paccar investigation of glass fiber reinforced nylon 6/6 for automotive application by doe

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PresentationPresentation to PACCARPACCAR

Analysis of Paccar Materials Zytel, 2000EZ and TPO

11/14/14

Andrew Hollcraft, Louisa McCuskey & Kyle Burns

WWU - AMSECWWU - AMSEC

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IntroductionIntroduction • Zytel 70GF33 HSL Zytel 70GF33 HSL

– High Performance Polyamide High Performance Polyamide Resin:Resin: PA 6/6, 33% Glass Filled

– Replaces many metal Replaces many metal powertrain componentspowertrain components

– Praised for it’s stiffness and Praised for it’s stiffness and heat resistanceheat resistance

– Capable of working in places Capable of working in places that may be too hot, humid or that may be too hot, humid or chemically aggressive for chemically aggressive for traditional nylons.traditional nylons.

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Project DefinitionProject Definition• Business ReasonBusiness Reason

• Testing materials prior to manufacturing will help Testing materials prior to manufacturing will help ensure the longest life and greatest durability of ensure the longest life and greatest durability of parts made from these materials. parts made from these materials.

• PurposePurpose• To complete a full MSA to qualify our experimental To complete a full MSA to qualify our experimental

procedure, and a DOE report on Zytel 70GF33procedure, and a DOE report on Zytel 70GF33

• ScopeScope• Investigation of mechanical properties as functions of Investigation of mechanical properties as functions of

temperature, strain and solvent exposure.temperature, strain and solvent exposure.

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Team

• Leaders• Professor: : Dr. Rider• Lab Supervisors:

• Jaime Campo • Sam Dansforth

• Mentors• PACCAR Support:

• Jordan Kiesser• Kirk Dunn

• Team Members• Andrew Hollcraft,

Engineering• Kyle Burns, Chemistry• Louisa McCuskey, Physics

• Other Support• Department: Chemistry• Department: Engineering

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MSAMSA• Material: Material:

Zytel 70GF33 HSL, Pulse 2000EZ, and TPO FT3250 Zytel 70GF33 HSL, Pulse 2000EZ, and TPO FT3250

• Test Method(s): Test Method(s): • Tensile test Tensile test • Gauge R&R (crossed)Gauge R&R (crossed)

• OperatorsOperators• Operator 1 Kyle Burns Operator 1 Kyle Burns • Operator 2 Louisa McCuskeyOperator 2 Louisa McCuskey• Operator 3 Andrew HollcraftOperator 3 Andrew Hollcraft

MSA Gauge R&R StudiesMSA Gauge R&R Studies

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Tensile ModulusTensile Modulus

Ultimate Tensile StrengthUltimate Tensile Strength

MSA Gauge R&R StudiesMSA Gauge R&R Studies

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Elongation at BreakElongation at Break

Elongation at YieldElongation at Yield

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Is the Data Trustworthy?Is the Data Trustworthy?• Measurement System EvaluationMeasurement System Evaluation

• Results of EvaluationResults of Evaluation– Operator 2 methodically consistent – flat slope on operator R chart.Operator 2 methodically consistent – flat slope on operator R chart.– Modulus and Peak Stress had Gauge R&R values under 30%Modulus and Peak Stress had Gauge R&R values under 30%– Strain at Break and % Elongation at Yield were both over 30% Strain at Break and % Elongation at Yield were both over 30%

gauge R&Rgauge R&R• Corrective Actions Corrective Actions

– Elongation at Yield was estimated due to inaccurate software Elongation at Yield was estimated due to inaccurate software calculations. calculations.

