
15
Topics Introduction to Solvay Advanced Polymers Description of Ultra Polymers Metals vs. Plastics Simulation Technology
Computer Aided Engineering (CAE) Optimization
Case Study
16
Computer Aided Engineering (CAE) Stress Analysis FEA

(Finite Element Analysis)
Flow Analysis Flow balance Pressure profile Weld line Fiber orientation
Stress distribution Deflection Optimization
CAE Insures Functionality and Moldability CAE Insures Functionality and Moldability
17
Stress Analysis (FEA)

Objective: Based on success of a smaller charged air cooler, conduct feasibility study to convert to larger size
Edge clamped on aluminum body
Design Requirements
1 million thermal cycles at 210C with 2 bar internal pressure
18
FEA Results Stress Distribution
Structural stiffness increased by adding rib
Maximum Stress Level Should Be Well Within Maximum Stress Level Should Be Well Within Design Limit of Plastic in a Given Environment Design Limit of Plastic in a Given Environment
19
Flow Analysis
Objective: Recommend gate location to minimize warpage and improve flatness for better sealing surface Options Edge gate Center gate Warpage affected by Flow balance Fiber Orientation Uniform Cooling
20
Pressure Profile
Edge Gate Center Gate
Flow Balance Provides Minimum Warpage Flow Balance Provides Minimum Warpage
21
Optimization Design Use only where needed Processing Insert molding Machining stock shapes New Approaches Collaboration CAE Integration
Stock Shapes Insert Molding
22
Collaboration - Team Approach
Designer
Molder
Material
Performance Geometry Regulations Cost
Processing Part Design Tooling & Processing

Tooling Moldability Cycle Time
Material Characteristics Resin Supplier

Application Database CAE Support Secondary Operations New Product Development
23
CAE Integration Traditional

(Silo Effect)
CAE Integration
(Accurate Prediction)
Material Material Stress Analysis Flow Analysis Tooling & Processing
Flow Analysis
Part Design
ORIENTATION EFFECT
Final Design Part Design
Stress Analysis Tooling & Processing
Design Team
Final Design
Integration of Flow Analysis with Stress Analysis Integration of Flow Analysis with Stress Analysis Gives More Accurate Prediction Gives More Accurate Prediction
24
Topics Introduction to Solvay Description of Ultra Polymers Plastics vs. Metals Computer Aided Engineering (CAE) Case Study
25
Case Study - Motor End Cap

Background Metal cap with thermoset brush card Five different parts Machining and anodizing Critical features Creep and flatness Chemical resistance Benefits Cost reduction Weight reduction Parts consolidation
26
Technical Support
Concept insert molding, crush ribs, improved flatness Material Selection chemical resistance, strength, and stiffness, plus improved creep requirements and flatness Design Finite Element Analysis (FEA) for improved performance and Flow Analysis for optimized gate location Prototype Development tooling and molding Testing process verification (viscosity and crystallinity) Production cycle optimization, fabrication, assembly, secondary operations
Solvay has Over 20 Years Experience Solvay has Over 20 Years Experience Successfully Replacing Metal with Plastic Successfully Replacing Metal with Plastic
27
Keys to Success Apply team approach Use flow analysis and stress analysis to validate functionality and moldability MUST redesign and optimize the design Select the right ultra polymer for the job
Well-Designed Part Made from the Right Plastic Well-Designed Part Made from the Right Plastic Can Outperform a Metal Part Can Outperform a Metal Part
28
SolvaSpire Ultra Polymers

KetaSpire PEEK (polyetheretherketone)
Broadest chemical resistance, highest strength
AvaSpire modified PEEK

Best way to bridge price and performance gaps
PrimoSpire self-reinforced polyphenylene

Worlds stiffest and strongest unreinforced plastic
EpiSpire high-temperature sulfone

Best combination of exceptional creep resistance at high temperatures with processing ease
Torlon polyamide-imide
Best wear-resistance and lowest friction properties
Solvay Offers More Plastics with More Performance Solvay Offers More Plastics with More Performance
29
Want To Know More?
For additional information, please e-mail us at
advancedpolymers@solvay.com
BUSINESS CONFIDENTIAL
30
Designing with Ultra Polymers

Practical Guidelines for Metal-to-Plastic Conversions
July 25, 2007
MO RE PL AST ICS WIT H MO RE PERFO RMANCE

Topics Introduction to Solvay Advanced Polymers Description of Ultra Polymers Metals vs. Plastics Simulation Technology Case Study
Solvay Advanced Polymers

Headquartered in Alpharetta, Georgia (US) with manufacturing, R&D sites and affiliates in NA, Europe and Asia Formed in 2001 when the Solvay Group acquired BP Amocos high-performance plastics business Dates back to 1974 and the inception of high-performance plastics production at Amoco and Union Carbide Recently acquired Mississippi Polymer Technologies and Gharda Polymers in Panoli, India 14 distinct product families which include Sulfone Polymers, Aromatic Polyamides and SolvaSpire Ultra Polymers
Solvay Offers More Plastics with More Performance Than Any Other Company in the World
Plastics Performance Pyramid

