bakelite properties

Thermoset MouldingCompounds for theAutomotive Industry

Product Bulletin

For years, thermoset materials fromHexion Specialty Chemicals have beenwell established and indispensable inmany automotive industry applications.Our thermoset moulding compoundsand engineering phenolics are used inproducts ranging from cutting-edgetechnology mouldings through insulatingmaterials and paneling to friction liningsmeeting the most stringent requirements.

Even at the development stage, we support our customers in selecting thebest possible product from the maingroups of plastics.

Compounds designed for processing inautomatic injection moulding machinessatisfy the ambitious demands of themarket with respect to

• Weight savings

• Cost reduction

• Design flexibility

• Integration capability

The specific, customized properties ofthese materials make them an obviouschoice to replace existing metals applications by innovative design solutions.

Resistance to PeakThermomechanical Stresses With Glass Fiber-ReinforcedBakelite® Moulding Compounds

Hexion Specialty Chemicals suppliesspecialty moulding compounds with highengineering demand profiles and stronggrowth potentials for its customers.

Particularly in this field, Hexion’s aim is to exploit new applications with the aidof High Performance Materials and anexcellent technical service system. Thefocus is on cooperative project team-work with the final customers. In theseactivities, Hexion views itself as both ahigh-performance plastics specialist, anda component designer and provider ofpackaged engineering services.

The product line includes

• High-strength, glass fiber-reinforced phenol-formaldehyde moulding compounds for mechanically and thermally stressed housings and drive elements in the engine compartment

• Carbon fiber-reinforced Carbomould®

moulding compounds designed tomeet tribologic demands in frictionaland sliding functional components

• Electrically sophisticated, eliminationproduct-free, glass fiber-reinforcedepoxy moulding compounds for hightension insulating components in theautomotive electrical system

Applications

Highly demanding housings and functionalcomponents in the engineering andautomotive fields

Bakelite® High Performance Materialsincreasingly replace functional elementsand system components that up to nowhave been made of metal. Such materialsinclude the particularly robust glass fiberextended, phenol-formaldehydemoulding compounds – Bakelite®

Engineering Thermosets. These are used in fields including the automotiveindustry in transmissions, brake systemsand engine assemblies. Moreover, theelectrical and electronics industries also rely on these innovative mouldingcompounds to manufacture high quality, thermally resistant functional elementswith high mechanical strength.

Material Advantages

• Peak thermal stability

• Low creep, low compression set

• High chemical resistance

• Low density

• High modulus of elasticity

• High dimensional stability

• High surface hardness

• High corrosion resistance

• Low thermal expansion coefficient

• Low shrinkage

• Economical alternative to materialsincluding PPS, PEI, PEEK, PPA and die cast aluminum

Bakelite® Moulding Compound PF 6771

Applications

• Automotive housing components exposed to high levels of mechanical stress

• Air, water and oil transporting applications

• Water pumps

Material Description

Highly glass fiber-reinforced phenol-formaldehyde moulding compound

Special Advantages

• Highly complex components can be produced

• Peak strength combined with great toughness

• Excellent processability

• Very high ratios of flow path to wallthickness possible

Technical Data Sheet Specifications (ISO)

Property Units Bakelite® PF 6771

Density g/cm3 1.69

Tensile Strength MPa 120

Tensile Modulus of Elasticity MPa 17,000

Bending Strength MPa 225

Modulus in Bending MPa 16,000

Charpy Impact Strength kJ/m2 19

Charpy Notched Impact Strength kJ/m2 4

HDTC deflection temperature under load °C 170

18000

050

Elasticity Modulus of Bakelite PF 6771 in the Untreated State and After Heat Treatment

16000

14000

12000

10000

8000

6000

4000

2000

Mod

ulus

in B

endi

ng [

MP

a ]

100 150 200

Temperature [ °C ] Untreated Heat Treated

®

250

00

Bending Strength of Bakelite PF 6771 in the Untreated State and After Heat Treatment

200

150

100

50

Ben

ding

Str

engt

h [ M

Pa

]

50 100 150

Temperature [ °C ] Untreated Heat Treated

200 250-50

300

350

400

®

Bakelite®-Moulding Compound PF 1110

Applications

• Dimensionally accurate, high precision housings

• High-strength components and housings

• Fuel transporting applications


Phenol-formaldehyde moulding compound, 80 % inorganic (silica-free) extender

Special Advantages

• Very high dimensional stability

• Very tight tolerances can be met

• Thermal expansion coefficient

similar to that of aluminum

• Very low wear in plastics machining

• Isotropic properties



Density g/cm3 2.07






Charpy Notched Impact Strength kJ/m2 4

HDT-C deflection temperature under load °C 190

Storage in FAM B Test Fuel for 250 h at 80 °C

0

-0.2

-0.4

[ % ]

