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超高性能聚合物在汽车行业的应用


Ultra high performance polymers for automotive applications 超高性能聚合物在汽车行业的应用
Dr. Brian. Stern April-2012

Plastic Pyramid
More Plastics with More Performance?

M

ODULUS

AMORPHOUS

Tg

Tg

SEMI-CRYSTALLINE

TEMPERATURE
Tg = GLASS TRNSITION TEMPERATURE Tm = MELTING POINT TEMPERATURE

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PRODUCT FAMILY

Spire? Ultra Polymers in Automotive
AvaSpire PAEK KetaSpire PEEK Torlon PAI
? ? ?

Best-in-Class properties for long-life performance in critical applications Performance advantages include superior chemical, thermal and wear resistance, and inherent flame retardancy

Key Automotive Applications where high wear resistance is required where high compressive properties are required at elevated temperatures where high stiffness and strength at elevated temperatures where good impact properties are required where electrical insulation is required where temperature resistance is required where chemical compatibility is required and more where light weight at above combined properties is required

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PRODUCT FAMILY

Spire? Ultra Polymers – Properties into benefits
Strength at Elevated temp. Temperature Resistance Chemical Resistance Wear Resistance Fatigue Resistance Compressive Properties Design Expertise Low CLTE

Under the hood ? ? ? ? ? ? Fuel Systems Turbocharger Vacuum Pumps Coupling Isolation Engine components Steering Systems ? ? Thrust Pads Bushings Interiors ? ? ? ? Bushings Plugs Gears Cables Transmissons ? ? ? ? Friction Discs Thrust Washers Seal rings Bearings Brake Systems ? ? Bushings Thrust Pads

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PEEK Introduction
KetaSpire? PEEK Resins
O O O C

HDT up to 315°C Excellent long term thermal oxidative stability
Continuous use temp up to 240°C

Outstanding chemical resistance to organics, acids, bases and steam/hot water Best-in-class fatigue resistance, Outstanding FW Lubricated
Flex Strength (psi)
60000 50000 40000 30000 20000 10000 0
Neat 30%GF 30%CF 23 °C 120 °C 250 °C

Flex Modulus (Kpsi)
3500 3000 2500 2000 1500 1000 500 0
Neat 30%GF 30%CF 23 °C 120 °C 250 °C

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AvaSpire? PAEK
Proprietary chemistries with unique advantages AV-600 Series: Lower crystallinity, higher ductility, better toughness and impact, better stiffness retention than PEEK from 150-190°C AV-800 Series: High temperature grades that offer higher stiffness than PEEK between 150-240°C
Aryl linkages provide modulus, thermal stability, and flame retardance Ether linkages provide toughness and ductility Ketones provide long term thermal oxidative resistance.

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Polyamide-imide Introduction
Torlon? PAI Resins
Exceptional strength and stiffness up to 275°C Outstanding wear resistance Excellent chemical resistance to automotive fluids Inherent flame resistance Low CLTE

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DMA Curve of Torlon (4275) versus KetaSpire (KT820SL30)

Torlon 4275
KT820SL30

Plastics Maintain Mechanical Properties at Elevated Temperatures
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Compressive Modulus versus Temperature
1000

Compressive Modulus (Kpsi)

900 800 700 600 500 400 300 200 100 0 4275
9

23C 100 C 150C 200C

KT820SL30
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AvaSpire KetaSpire Stress Strain Curve
RM TEMP
16 14 12
8 Tensile?(Kpsi) 12

100C

10

Tensile?(Kpsi)

10 8 6 4 AV‐621?NT?23C KT‐820?NT?23C

6

AV‐621?NT?100C KT‐820?NT?100C

4

2

2
0

0 0 20 40 60 80 Elongation?(%) 100 120 140

0

20

40

60

80 Elongation?(%)

100

120

140

150C
8 7 6 5 4 3 2 1 0 0 20 40 60 80 Elongation?(%) 100 120 140 AV‐621?NT?150C KT‐820?NT?150C 4 3.5 3 2.5 2 1.5 1 0.5 0 0 20 40 60

200C

Tensile?(Kpsi)

Tensile?(Kpsi)

AV‐621?NT?200C KT‐820?NT?200C

80 Elongation?(%)

100

120

140

AvaSpire shows significant improved Strain at Break up to Tg of PEEK
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Triaxiality : a very important concept
σe =
1 2 (σ 1 ? σ 2 ) 2 + (σ 1 ? σ 3 ) 2 + (σ 2 ? σ 3 2

(

)

more ductile
TRIAXIALITY

Von Mises stress uniaxial tension simple shear biaxial tension (plain stress)

more brittle
very ductile plain strain hydrostatic tension (triaxial tension) mean stress
compressive
even rocks are ductile under pressure….
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σ m = × (σ 1 + σ 2 + σ 3 )
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1 3

