ultramid structure - brochure - basf.com · ultramid® structure a3eg8 / g10 / g12 lf pa66,...
TRANSCRIPT
Ultramid® Structure Recommended by leading testers.
Ultramid® Structure in the web:
www.ultramid-structure.basf.com
Ultramid® Structure
High-performance polyamide with long-glass fiber reinforcement 4
Product range 5
Unique property profile 6
Fiber network of long fibers 7
Mechanical properties 8
Stiffness 8
Impact strength and energy absorption 10
Creep and fatigue behavior 11
Warpage 13
Processing 14
Design of parts using Ultrasim® 16
Product overview 17
4
100
90
80
70
60
50
40
30
20
10
00 5,000 10,000 15,000 20,000
Tensile modulus [MPa]
Cha
rpy
notc
hed
imp
act
stre
ngth
[kJ/
m2 ]
impact modified
mineral + impact modified
mineral
unreinforced
GF + impact modified
KGF
CF
LGF
Fig. 1: Long-glass fiber reinforced polyamides offer a benefit in the stiffness/toughness ratio
This makes Ultramid® Structure particularly suitable for applications in parts exposed to high levels of stress in mechanical and automotive engineering, in power tools and household appliances as well as in the leisure and sports sector, for example in:
energy absorption structures (crash absorbers, applications in seats and interior components in vehicles)
structural components with demands on greater stiffness at elevated temperatures and reduced creep behavior (chassis and bearings)
components which have to be robust in industry, handcraft and sports
fixing elements used in the construction sector
Ultramid® Structure High-performance polyamide with long-glass fiber reinforcement
BASF offers long-glass fiber reinforced polyamides under the trade name Ultramid® Structure. This product group with its specific range of properties opens up new possibilities when it comes to metal replacement. The resulting 3D fiber network is a leap forward in performance for certain properties in comparison with short-glass fiber reinforced polyamides (Fig. 1).
5
Ultramid® PA Chemical structure Melting point [°C]
Ultramid® B 6 polycaprolactam – NH(CH2)5CO 220
Ultramid® A 66 polyhexamethylene adipinamide – NH(CH2)6NHCO(CH2)4CO 260
Ultramid® C Copolyamides 66/6 copolymer of hexamethylene diamine adipic acid and caprolactam 243
Ultramid® D – special polymer 254
Table 1: Ultramid® grades
Table 2: Brief description of different Ultramid® Structure grades
Product rangeThe Ultramid® Structure grades are based on PA6 and PA66 matrix materials which are supplied with different additives and degrees of fiber reinforcement. More details about the individual products can be found in the Ultramid® product range.
A brief description of the range of Ultramid® Structure is provided in Table 2. The associated product values can be found in Table 3 on page 17.
Ultramid® Structure B3WG8 / G10 / G12 LF PA6, long-glass fiber reinforced, stabilized, high heat aging resistance, can only be supplied in black, less suitable if high demands are placed on the electrical properties of the parts
Ultramid® Structure B3ZG9 LF PA6, long-glass fiber reinforced, impact-modified and stabilized, with increased impact strength and elongation at break
Ultramid® Structure A3EG8 / G10 / G12 LF PA66, long-glass fiber reinforced, stabilized, inherent light color, increased resistance to heat aging, weather and hot water, can be used for electrical applications
Ultramid® Structure B3EG8 / G10 / G12 LF PA6, long-glass fiber reinforced, stabilized, inherent light color, increased resistance to heat aging, weather and hot water, can be used for electrical applications
Ultramid® Structure A3WG8 / G10 / G12 LF PA66, long-glass fiber reinforced, high heat aging resistance, can only be supplied in black, less suitable if high demands are placed on the electrical properties of the parts
Ultramid® Structure C3WG10 / G12 LF Co-polyamide, long-glass fiber reinforced, can only be supplied in black, less suitable if high demands are placed on the electri-cal properties of the parts
Ultramid® D3EG12 HMG LF Special polyamide, long-glass fiber reinforced, reduced water uptake, very good surface quality
6
Fig. 2: The property range of Ultramid® Structure compared to a standard short-glass fiber reinforced PA (glass fiber content of 50%).
0
1
2
6
Tensile modulus +120° C
reference (ref.) 7,335 MPa
Creep modulus 1,000 h, 40 MPa +120° C
ref. 5,200 MPa
Charpy notched impact strength -30° C
ref. 14.0 kJ/m²
Total energy, puncture test -30° C
ref. 4.5 J
Tensile strength +120° C ref. 118 MPa
Continuous vibration test cycles 70 MPa, R = -1, +23° C, ref. 4,850
Ultramid® Structure B3WG10 LF PA6 GF50
Unique property profile The main feature of the long-glass fiber reinforced Ultramid® Structure is its unique property profile (Fig. 2):
very stiff and strong at high temperatures
excellent low-temperature impact strength
much better creep and fatigue behavior
much higher energy absorption and improved crash performance
compared with conventional short-glass fiber polyamides
In addition to the outstanding mechanical properties, parts made of Ultramid® Structure benefit from its higher heat distortion resistance, the considerably reduced warpage (as much as -50%) and the excellent surface quality.
