High Heat Plastics - New Material Developments & Innovations

Among the several advances in high heat plastics application, exciting latest development that 'turned up the heat' is 3D printing of reinforced polymer composite parts capable to withstand high temperatures.

Polymer matrix composites are extremely attractive to Air Force researchers working on next-generation applications. Their main benefits include:

 

• Light-weight properties
• Ability to withstand extreme conditions in high temperature environments

Researchers at the Air Force Research Laboratory have developed a state-of-the-art material made up of a high temperature thermoset resin infused with carbon fiber filaments for use in extreme environments. This material breakthrough sets the stage for next generation, cost-efficient Air Force manufacturing needs.

Dr. Jeffery Baur, a Principal Materials Engineer at AFRL said: 'High temperature materials are notoriously hard and expensive to process, even using conventional manufacturing techniques,' 

'Since they typically wind up being used in military specific applications, there is not a large supplier base for these types of materials. This breakthrough will enable us to additively manufacture high temperature, composite parts in a cost-efficient manner. Moreover, high temperature polymer composite parts that are small and have complex features will be extremely beneficial and advantageous not only for the Air Force, but have the potential to be a game-changer throughout industry.', he added.


 

#1 Glass-reinforced PA 66 Replace Metal in Under-the-Hood Parts

Teknor Apex has recently developed a new series of high-heat glass-reinforced polyamide 66 compounds. The company offers injection molders with a more economical alternative for automotive and other metal-replacement parts. The Creamid® 240 H7.5 PA Compounds are claimed to bridge cost-performance gap between standard heat-resistant polyamides and costly specialty polymers.

 

Features of Creamid® 240 H7.5 Series PA Compounds

• They provide the strength and stiffness of highly glass filled engineering polymers while maintaining high levels of critical mechanical properties even after continuous service at temperatures of 240°C
• Grades with glass fiber content of 35, 50, or 60%, exhibit dramatically improved property retention in comparison with similarly glass-filled standard PA 66 compounds
• They cost around 30% less per kilogram than high-performance polymers such as polyphthalamide (PPA) or PA 4.6, while providing comparable performance

While the new compounds have processing temperatures in the range of 280 to 300°C and mold temperatures of 80 to 110°C, the corresponding ranges for PPA or PA 4.6 are 330 to 350°C and 130 to 150°C.

Possible applications include:
 

• Automotive under-hood components such as charge air cooler end caps, air intake manifolds, quick-fit connectors, radiator end tanks, turbo air ducts and resonators, oil pump wheels, EGR valves, and thermostatic casings.
• Electronic connectors, diode carriers, and bobbins
• Consumer products such as lamp sockets and connectors

#2 Heat Stabilized PA Raises Performance of Turbocharger Systems

Solvay has developed a highly heat stabilized polyamide designed especially for automotive applications. According to the company, Technyl® Red S provides >automotive industry applications with enhanced thermal aging stability without compromising performance or competitiveness. 
 

Charge Air Coolers Made up for Technyl® Red S 
(Source: Solvay)

Key Features of Technyl® Red S

• It can withstand a continuous operating temperature of up to 210°C (at 1,000h) or 200°C (at 2,000 hours)
• It improves strong impact and resistance to acid condensates
• It offers high flowability, superior surface aspect and excellent weldability 

WACKER has developed a heat-resistant high consistency silicone rubber for formulating heat-resistant, addition-curing silicone elastomers. It can be used to make extremely heat-resistant tubing and sealing profiles. 

Due to heat stabilizers, it can endure temperatures up to 300°C, without a substantial impact on its elasticity or mechanical properties. The type of stabilizer and the amount used have a significant influence on the heat resistance of the cured rubber, which is easy to process in extruders.

According to the heat-aging tests, key mechanical properties such as Shore A hardness and elongation at break change very little at temperatures above 200°C even after as many as 2,000 hours for this material.

 

Source: WACKER

After it has cured, ELASTOSIL® R plus 4350/55 achieves a Shore A hardness value of 55 and is ideal for manufacturing heat-resistant profile gaskets, such as for oven and stove doors or for engine-compartment parts.


 

Solvay has introduced a new high-performance polyvinylidene fluoride to improve the capabilities of steel pipes, flexible risers and flowlines used in oil and gas recovery. 

Solef® 90615/2002 PVDF combines high ductility, thermal stability up to 150°C (302°F) and exceptional resistance to oilfield chemicals and fluids. Hence, it delivers reliable performance despite the high temperatures and pressures required for oil transmission in onshore and offshore environments. 

 

Unique Benefits of New PVDF

• Solef® 90615/2002 PVDF-based liners' high chemical resistance helps slow corrosion.
• Its low-stick & ultra-smooth surface support more consistent flow rates and flow assurance over time.
• It also reduces the need for corrosion inhibitors, antibacterial agents and other additives.
• Polymer's excellent thermo-mechanical properties and resistance to permeation of gases and hence promote long-term liner integrity.

Evonik has developed a new PPA base polymer - VESTAMID® HTplus TGP3717.

 

• The new high-temperature polymer can withstand mechanical stress up to 135°C
• The glass transition temperature is 155°C.
• While the modulus of elasticity of a standard product falls by approximately 80% at 120°C, the decrease for base polymer is only 15%

It is distinguished by stable mechanical properties at sustained high temperatures. VESTAMID® HTplus has been specially developed as a substitute for metal in classic metal applications such as highly filled molding compounds. 


 

Thermoplastic resins can offer cost efficient production of large build numbers versus thermoset, but often do not offer sufficient heat for soldering (e.g. PMMA or PC resins) or amber color (e.g. PEI or PSU resins). SABIC has developed a new range of high-clarity, high-heat, injection moldable polycarbonate copolymer resins. The new LEXAN™ CXT resins offer a unique balance of:
 

• High heat (Tg up to 195°C)
• High flow in broad processing window without discoloration
• High transmission in visible (> 87% at 3 mm) and IR regions (> 89% at 3 mm)
• High refractive index (nD > 1.60)
• Stable color and transmission during part life time (heat, humidity, light)

LEXAN CXT resins can be used in optical applications in the electronics, consumer & industrial, and healthcare industries. Typical products in the first two areas include lenses and small sensors that detect visible light. In healthcare, the materials answer the call for excellent optical quality and the ability to resist high temperatures involved, for example, when over-molding clear face shields with silicone rubber.


Plastic Professionals: Stay Alert! 

  
Enhance your knowledge in high heat materials and applications! Become an expert by learning key features and properties about some of the high temperature thermoplastics such as: 

 

• Polyetheretherketone (PEEK): A Complete Guide on High-Heat Engineering Plastic
• Polyetherimide (PEI): A Comprehensive Review
• Polyethersulfone (PES) - Complete Guide on High-temperature Engineering Polymer
• Polyphenylene Sulfide (PPS): A Comprehensive Guide on High Heat Plastic