0.2

0.4

0.6

0.8PF 1110 PF 6771

Volume Change

0.1 %

0.3 %

Thickness Change

0.1 %

0.6 %

Length Change

0,0 %

0.1 %

Bakelite®-Moulding Compound PF 6501

Applications

• High-strength components and housings

• Pulleys for automotive and household use

• Pistons, flanges and pump rotors


Glass fiber-reinforced, mineral extended phenol-formaldehyde moulding compound

Special Advantages

• Very low compression set permits immediate assembly

• Very high reverse bending fatigue strength



Density g/cm3 1.6






Charpy Notched Impact Strength kJ/m2 3.5

HDT-C deflection temperature under load °C 170

2.00

0.00

Thermal Expansion Coefficient of Bakelite PF 1110, 10 °C / min

1.00

Long

itudi

nal E

xpan

sion

by

TMA

[ %

]

100.00 200.00

Temperature [ °C ] Normal High

300.00

Transverse

®

30000

0

25000

20000

15000

10000

5000

Storage at 180 °C

Initial 100 h 200 h 300 h

28500 28500 2850027500

Tens

ile M

odul

us o

f Ela

stic

ity [

MP

a ]

Very High and Uniform Residual Strength After Ageing at Elevated Temperatures Using theModulus of Elasticity as an Example (Bakelite PF 1110)®

1,46 μm 18,25 x10-6/ K

3,03 μm 18,94 x10-6/ K

4,59 μm 19,13 x10-6/ K

6,03 μm 18,84 x10-6/ K

7,55 μm 18,88 x10-6/ K

9,15 μm 19,06 x10-6/ K

10,83 μm 19,34 x10-6/ K

12,89 μm 20,14 x10-6/ K

16,92 μm 23,50 x10-6/ K

60,00 °C

80,00 °C

100,00 °C

120,00 °C

140,00 °C

160,00 °C

180,00 °C

200,00 °C

220,00 °C

3,71 μm 18,53 x10-6/ K

7,69 μm 19,21 x10-6/ K

11,67 μm 19,43 x10-6/ K

15,69 μm 19,59 x10-6/ K

19,90 μm 19,88 x10-6/ K

24,28 μm 20,21 x10-6/ K

28,89 μm 20,62 x10-6/ K

34,01 μm 21,24 x10-6/ K

42,28 μm 23,47 x10-6/ K

1.30 μm 11.23 x10-6/ K

2.60 μm 11.23 x10-6/ K

3.81 μm 10.97 x10-6/ K

5.06 μm 10.92 x10-6/ K

6.45 μm 11.14 x10-6/ K

7.82 μm 11.26 x10-6/ K

9.27 μm 11.44 x10-6/ K

10.77 μm 11.63 x10-6/ K

13.35 μm 12.81 x10-6/ K

The thermal expansion coefficient is uniform along the three coordinate axes.In view of the thermal ex-pansion of 20 x 10-6 / °K, very tight fits can beaccomplished in combinations withmetallic materials over a wide range of temperature.

Inorganically Extended Bakelite®

Moulding Compounds With PeakThermal Resistance

Carbon Fiber-ReinforcedCarbomould® Moulding CompoundsFor Enhanced Tribologic Properties


High-performance plastics based on carbon fiber-reinforced phenolic moulding compounds.

Applications

Highly demanding functional componentswith excellent wear resistance

• Automotive pump parts

• Bearing elements, slide bearings

• Gear wheels and cams

• Guide elements

• Sliding components

Material Advantages

• Peak thermal stability

• Low creep, low compression set

• Grades with very low friction coefficients

• Tribologic grades with low specificrates of wear

• High chemical resistance

• Low density

• High dimensional stability and modulus of elasticity

• Economical alternative to PEEK or coated aluminum

• High surface hardness

• High corrosion resistance

Carbon Fiber Plastics Properties

• Low density

• High modulus of elasticity and rigidity

• High mechanical strength

• Low abrasion

• Low and uniform coefficient of friction

Comparison of Carbon to Glass Fiber Plastics

Property Units Carbon Fiber Plastic Glass Fiber Plastic

Density g/cm3 1.8 2.6

Modulus of Elasticity MPa 240,000 77,000

Bending Strength MPa 4,000 3,500

Further Properties Thermal and electrical Insulator, high attritionconductivity, low attrition

Carbomould® S, M and T

Material Advantages

Various grades of material are availableto provide optimal application properties.Carbomould® S exhibits high strengthlevels, Carbomould® M offers a highmodulus of elasticity and Carbomould®

T is a tribologically optimized material.

Pin-on-Disk Setup:

Contact ball size: 4 mmFN = 10 [N]t = 4 [h]v = 0.25 [m/s]

The contact ball wear is low.