In injection molding and similar to that of short glass fiber-reinforced plastic, a three-layer structure with border layers higher oriented in flow direction and a vertically oriented core layer forms. However, be-cause of the long fibers and the resulting melt properties a more isotropic material is made. The main difference to short glass fiber-reinforced plastic is the three-dimensional network which is formed by the long fibers and which is developed directly in injection molding.
The fiber network forms the skeleton and remains even after ashing of the plastic (Figs. 4 and 5). This structure gives the end product its tremendous mechanical properties at both low and high tempera-tures. It is also responsible for the fact that creep behavior and energy absorption closely match those of the metals without losing the traditional advantages of a plastic.
Fig. 3 Comparison of granule length: Ultramid® Structure (left) and standard polyamide with short-glass fibers
Fiber network of long fibersThe manufacture of Ultramid® Structure initially produces continuous, fully impregnated plastic strands in a process known as pultrusion. In a second step, these are trimmed to a granule length of about twelve millimeters (Fig. 3).
7
Fig. 5: Structure of a ski binding made of Ultramid® Structure – after and before ashing
Fig. 4: Three-dimensional long-glass fiber network in close-up after ashing
20,000
18,000
16,000
14,000
12,000
10,000
8,000
6,000
4,000
-50 -30 -10 10 30 50 70 90 110 130 150
Temperature [°C]
Mod
ulus
of e
last
icity
[MP
a]
PA 66 GF 50 (dry) PA 66 GF 50 (cond.)
Ultramid® Structure A3WG10 LF (dry) Ultramid® Structure A3WG10 LF (cond.)
8
Fig. 6: Comparison of the modulus of elasticity of short-fiber and long-fiber reinforced PA66
StiffnessOne outstanding property of Ultramid® Structure is its higher stiffness compared with short-glass fiber reinforced polyamide at elevated temperature. In particular in a conditioned state, long-fiber reinforced polyamides show a higher stiffness (Fig. 6).
Mechanical propertiesThanks to their length and the spatial overlap in the three-dimensional fiber skeleton, the long glass fibers create a reinforcing structure which is capable of carrying more load via the fibers due to the mechanical interlooping. This shows itself in the form of the material advantages described below.
250
200
150
100
50
0
250
200
150
100
50
00 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10
PA 66 GF 50 (lengthwise) PA 66 GF 50 (crosswise) Ultramid® Structure A3WG10 LF (lengthwise) Ultramid® Structure A3WG10 LF (crosswise)
Expansion rate 0.1/s, cond., 23°CExpansion rate 0.1/s, dry, 23°C
9
Fig. 7: Stress-strain curves of Ultramid® Structure and PA66, in each case with 50% glass fibers
Str
ess
[MP
a]
Strain [%]
Str
ess
[MP
a]
Strain [%]
Parts are frequently subjected to multiaxial stresses. As a result of the high anisotropy of short-glass fiber reinforced polyamides, it can occasionally be difficult to produce a balanced design. Long-glass fiber reinforced material allows a better balance here (Fig. 7). Another advantage of long-fiber material is the almost linear behavior through to fracture. This means that parts made of Ultramid® Structure show smaller deformations at higher stresses. The visible difference in the elongation at break can also be attributed to the fiber skeleton and the mutual mechanical hindrance of the fibers.
Fig. 8: Left: Crack behavior of an Ultramid® Structure test part in a notched impact strength test; right: Notched impact strength of Ultramid® Structure compared to a standard short-glass fiber reinforced PA (50%)
Fig. 9: Impact strength of Ultramid® Structure compared to aluminum and magnesium
2.000 μm
100
75
50
25
0
Imp
act
stre
ngth
[kJ/
m²]
Ultramid® Structure
B3WG10 LF
aluminum magnesium
+ 33 % + 55 %
Impact strength and energy absorptionUltramid® Structure has excellent toughness, particularly at low temperatures. An induced crack is de-flected by the glass fiber network in such a way that more energy is consumed by the formation of larger crack areas (Fig 8, left). This results in an excellent notched impact strength without negative effects on stiffness and strength (Fig. 8, right). This is achieved by the fiber skeleton within the part which, compared with short-fiber reinforced polyamide, results in a much tougher crack behavior.