PrimoSpire
self-reinforced polyphenylene
Ultra Polymers
Exceptional thermal properties Excellent mechanical properties Superior chemical resistance Outstanding flame resistance Un-matched wear resistance
Applications - PrimoSpire SRP

Why PrimoSpire SRP?
Superior strength and stiffness without reinforcements Excellent chemical resistance Superior surface hardness Ease of machinability
Orthopedic Fixation Device
Semiconductor Test Sockets
Fasteners
Stock Shapes
PrimoSpire SRP Comparison with Unfilled Plastics

Tensile Properties
250 200 150
10
Strength, MPa
Strength Modulus
Modulus, GPa
8 6
100 50 0 PrimoSpire PR-120 PrimoSpire PR-250 PPS PI PEEK PEI
4 2 0
PrimoSpire SRP is the Stiffest and Strongest Unreinforced Plastic in the World
PrimoSpire SRP Comparison with Metal

Specific Tensile Strength
(MPa/g/cm3)
250 200 150 100 50 0
PrimoSpire PrimoSpire Aluminum, Aluminum PR-120 PR-250 Heat 6061-T4 Treated Die Casting, 296 Carbon Steel, C1018 Magnesium Stainless AE42-F Steel, 301 Titanium 62-4-2
PrimoSpire SRP has Properties Similar to Metals On a Strength-to-Weight Basis

Topics Introduction to Solvay Description of Ultra Polymers Metals vs. Plastics Simulation Technology Case Study
Metals vs. Plastics

Reinforced Polymers Metal
Fiber-Reinforced Polymers
Flow Direction
STRESS
STRESS
PrimoSpire SRP
Unfilled Polymers ELONGATION
Transverse Direction
ELONGATION
PrimoSpire SRP has Exceptional Strength and PrimoSpire SRP has Exceptional Strength and Stiffness Without Reinforcements Stiffness Without Reinforcements
Material Strength in Molded Part Several Factors Affect Strength Fiber orientation Weld line Gate location Processing
WELD LINE GATE
OR IE ON ATI NT
GATE
10
Metals vs. PrimoSpire SRP

Tensile Strength (MPa) Metals Aluminum Die Cast Zinc Magnesium Self-Reinforced Polymers PrimoSpire PR-120 PrimoSpire PR-250 207 152 8 5 1.2 1.2 320 280 225 70 70 40 2.8 6.6 1.8 Youngs Modulus (GPa) Specific Gravity
11
Equivalent Stiffness
METAL PLASTIC
W T/3
x
T
x
W = 2T
W
x x
For Same Deflection: Tensile Modulus (E) x Moment of Inertia (I) for metal and plastic should be the same With Same Area: Moment of Inertia of plastic cross section is approximately 12 times the Moment of Inertia of metal cross section along the x-axis
Difference in Modulus Can Be Compensated By Difference in Modulus Can Be Compensated By Geometrical Stiffness Without Increasing the Volume Geometrical Stiffness Without Increasing the Volume
12
Stress vs. Strain

Linear
30% GF Polymer
Tensile Stress, MPa
250 200 150 100 50 0
Non-linear
23C 50C 70C 80C 100C 120C 130C 150C 180C 200C
Latch Assembly
Strain (%)
Ultra Polymers Offer Higher Strain and Ultra Polymers Offer Higher Strain and Strength at Higher Temperature Strength at Higher Temperature
13
What is Creep? Creep Is Deformation Under Constant Load

1
Elastic STRAIN Viscoelastic Relaxation Elastic
2
TIME
TYPES OF INSERTS 1. Molded in 2. Ultrasonically assembled 3. Press fit

14
What is Tolerance?
Tolerance is a Combined Effect of Variations in Tool dimension Shrinkage Process parameters Optimize Tolerance in Part Design Design for plastics Make Certain CPk is Achievable
Plastic has advantage of lower modulus
Interference Fit
Metal
Plastic
Tight Tolerance Represents Poor Plastic Design Tight Tolerance Represents Poor Plastic Design
15
Topics Introduction to Solvay Advanced Polymers Description of Ultra Polymers Metals vs. Plastics Simulation Technology
Computer Aided Engineering (CAE) Optimization
Case Study
16
Computer Aided Engineering (CAE) Stress Analysis FEA

(Finite Element Analysis)
Flow Analysis Flow balance Pressure profile Weld line Fiber orientation
Stress distribution Deflection Optimization
CAE Insures Functionality and Moldability CAE Insures Functionality and Moldability
17
Stress Analysis (FEA)

Objective: Based on success of a smaller charged air cooler, conduct feasibility study to convert to larger size
Edge clamped on aluminum body
Design Requirements
1 million thermal cycles at 210C with 2 bar internal pressure
18
FEA Results Stress Distribution
Structural stiffness increased by adding rib
Maximum Stress Level Should Be Well Within Maximum Stress Level Should Be Well Within Design Limit of Plastic in a Given Environment Design Limit of Plastic in a Given Environment
19
Flow Analysis
Objective: Recommend gate location to minimize warpage and improve flatness for better sealing surface Options Edge gate Center gate Warpage affected by Flow balance Fiber Orientation Uniform Cooling
20
Pressure Profile
Edge Gate Center Gate
Flow Balance Provides Minimum Warpage Flow Balance Provides Minimum Warpage
21
Optimization Design Use only where needed Processing Insert molding Machining stock shapes New Approaches Collaboration CAE Integration
Stock Shapes Insert Molding
22
Collaboration - Team Approach
Designer
Molder
Material
Performance Geometry Regulations Cost
Processing Part Design Tooling & Processing