• Algorithm / computer generated method.Algorithm / computer generated method.– Elongation at Break could be inaccurate due to slipping, which Elongation at Break could be inaccurate due to slipping, which

occurred 4 times. occurred 4 times. • Revise gripping procedureRevise gripping procedure

– TabsTabs– Additional operator trainingAdditional operator training

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DOEDOE• Material Tested: Material Tested:

Dupont Zytel 70GF33 HSL , Polyamide 6/6 33% Glass Dupont Zytel 70GF33 HSL , Polyamide 6/6 33% Glass Filled Filled

• Test Method(s): Test Method(s): Tensile testTensile test• Experimental Design: Experimental Design: 3 factors with 2 levels = 23

factorial design. Total of 8 runs, with 3 replicates total of 24 runs.

• Factors and Factor LevelsFactors and Factor Levels: : Temperature (23°C and 85°C)Temperature (23°C and 85°C)Strain Exposure (No or Yes)Strain Exposure (No or Yes)Solvent Exposure* (No or Yes)Solvent Exposure* (No or Yes)*concrete cleaner with muriatic acid*concrete cleaner with muriatic acid

• Response (s): Response (s): Ultimate Tensile Strength, Tensile Ultimate Tensile Strength, Tensile Modulus, Strain at Yield, and Strain at BreakModulus, Strain at Yield, and Strain at Break

Regression Result

Ultimate Tensile

Strength (Δ%)

Tensile Modulus (Δ

%)

ElongationYiel

d (Δ%)ElongationBre

ak (Δ%)

Model Adjusted R2

0.652 0.785 0.687 0.931

A: Solvent Exposure

- - - -

B: Temperature

17.6 36.3 -11.7 -77.5

C: Prestrain - - 9.28 -AB -7.97 - -6.23 -AC - - - -BC - - 7.62 -ABC - - 7.71 -

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DOE ResultsDOE Results

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DOE Analysis SummaryDOE Analysis Summary• ObservationsObservations

– Tensile modulus and ultimate tensile strength Tensile modulus and ultimate tensile strength both increased with increased temperature both increased with increased temperature • Polyamide 6/6 is known for heat resistance and Polyamide 6/6 is known for heat resistance and

stiffnessstiffness• Annealing Annealing

– Elongation at yield and break both decreased Elongation at yield and break both decreased with increased temperaturewith increased temperature• Imparting thermal stress into the sampleImparting thermal stress into the sample• Higher crystallinity sample Higher crystallinity sample

DOE Analysis SummaryDOE Analysis Summary

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• Increased temperature is the main Increased temperature is the main concern concern – Solvent exposure further increases Solvent exposure further increases

the temperature effect magnitudethe temperature effect magnitude– Solvent exposed samples tended to Solvent exposed samples tended to

fracture at the interface of solvent fracture at the interface of solvent and non solvent exposed materialand non solvent exposed material

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Project Results – Key Project Results – Key TakeawaysTakeaways

• Additional operator practice and process revision is Additional operator practice and process revision is necessary to reduce external errornecessary to reduce external error

• Elevated temperatures appears to have a negative Elevated temperatures appears to have a negative statistically relevant effect for Elongation at Yield statistically relevant effect for Elongation at Yield and Breakand Break– Increases Ultimate Tensile Strength and Tensile Modulus Increases Ultimate Tensile Strength and Tensile Modulus

• AnnealingAnnealing– Additional testing under increased time frames may be Additional testing under increased time frames may be

beneficial beneficial – Solvent and temperature interaction may also play a role, Solvent and temperature interaction may also play a role,

but statistical significance was not observedbut statistical significance was not observed

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Lessons Learned Lessons Learned

• Lessons Learned Lessons Learned – Measurement systems analysis are a valuable Measurement systems analysis are a valuable

tool to evaluate how robust a method istool to evaluate how robust a method is– Designed experiments allow for straightforward Designed experiments allow for straightforward

evaluation of test resultsevaluation of test results

Questions?Questions?

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AppendixAppendix

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Ultimate Tensile StrengthUltimate Tensile Strength

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Tensile ModulusTensile Modulus

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Strain at YieldStrain at Yield

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Strain at BreakStrain at Break

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DiscolorationDiscoloration

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Low heat, no solvent; low heat, solvent;high heat and solvent