In order to achieve similar properties in short-glass fiber reinforced polyamides, these must be impact-modified, leading to lower stiffness and strength. In terms of impact strength, Ultramid® Structure is superior to the traditional lightweight metals aluminum and magnesium (Fig. 9)
Long-glass fiber Short-glass fiber
50
40
30
20
10
0Cha
rpy
notc
hed
imp
act
stre
ngth
[kJ/
m²]
-30 +23 +23, cond.*
*conditioning: 15 days, 70° C, 70 % relative humidity
Temperature [°C]
10
Ult
ram
id® S
truc
ture
Fig. 10: Creep behavior of Ultramid® Structure compared to short-glass fiber reinforced polyamide, PA66 with 50% glass fibers
Ultramid® Structure A3WG10 LF PA 66 GF 50
2.62.42.22.01.81.61.41.21.00.80.60.40.2
0
Str
ain
[%]
Str
ain
[%]
100
100
1,000
1,000
10,000
10,000
1
1
Time [h]
Time [h]
23 °C, 60 MPa
120 °C, 60 MPa
2.62.42.22.01.81.61.41.21.00.80.60.40.2
0
11
Creep and fatigue behaviorThe high performance of Ultramid® Structure can also be seen under permanent static and dynamic loading. Parts made of Ultramid® Structure show lower creep and much slower fatigue behavior than structures made of short-glass fiber reinforced polyamide (Fig. 10). This advantage is obvious in particular at elevated temperatures.
In a dynamic fatigue test (Fig.11), it can be de-monstrated that Ultramid® Structure reaches a number of load cycles that is up to 100 times higher compared to a polyamide with short-glass fiber reinforcement (23°C, R=-1, changing load, showcased at a maximum stress of 60 MPa).
Ultramid® Structure A3WG10 LF PA66 GF50
12
Fig. 11: Fatigue behavior of Ultramid® Structure compared to a standard short-glass fiber reinforced polyamide (50%)
1,000
100
10
Max
imum
str
ess
[MP
a]
1 10 100 1,000 10,000 100,000 1,000,000 10,000,000
Cycles
load cycle increase by factor 100
13
8
7
6
5
1
2
3
4
29
28
23
22
31
26
25
20
32
19
17
34
3330
27
24
2118
y
zx
0.75
0.50
0.25
0 Arit
hmet
ic m
ean
of
abso
lute
val
ues
of
war
pag
e in
z d
irect
ion
[mm
]
Ultramid® Structure
A3WG10 LF
PA66 GF50
Fig. 12: Warpage of Ultramid® Structure compared to a standard short-glass fiber reinforced polyamide (50%)
WarpageApart from improving the mechanical properties, the fiber skeleton brings about a lower warpage, as the warpage on a plastic structure determined from 34 indi vidual measuring points shows (Fig. 12).
34 measuring points on part
10 mm
14
ProcessingGentle processing during the injection-molding process also prevents breaks in the fibers. Ultramid® Structure can be processed on conventional thermoplastic injection-molding machines which are fitted with a standard three-section screw and are suitable for processing glass-fiber reinforced poly amides.
The diameter of the screw should be at least 40 mm. An open machine nozzle should be used. Shearing and mixing elements are not advisable because the strong shear causes unwanted shortening of the glass fibers. The screw speed, the back pressure and the injection speed should therefore be kept as low as possible. The hold pressure should also not be set too high. Under correctly configured conditions, a high proportion of long fibers are also obtained in the part (Fig. 13).
Fig. 13: Long-fiber granules during processing
15
Fig. 15: Comparison of the flowability of Ultramid® Structure grades with corresponding short-glass fiber reinforced grades
Fig. 14: Mold wear – comparison of a short and long-glass grade, PA66 with 50% glass fibers
10
7,5
5
2,5
0M
old
wea
r [m
g/c
m2 ]
Ultramid® Structure
A3WG10 LF
PA66 GF50
- 60 %
60
50
40
30
20
10
0
Flo
w le
ngth
[cm
]
Ultramid® Structure
A3WG10 LF
Ultramid® Structure
A3WG10 LF
PA66 GF50
PA66 GF50
60
50
40
30
20
10
0
Flo
w le
ngth
[cm
]
Ultramid® Structure
B3WG10 LF
Ultramid® Structure
B3WG10 LF
PA6 GF50
PA6 GF50
A horizontal temperature profile delivers good results with Ultramid® Structure grades which are based on PA6, whereas grades based on PA66 should be processed with a falling temperature profile. In most cases, molded parts made of Ultramid® Structure can be produced on existing molds. It is important that the granules arrive in the compression zone already in a soft state. In general, cross sections and radii which are as large as possible are to be preferred in the design of molds. Right-angled deflections where the melt flow is three-dimensionally deformed are to be regarded fairly critically here. Elongation flows appear less critical.
