Speciality Polyamides for Metal Replacement
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This document appears to be from a forum on metal replacement that was held on June 6-7th, 2013 in Malpensa, Italy. It includes presentations on structural polyamides from Radici Plastics that can replace metals, including Radilon and Radistrong grades. Data shows the polyamides offer higher strength, stiffness, fatigue resistance, and lower density compared to aluminum and magnesium alloys. The document also discusses using coupled simulation and analysis tools to optimize plastic part design for requirements like burst pressure that consider fiber orientation from molding. Overall it promotes using structural polyamides from Radici Plastics to replace metals in applications.
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Speciality Polyamides for Metal Replacement
- 1. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 1 Erico SPINI, Radici Plastics MKT Director
- 2. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 2
- 3. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 4. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 5. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 6. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 7. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 8. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 9. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 10. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 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) PA66-GF50 Radilon® ARV500RW + 12 % tensile strength at break + 20 % tensile deformation at break
- 11. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 0 20 40 60 80 100 120 0,00% 0,20% 0,40% 0,60% 0,80% 1,00% 1,20% 1,40% Stress(Mpa) Strain (%) Stress-Strain Curves Comparison (23°C, DAM) ISO 527 Double Injection Radilon® ARV500RW PA66-GF50 + 20 % tensile strength at break + 30 % tensile deformation at break
- 12. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 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 in case of impact. 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 Curve Comparison at Different Speeds (23°C, DAM, ISO 527) Rad A RV500RW : 1 mm/sec Rad A RV500RW : 100 mm/sec PA66-GF50 : 1 mm/sec PA66-GF50 : 100 mm/sec
- 13. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 0 20 40 60 80 100 120 2 3 4 5 6 7 Smax(Mpa) Cycles to Failure (Millions) Fatigue Behaviour Wöhler Diagram - Sinusoidal Displacement, 5hz, R= min stress/max stress =0.1 23°C - RH50 (water content 1.24 %) PA66-GF50 Radilon® ARV500RW Radilon® A RV500 RW blk 339 higher performances versus standard grades are fully confirmed in case of long term dynamic loading (fatigue)
- 14. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Tensile Strength at Break is not affected by a melt temperature until 320°C. The material has been designed to withstand high processing temperature. 252 254 256 258 260 262 264 266 270 280 290 300 310 320 330 TensileStrength(Mpa) Melt Temperature (°C) Tensile Strength at Break at Different Melt Temperatures (23°C, DAM, ISO 527) Barrel residence time 10 minutes
- 15. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 16. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 16 Flow Length + 40% 0 100 200 300 400 500 600 700 800 60 70 80 90 100 110 120 130 SpiralLength(mm) Injection Pressure (Bar) Spiral Length Comparison High Flow Radilon® S URV600LW PA6-GF50 High Flow Radilon® S URV600LW PA6-GF50
- 17. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 18. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013
- 19. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 0 20 40 60 80 100 120 140 0,00% 1,00% 2,00% 3,00% 4,00% 5,00% 6,00% 7,00% Stress(Mpa) Strain (%) Stress-Strain Curve Comparison ISO 527 (DAM) at 150 °C Radistrong® A LGF50W PA66-GF50 + 25 % tensile strength at break
- 20. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Radistrong© LGF PA66 versus PA66-GF properties comparison Charpy Notched Impact Impact Energy Absorption Tensile Strength at Break (23 °C) Tensile Strength at Break (150 °C) Elongation at BreakCreep Heat resistance Tensile Modulus (23 °C) Tensile Modulus (150 °C) PA66-GF Radistrong© LGF
- 21. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Structural Polyamides show comparable tensile strength at break versus light metal alloys 0 50 100 150 200 250 300 Al Die Cast AlloyZn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW 339 Ner Radilon S URV600 100 Nat TS(Mpa) Tensile Strength at Break Al Die Cast Alloy Zn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW 339 Ner Radilon S URV600 100 Nat Radilon® versus metals properties comparison
- 22. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Structural Polyamides show better fatigue behaviour than light metal alloys 0 10 20 30 40 50 60 70 Al Die Cast Alloy Zn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW 339 Ner Radilon S URV600 100 Nat Mpa Tensile Fatigue Limit at 7 million cycles Radilon® versus metals properties comparison
- 23. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Structural Polyamides show low density than light metal alloys 0 1 2 3 4 5 6 7 Al Die Cast Alloy Zn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW 339 Ner Radilon S URV600 100 Nat g/cm3 Density Radilon® versus metals properties comparison
- 24. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets
- 25. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets
- 26. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part name : Transmission Reaction Bracket Parts/year : 150000 Life time : 6 years Materials : Radilon® A RV500RW versus Aluminium Cost (€) Radilon® A RV500RW Tool cavities : 2 Aluminium Tool cavities : 2 Material 1 0,8 Processing 0,3 1,1 Assembly & Finishing 0,15 Machining 0,35 Tool Amortization 0,1 0,28 Total cost 1,55 2,53
- 27. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets
- 28. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Virtual design from metal to plastics through optimization step. Interactive collaboration with development partners in : 1- part design optimization 2- stress analysis 3- process analysis STEP 1 STEP 2
- 29. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part design approach comparison. Part name : gas/water connector Objective : burst pressure calculation at 23 °C Material: Radilon A RV500RW (PA66-GF50, enhanced mech properties) Hp 1 : isotropic material Hp 2 : coupled process simulation + structural analysis Type of analysis : non linear
- 30. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part design approach comparison Hp1 : isotropic behaviour Stress and strain distribution, as expected, is the same for the different part section Calculated burst pressure is overestimated Difference between calculated and measured burst pressure 20%
- 31. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part design approach comparison Hp2: coupled process simulation + structural analysis First step : moldflow analysis Welding line presence ! Part weakest section
- 32. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part design approach comparison Hp2: coupled process simulation + structural analysis First step : moldflow analysis Output : fibers orientation tensor to be used as input for structural analysis
- 33. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets Part design approach comparison Hp2 : coupled process simulation + structural analysis Stress and strain distribution are not anymore simmetric since fiber orientation is considered Difference between calculated and measured burst pressure down to 5%
- 34. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 Metal Replacement Typical Targets
- 35. REPLACEMENT FORUM 2013METALMalpensa, 6th and 7th June 2013 35 Erico SPINI, Radici Plastics MKT Director