Radici Plastics: Innovation in Polyamides Rethinking the Materials Map for higher temperatures and for critical fuel components. SPE Auto EPCON May 2014 Bryan Fox: NAFTA Business Development; Radici Group

1. Radici Plastics: Innovation in Polyamides
Rethinking the Materials Map for higher
temperatures and for critical fuel components.
SPEAuto EPCON May 2014
Bryan Fox: NAFTA Business Development; Radici Group

3. RadiciGroup
Synergy & Integration Polyamide 66

4. RadiciGroup – Global Player in
Engineering Plastics

5. • Radici Innovations in Nylon Compounds:
– A line of improved Polyamide 6.6 compounds (HHR, with
proprietary Heat Stabilization technology) that maintain long
term mechanical properties better
– A Line of Modified PA ( not 6.6) grades that can maintain
properties to 220oC in air, yet still be molded in hot water
heated molds (Radilon XTREME)
– Highly glass filled PA66 materials that offer improved weld
line, fatigue and impact performance.
– A Line of 6.10 and 6.12 Copolymers that can offer similar
performance to PA11 and PA12 in fuel and braking
components

6. What is needed to take advantage of these Innovative New
Materials?
1 Design Engineers need to be aware of these property advantages and the
performance advantages they offer.
All Nylon compounds are NOT created equal!
2 Failure Analysis Teams at the OEM and Tier 1 & 2 levels should consider using these
materials as problem solving weapons-Higher heat capability and/or weld line and
fatigue situations (when other nylons and high heat materials do not work)
3 Value Engineering Teams should be on the lookout for opportunities to convert HHN
and long chain PA components to these lower cost and easier molding materials
4 Materials and Specification Engineers: How do we capitalize on these improved
properties within the framework of the specifications? What additional data is
needed from Radici?? How can it fit into your current specification?

7. Increasing
Temperature
requirements
have been
resolved with
specialty
polymers…
PolyPropylene
PA6
PPS
HiTemp PA’s, 4/6
PA6.6
T
E
M
P
30-35% GF

8. Some recent
innovations by
Radici Plastics
will show how
this map may
have to be
adjusted…
First, we can show that the
temperature capabiltiies
can be increased with
proprietary stabilization
Technologies, and also see
later how the 6/6
polymerization can be
modified to produce other
polymers.
Radilon A HHR grades,
with improved heat
stabilization
Radilon A HHR
PPS
HiTemp PA’s

9. Radici Heat aging Benchmarking
Tests in Europe (recent)
• BMW
– Radilon A RV350HHR 190oC
– Radilon XTREME RV350 220oC
– Requirements: 50% retention of initial tensile
strength after 3000 hours; and 50% retention for
Unnotched Charpy residual.

10. Material :
Radiflam A RV150HHR AF, a 15%-glass-fiber filled V-0 PA66
(under the hood, automotive application)
Technical specifications :
• Maximum 35% mechanical property degradation after
ageing at 170°C for 1,000 hours
• Retention of a UL94 V0 flame-class rating by a 0.8-mm
thick specimen after ageing at 170°C for 3,000 hours
HHRTechnology is also suitable for FR grades!!

11. The performance versus polyphthalamide (PPA) :
•Radilon® A RV350 HHR 3800 Ner : 66% of initial value
•PPA-GF35 : 48% of initial value
0,0
50,0
100,0
150,0
200,0
250,0
0,0 1000,0 2000,0 3000,0 4000,0
TensileStrengthatBreak(Mpa)
Time (h)
Heat Ageing in Air at 200 °C
Radilon ARV350 HHR 3800 Ner
PPA-GF35

12. Charpy unnotched retention :
•Radilon® A RV350 HHR 3800 Ner : 20 KJ/m² after 3000 h
•PA66-GF35 Heat Stabilized : 0 KJ/m² after 2000 h
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
0 1000 2000 3000 4000
CharpyUn-notched(KJ/m2)
Time (h)
Heat ageing in air at 210 °C
Radilon ARV350 HHR 3800 Ner
PA66-GF35 HS

13. The performance versus polyphthalamide (PPA) :
•Radilon® A RV350 HHR 3800 Ner : 27% of initial value
•PPA-GF35 : 26% of initial value
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
0 500 1000 1500 2000 2500
CharpyUn-notched(KJ/m2)
Time (h)
Heat ageing in air at 200 °C
Radilon ARV350 HHR
PPA-GF35

14. The tensile strength at break retention for a blow molding grade
•Radilon® A BMV150 HHR : 90% of initial value
•Benchmark : 41% of initial value
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000
TensileStrengthatBreak(Mpa)
Time (h)
Heat ageing in air at 210 °C
CompPA66-GF15
RadilonA BMV150 HHR

15. The elongation at break retention of blow molding grade :
•Radilon® A BMV150 HHR : 55% of initial value
•Radilon® A BMV200 HHR : 37% of inital value
•Benchmark : 21% of initial value
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
0 500 1000 1500 2000
ElongationatBreak(%)
Time (h)
Heat ageing in air at 210 °C
CompPA66-GF15
RadilonA BMV150 HHR