Tooling Moldability Cycle Time
Material Characteristics Resin Supplier

Application Database CAE Support Secondary Operations New Product Development
23
CAE Integration Traditional

(Silo Effect)
CAE Integration
(Accurate Prediction)
Material Material Stress Analysis Flow Analysis Tooling & Processing
Flow Analysis
Part Design
ORIENTATION EFFECT
Final Design Part Design
Stress Analysis Tooling & Processing
Design Team
Final Design
Integration of Flow Analysis with Stress Analysis Integration of Flow Analysis with Stress Analysis Gives More Accurate Prediction Gives More Accurate Prediction
24
Topics Introduction to Solvay Description of Ultra Polymers Plastics vs. Metals Computer Aided Engineering (CAE) Case Study
25
Case Study - Motor End Cap

Background Metal cap with thermoset brush card Five different parts Machining and anodizing Critical features Creep and flatness Chemical resistance Benefits Cost reduction Weight reduction Parts consolidation
26
Technical Support
Concept insert molding, crush ribs, improved flatness Material Selection chemical resistance, strength, and stiffness, plus improved creep requirements and flatness Design Finite Element Analysis (FEA) for improved performance and Flow Analysis for optimized gate location Prototype Development tooling and molding Testing process verification (viscosity and crystallinity) Production cycle optimization, fabrication, assembly, secondary operations
Solvay has Over 20 Years Experience Solvay has Over 20 Years Experience Successfully Replacing Metal with Plastic Successfully Replacing Metal with Plastic
27
Keys to Success Apply team approach Use flow analysis and stress analysis to validate functionality and moldability MUST redesign and optimize the design Select the right ultra polymer for the job
Well-Designed Part Made from the Right Plastic Well-Designed Part Made from the Right Plastic Can Outperform a Metal Part Can Outperform a Metal Part
28
SolvaSpire Ultra Polymers

KetaSpire PEEK (polyetheretherketone)
Broadest chemical resistance, highest strength
AvaSpire modified PEEK

Best way to bridge price and performance gaps
PrimoSpire self-reinforced polyphenylene

Worlds stiffest and strongest unreinforced plastic
EpiSpire high-temperature sulfone

Best combination of exceptional creep resistance at high temperatures with processing ease
Torlon polyamide-imide
Best wear-resistance and lowest friction properties
Solvay Offers More Plastics with More Performance Solvay Offers More Plastics with More Performance
29
Want To Know More?
For additional information, please e-mail us at
advancedpolymers@solvay.com
BUSINESS CONFIDENTIAL
30

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SOLVAY ADVANCED POLYMERS

Designing with Ultra Polymers

MO RE PL AST ICS WIT H MO RE PERFO RMANCE

SOLVAY ADVANCED POLYMERS

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

Solvay Advanced Polymers

SOLVAY ADVANCED POLYMERS

Plastics Performance Pyramid

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

Applications - PrimoSpire SRP

Semiconductor Test Sockets

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

PrimoSpire SRP Comparison with Unfilled Plastics

100 50 0 PrimoSpire PR-120 PrimoSpire PR-250 PPS PI PEEK PEI

SOLVAY ADVANCED POLYMERS

PrimoSpire SRP Comparison with Metal

PrimoSpire SRP has Properties Similar to Metals On a Strength-to-Weight Basis

SOLVAY ADVANCED POLYMERS

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

Metals vs. Plastics

Unfilled Polymers ELONGATION

SOLVAY ADVANCED POLYMERS

SOLVAY ADVANCED POLYMERS

Metals vs. PrimoSpire SRP

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

SOLVAY ADVANCED POLYMERS

Stress vs. Strain

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

What is Creep? Creep Is Deformation Under Constant Load

TYPES OF INSERTS 1. Molded in 2. Ultrasonically assembled 3. Press fit

SOLVAY ADVANCED POLYMERS

SOLVAY ADVANCED POLYMERS

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

Computer Aided Engineering (CAE) Stress Analysis FEA

Stress distribution Deflection Optimization

SOLVAY ADVANCED POLYMERS

Stress Analysis (FEA)

Edge clamped on aluminum body

SOLVAY ADVANCED POLYMERS

FEA Results Stress Distribution

Structural stiffness increased by adding rib

SOLVAY ADVANCED POLYMERS

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

SOLVAY ADVANCED POLYMERS

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

Collaboration - Team Approach

Processing Part Design Tooling & Processing

Material Characteristics Resin Supplier

2007 Solvay Advanced Polymers, LLC

SOLVAY ADVANCED POLYMERS

CAE Integration Traditional

Material Material Stress Analysis Flow Analysis Tooling & Processing

Final Design Part Design