Material Advantages

Property Units Carbomould® S Carbomould® M Carbomould® THigh strength Peak modulus Tribologic

of elasticity

Density g/cm3 1.5 1.8 1.7

Tensile Strength MPa 110 110 80

Tensile Modulus of Elasticity MPa 29,000 31,000 23,000

Bending Strength MPa 250 200 180

Modulus in Bending MPa 28,000 31,000 24,000

Compression Strength MPa 270 250 200

1.0

0

Standard Material

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

Fric

tion

Coe

ffici

ent

3 6 9 12 15 18 21 24

Time [ h ] Bakelite Carbomould® ®

Friction Coefficient Curve at 90 °C, 0.25 m/s and 43 N/mm2

Glass Fiber-Reinforced Epoxy andPolyester Moulding Compounds for Electrical Insulation of Current-Carrying Parts

Bakelite® Epoxy Moulding Compound EP 8412

Applications

• High-tension carrying ignition system components

• Spark plug connectors

Material Advantages

• High thermal resistance

• Low viscosity grades

• Free of shrinkage and elimination products

• Peak chemical resistance

• No stress corrosion cracking

• Electrically sophisticated

Additional Advantages

• Embedding of sensitive electronicspossible

• Encapsulation of mechanically sensitive components

• Crack-free enclosure of metallic insertseven at low wall thicknesses

• Environmentally friendly (free of aromatics and amines)

Hexion not only offers you the mostappropriate material for your application,but also supports your efforts to combine cost advantages with innovative solutions.

1. New design concept, system design

2. Feasibility study

3. Simulation

4. Prototyping

5. Sampling

6. Tests, specifications

7. Series production


Property Units EP 8412 EP 8416 UP 802

Density g/cm3 1.85 1.85 2

Tensile Strength MPa 55 70 -

Tensile Modulus of Elasticity MPa 13,000 15,000 -

Bending Strength MPa 120 120 100

Modulus in Bending MPa 14,500 14,500 13,500

Charpy Impact Strength kJ/m2 8.5 8.0 7

Charpy Notched Impact Strength kJ/m2 3.5 2.5 3.5

Spark Plug Connectors, DistributorRotors and Caps

RequirementsHigh electrical stability, stress-free withmetallic inserts

Material OptionsPolyester moulding compound UP 802Epoxy moulding compound EP 8416

Material DescriptionGlass fiber-extended thermosets (epoxyand polyester GF 15) and thermoplasticpolyester (PBT GF 30)

H2 / H4 Lamp Sockets

RequirementsGas tightnessLow foggingLong-term thermal stabilitySpecial types for manufacture of smallcomponents

Material OptionsEpoxy moulding compound EP 8412 for H2Polyester moulding compound UP RW1411 for H4

Material DescriptionMineral and glass fiber-extended epoxyand unsaturated polyester mouldingcompounds for compression moulding

The information provided herein was believed by Hexion Specialty Chemicals ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be reli-able, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safehandling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and condi-tions of sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANYPURPOSE OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothingcontained herein constitutes an offer for the sale of any product.

Hexion Specialty Chemicals GmbHGennaer Straße 2-458642 IserlohnGermany+49 2374 925 0

Hexion Specialty Chemicals B.V.Koddeweg 673194 DH HoogvlietRotterdam, The Netherlands+31 10 295 4000

For worldwide locations visithexion.com

® and TM Licensed trademarks of Hexion Specialty Chemicals, Inc. © 2006 Hexion Specialty Chemicals, Inc. HCI- 500 11/06 Printed in Germany.

The Global Leader in Thermoset Resins As the world’s largest producer of thermoset resins and the leader in adhesive and structural resins and coatings, Hexion Specialty Chemicals meets customers’ specific application needs with a total solutions approach of products and services.Hexion offers the broadest range of thermoset resin technologies and unmatched technical support – and provides them around the globe.With our extensive research and development capabilities and applications know-how, we are uniquely able to work in partnership with customers to co-develop better products and systems.Plus, Hexion’s worldwide production network facilitates assured supply and prompt delivery wherever our customers do business.

World Headquarters / North America:

Hexion Specialty Chemicals, Inc.180 East Broad StreetColumbus, OH 43215-3799+1 614 225 4000

Regional Headquarters:

Asia

Hexion Specialty Chemicals Trading Co., Ltd.Lippo Plaza # 3701 222 Central Huai Hai Road Shanghai 200021 China +86 21 3318 4800

Australia

Hexion Specialty Chemicals Australia Pty.2- 8 James StreetLaverton North Victoria 3026Australia+61 39 369 2377

Europe

Hexion Specialty Chemicals B.V.Koddeweg 673194 DH HoogvlietRotterdam, The Netherlands+31 10 295 4000

Latin America

HexionQuímica Indústria e Comércio Ltda.Rua Cyro Correa Pereira, 2525Area-Sul – CIC81450-090 Curitiba, Brazil+55 41 212 1600

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