16. As we can observe from the cross-section in Fig.1 after 1000
hours of heat ageing at 210°C, the Radilon A RV350 HHR
specimen has remained practically intact, except for slight
degradation on the surface. In contrast, as we see in Fig.2 the
heat stabilized PA66-GF35 specimen exhibits a deeply degraded
structure after the same heat ageing process: about 70% of the
specimen thickness is destroyed.
Fig. 1 Fig. 2
Thickness 3 mm
Thickness 3 mm

17. Hot side turbo air duct
Radilon® A BMV150 HHR
Air resonator box
Radilon® A RV350HHR

18. CAC
Radilon® A RV350 HHR
Engine cover
Radiflam® A RV150HHR AF (FR)
Electrical motor components
Radilon® A RV350 HHR
(H Class rating – 180 °C)

19. Some recent
innovations by
Radici Plastics
will show how
this map may
have to be
adjusted…
First, we can show that the
temperature capabiltiies
can be increased with
proprietary stabilization
Technologies, and also see
how the 6/6 polymerization
can be modified to produce
other polymers.
Radilon A HHR grades,
with improved heat
stabilization
Radilon XT, a new
polymer ( but
produced in a 6.6
polymerization plant)
Radilon HHR
Radilon XTREME

20. Radilon® XTreme-HHR : Basic Properties
• Melt temperature (matrix) : 280 °C (+ 20 °C versus PA66)
• Glass Transition Temperature : 90 °C (+ 20 °C versus PA66)
• Moisture Absorption at Saturation : 7 % ( -25% versus PA66)
• Range of viscosity available : from injection molding to
blow molding
• Recommended mold temperature : 90 to 100 °C
Radilon® XTreme key features

21. Radilon® XTreme-HHR Heat Ageing Properties
Heat Ageing in Air at 220 °C120
Radilon XT RV350HHR
PA*-GF35
100
PA46-GF40
PPA-GF45
80
60
40
20
0
0 500 1000 1500 2000 2500
Time (h)
50%
Retention
3000 3500
Radilon® XTreme RV350HHR: no tensile modulus change
after heat ageing (property measured at 23 °C)

22. 0,0
20,0
40,0
60,0
80,0
100,0
120,0
0 500 1000 1500 2000 2500 3000 3500
CharpyNotchedImpactretention(%)
Time (h)
Heat Ageing in Air at 220 °C
Bench
RadilonXTreme RV350HHR
Bench2(GF40)
Radilon® XTreme-HHR : heat ageing properties
50%
Retention
Radilon® XTreme RV350HHR : Charpy Notched Impact
Strength retention > 70% after 3000 h at 220 °C !

23. Increasing
Temperature
requirements
have been
resolved with
specialty
polymers…
PolyPropylene
PA6
PPS
HiTemp PA’s, 4/6
PA6.6
T
E
M
P
30-35% GF
…and also by using higher glass
filler levels”

24. And we can also
show how
combining
knowledge of
the polymers,
formulation and
compounding
technology can
produce a better
solution for
highly filled
polyamide
compounds.
33% GF PA66
Radilon A RV500 RW
30-35% GF 50-60%GF
Superior
technology
can improve
fatigue,
weld line
strength
and impact,
vs “just
adding
more glass”

25. Key features
Radilon A RV 500 RW 339 blk versus standard PA66-GF50 :
(Standard PA6.6 Technology for this comparison, not HHR or XTREME)
• Higher tensile strength and deformation at break
• Enhanced weld line properties
• Higher performance for high speed loading
• Higher performances for dynamic load (fatigue)
• Ideal for metal replacement including automotive underhood
parts

26. High Performance Radilon
0
50
100
150
200
250
300
0,00% 0,50% 1,00% 1,50% 2,00% 2,50% 3,00%
Stress(Mpa)
Strain(%)
Stress-Strain Curves Comparison (23°C, DAM, ISO 527)
Radilon A RV500 RW 339 Blk
PA66-GF50
0
20
40
60
80
100
120
0,00% 0,50% 1,00% 1,50%
Stress(Mpa)
Strain(%)
Stress-Strain Curves Comparison (23°C, DAM) ISO 527
Double Injection
Radilon A RV500 RW 339 Blk
PA66-GF50
Radilon® A RV500 RW blk 339 offers higher stress and strain
capability versus standard PA66-GF50, particularly in case
critical weld line locations

27. High Performance Radilon
85 90 95 100 105 110 115
RadilonARV500RW
339BlkPA66-GF50
CharpyUn-notched(Kj/m²)
ImpactComparison (23°C)
Conditioned
DAM
0 5 10 15 20 25 30 35 40
RadilonARV500RW
339BlkPA66-GF50
CharpyNotched(Kj/m²)
ImpactComparison (23°C)
Conditioned
DAM
Radilon® A RV500 RW blk 339 offer higher impact strength
versus standard PA66-GF50