4203 in Compression Did not Fail

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4275 Lubricated FW @ 500K PV
Virgin Torlon 4275, 2"Disc, 26 Grooves, 300 Micron Deep x 1 mm Wide in Dexron 3 ATF at 0.20 lpm, 90°C, 1770 V, 283 P, 500 K PV
200 180 160 Temperature, °C 140 120 100 80 60 40 20 0 0.00 20.00 40.00 60.00 Time, hrs 80.00 100.00 120.00 Chamber Temp, C Spec Temp, C

9.3 microns

w ear = 3.4 m icrons

w ear = 3.7 m icrons

2.5 microns

Sample after 100 hours
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4275 FW in Lubricated Environment (V vs P)

Wear After 100 Hours
4000 3500 3000 Velocity, ft/min 2500 2000 1500 1000 500 0 0 250 500 750 Pressure, psi 1000 1250 1500

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Torlon 4275 DCT Exposure – 1500 Hours
Mechanical Properties After 150 篊 Exposure
130 120 110 100 90 80 70 60 50 40 30 20 10 0 Tensile Elong.% Tensile Mod. GPa Tensile Str. MPa Hardness RHR

tested at 23 篊

sample A control sample B 70 hrs sample C 1008 hrs

sample B control sample C 70 hrs sample A 1500 hrs
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sample C control sample A 1008 hrs sample B 1500 hrs

sample A 70 hrs sample B 1008 hrs sample C 1500 hrs
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FEA Model Comparison

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MASS CENTER
shrink “center?of?mass,?the?point?at?which?all?the?mass?of?a?body?may?be? considered?to?be?concentrated?in?analyzing?its?motion.?The?center? of?mass?of?a?sphere?of?uniform?density?coincides?with?the?center of?the?sphere.?The?center?of?mass?of?a?body?need?not?be?within? the?body?itself;?the?center?of?mass?of?a?ring?or?a?hollow?cylinder? is?located?in?the?enclosed?space,?not?in?the?object?itself.?“ The?Columbia?Encyclopedia

The?mass?center?of?an?interrupted?/?cut?ring?is?the?same?as?its?flat?shape:

shrink shrink

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UP-Auto Session Interiors Under the hood

Suspension

Brake Systems Steering Systems Transmissions Heavy Duty

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Transmissions-Driveline
? ? ? Dual Mass Fly Wheel (Friction Disc, Clutch Spring Cap) Axial Thrust Bearing (Torque converter, Differential, Gear Box)** Radial Thrust Bearing

? ? ?

Seal Rings Shift Fork Check ball**

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Hydraulic Seal Ring
Effect on Material Selection
Retention of strength up to 150°C Excellent sealing and conformability (non-leaking) Ease of installation (elongation for flexibility) Dimensional stability Molded-in joint geometries reduce costs Excellent wear properties in dry and lubricated

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Commercial Thrust Bearing Applications
Effect on Material Selection
Low creep High compressive strength Low coefficient of friction Excellent wear properties in dry and lubricated environments Suitable for very high pressures and velocities Molded-in oil grooves to eliminate secondary machining costs

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Check Balls For Automotive Transmission: Torlon 4203L

Requirements
Lightweight (quicker response) Conformability (non-leaking) Non-pinging (noise reduction)

Competitive Material
Metal Viton

Manufactured by Daimler-Chrysler and Ford
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Power Train/Transmission: Commercialized Applications

Auto Trans. Solenoid Snout Hydraulic seal rings
Torlon? /KetaSpire PEEK/AvaSpire Amodel? A-1145HS

Thrust Washers
Torlon KetaSpire PEEK/AvaSpire

Turbo Charger Actuation and Thermal
Torlon

On/Off Auto Tran. Solenoid Valve
Amodel? A-1133 HS

Check Balls Clutch Cylinder
Ixef? 1022 23 ? 2011 Solvay Specialty Polymers Torlon? 4203L/KetaSpire PEEK

Commercial Applications - Industrial

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Collaboration - Team Approach
Resin Supplier

Designer

? Performance ? Geometry ? Regulations

Part Design Success

? Properties Material
? CAE Support ? Secondary Operations

? Productivity ? Quality ? Consistency

Processing

Tooling

? Moldability ? Maintenance ? Cycle Time

Molder Application Database
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Tool Builder

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PRODUCT FAMILY

Spire? Ultra Polymers in Automotive

AvaSpire PAEK KetaSpire PEEK Torlon PAI
? ? ?

Best-in-Class properties for long-life performance in critical applications Performance advantages include superior chemical, thermal and wear resistance, and inherent flame redundancy

Key Automotive Applications where high wear resistance is required where high compressive properties are required at elevated temperatures where high stiffness and strength at elevated temperatures where good impact properties are required where electrical insulation is required where temperature resistance is required where chemical compatibility is required and more where light weight at above combined properties is required

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