28. High Performance Radilon
Radilon® A RV500 RW blk 339 offers higher stress and strain
at break versus standard PA66-GF50 at high speed and
therefore absorbs more energy,making this grade suitable for
engine oil pans
0,00
50,00
100,00
150,00
200,00
250,00
300,00
350,00
0,00% 0,50% 1,00% 1,50% 2,00% 2,50% 3,00%
Stress(Mpa)
Strain (%)
Stress-Strain Curves Comparison at different Speeds
(23°C, DAM, ISO 527)
Rad A RV500RW : 1 mm/sec
Rad A RV500RW : 5 mm/sec
Rad A RV500RW : 10 mm/sec
Rad A RV500RW : 100 mm/sec
PA66-GF50 : 1 mm/sec
PA66-GF50 : 5 mm/sec
PA66-GF50 : 10 mm/sec
PA66-GF50 : 100 mm/sec
Courtesy of Politecnico di
Milano

29. High Performance Radilon
0,00
20,00
40,00
60,00
80,00
100,00
120,00
2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7
Smax(Mpa)
Cycles to Failure (Million)
Fatigue Wöhler Diagram - Sinusoidal
Displacement, 5hz, R= min stress/maxstress =0.1
23°C - RH50 (water content 1.24 %)
PA66-GF50
Radilon A RV500 RW 339
Radilon® A RV500 RW blk 339 higher performances versus
standard grades are fully confirmed in case of long term
dynamic loading. This property is appreciated when parts are
submitted to millions of vibration or pulsating pressure cycles
Courtesy of Politecnico di
Milano

30. High Performance Radilon
Radilon® A RV500 RW blk 339 The exceptional fatigue
property improvement is confirmed at 90 and 140 °C. The
lifetime increase can be 15 to 20% versus standard grades.
0,00
20,00
40,00
60,00
80,00
100,00
120,00
2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7
Smax(Mpa)
Cyclesto Failure (Million)
Fatigue Wöhler Diagram - Sinusoidal
Displacement, 5hz, R= min stress/maxstress =0.1
90°C - DAM
PA66-GF50
Radilon A RV500 RW 339
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
90,00
2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7
Smax(Mpa)
Cyclesto Failure (Million)
Fatigue Wöhler Diagram - Sinusoidal
Displacement, 5hz, R= min stress/maxstress =0.1
140°C - DAM
PA66-GF50
Radilon A RV500 RW 339

31. Radilon® A RV500 RW blk 339 is the ideal material for metal
replacement particularly when static strength resistance, impact
strength and vibration resistance are key factors. The right
choice for engine mounting, oil pans, seat frame, etc
Possible Metal Replacement Targets

32. PA6.6
T
E
M
P
Improved ZN Cl, moisture and fuel
resistance for Fuel and brake tube
applications
PA11 & 12

33. PA6.6
T
E
M
P
Improved ZN Cl, moisture and fuel
resistance for Fuel and brake tube
applications
PA11 & 12
PA6.10
PA6.12
(60% renewable resin
content)
Various requirements including
DIN 74324, 73378, SAE J844
J2260, FMVSS 106, etc)

35. PA6.10/6.12 exhibit are less hygroscopic than PA6 and PA66, and its water
uptake at saturation is similar to PA12.

36. PA6.10/6.12 exhibit higher tensile stress at yield than PA11 and PA12 for both
dry and conditioned test pieces. The graph also shows a smaller variation in
properties values for PA6.10/6.12 after water uptake, compared to PA6 and
PA66.

37. Charpy notched impact strength at - 30°C is greater for PA6.10/6.12 than for
PA6, PA66 and PA12; lower than PA11

38. Bending specimens
Radius 44 mm
Flexural strain at tensile surface
h / (2r+h) = 4.35%
Radius 8 mm
Flexural strain at tensile surface
h / (2r+h) = 20%

39. Results – DAM conditions
DAM STATE 23°C
Radius = 44mm Radius = 8mm
PA610
RADILON D
PA612
RADILON DT
PA12
Bench
PA610
RADILON D
PA612
RADILON DT
PA12
Bench
24 h       24 h
48 h       48 h
120 h       120 h
200 h       200 h
Symbol Description Symbol Description
 No cracks visible 
Cracks on specimen sides, max 1/2
of width

Cracks on specimen sides, max 1/8 of
width 
Cracks on specimen sides, more
than 1/2 width

Cracks on specimen sides, max 1/4 of
width  Breaking (also partial) of specimen

42. Fuel vapour vent hose made
of Radilon® D40EP25ZW

43. Fuel connector made of
Radilon® D RV300W 333
Ner (injection molding
grade)

44. What is needed to take advantage of these Innovative New
Materials?
1 Design Engineers need to be aware of these advantages and the performance
advantages they offer.
All Nylon compounds are NOT created equal!
2 Failure Analysis Teams at the OEM and Tier 1 & 2 levels should consider using these
materials as problem solving weapons-Higher heat capability and/or weld line and
fatigue situations (when other nylons and high heat materials do not work)
3 Value Engineering Teams should be on the lookout for opportunities to convert HHN
components to these lower cost and easier molding materials. Same for PA11 &12
components.
4 Materials and Specification Engineers: How do we capitalize on these improved
properties within the framework of the specifications? What additional data is
needed from Radici?? How can it fit into your current specification?