Long-fiber polyamides are frequently viewed critically because of possible wear to molds. However, with the same fiber weight proportion, long-fiber reinforced polyamides contain consider-ably fewer free, sharp-edged fiber ends which are responsible for wear. Measured in a test, it is apparent that the wear with long-fiber polyamide is 60% less (Fig. 14).
It is assumed just as frequently that long-fiber polyamide shows worse flow than corresponding short-glass grades because of the high glass content and the long fiber. A comparison with the flow spiral shows that Ultramid® Structure grades deliver approximately or completely identical results (Fig. 15).
Long-glass fiber Short-glass fiber
Long-glass fiber Short-glass fiber
2.5 mm thickness
1.5 mm thickness1.5 mm thickness
2.5 mm thickness
Fig. 16: Prediction of the part behavior of a crash absorber made of Ultramid® Structure using Ultrasim®
(left to right: simulation – part – part after ashing)
36
30
24
18
12
6
0
0 10 20 30 40 50 60 70 80
Experiment Simulation
Displacement [mm]
Design of parts using Ultrasim®
BASF’s simulation tool Ultrasim® is used mainly in the design of parts in automotive and mechanical engineering, but also for power tools and household appliances. As well as accurately forecasting the behavior of the part on the basis of injection parameters, fiber anisotropy and load speed, with the mathematical part optimization the best possible design under the given conditions can be determined. With customized models, BASF has extended the calculation tool so that parts that are reinforced with long-glass fibers can also be simulated. An example of this is a crash absorber made of Ultramid® Structure whose specific failure on impact is accurately reproduced and predicted by Ultrasim® (Fig. 16)
Forc
e [k
N]
16
17
Pro
duc
t o
verv
iew
Tab
le 3
: Pro
duc
t ov
ervi
ew a
nd p
rod
uct
pro
per
ties
Unit
Test
met
hod
Cond
ition
A3W
G8 L
FA3
WG1
0 LF
A3W
G12
LFB3
WG8
LF
B3W
G10
LFB3
WG1
2 LF
C3W
G12
LFD3
EG12
LF
Prop
ertie
s
Sym
bol
–IS
O 10
43PA
66-L
GF40
PA66
-LGF
50PA
66-L
GF60
PA6-
LGF4
0PA
6-LG
F50
PA6-
LGF6
0PA
6/66
-LGF
60PA
-GF6
0
Dens
ityg/
cm³
ISO
1183
1.47
1.56
1.68
1.46
1.56
1.68
1.68
Visc
osity
num
ber (
solu
tion
0.00
5 g/
ml s
ulfu
ric a
cid)
ml /
gIS
O 30
711
512
011
511
511
090
130
105
Wat
er a
bsor
ptio
n (s
atur
atio
n in
wat
er a
t 23
°C )
%IS
O 62
4.4
- 5.
03.
7 -
4.3
4.9
- 6.
04.
5 -
5.1
Moi
stur
e ab
sorp
tion,
sat
. in
stan
dard
con
d. a
tmos
pher
e 23
°C
/ 50
% r.
h.%
ISO
621.
3 -
1.7
1.0
- 1.
41.
6 -
2.0
1.3
- 1.
7
Proc
essi
ng
Mel
ting
poin
t, DS
C°C
DIN
53 7
6526
026
026
022
022
022
024
0
Mel
t tem
pera
ture
, inj
ectio
n m
oldi
ng /
extru
sion
°C–
290
- 31
029
0 -
310
290
- 31
029
0 -
300
291
- 30
029
2 -
300
290
- 31
0
Mol
d te
mpe
ratu
re, i
njec
tion
mol
ding
°C–
80 -
100
80 -
100
80 -
100
80 -
100
81 -
100
82 -
100
80 -
100
Mec
hani
cal p
rope
rtie
s
Tens
ile m
odul
usM
PaIS
O 52
7-1/
-2dr
y (2
3°C)
1320
0/10
700
1650
0/12
300
2060
0/16
000
1330
0/95
0016
800/
1040
020
900/
-20
300/
1300
021
000/
2100
0
Stre
ss a
t yie
ld (v
=50
mm
/min
), st
ress
at b
reak
(v =
5 m
m/m
in)
MPa
ISO
527-
1/-2
dry/
cond
.21
0/13
224
0/18
725
0/21
022
0/13
024
0/15
525
0/-
265/
175
260/
220
Stra
in a
t yie
ld (v
=50
mm
/min
), st
rain
at b
reak
(v =
5 m
m/m
in)
%IS
O 52
7-1/
-2dr
y/co
nd.
2/2.
12/
2.1
1.6/
1.8
2.1/
2.3
2/2.
11.
8/-
2.1/
2.5
2.0/
1.7
Flex
ural
mod
ulus
MPa
ISO
178
dry/
cond
.11
500/
1000
015
400/
1200
019
40/1
6400
1170
0/88
0015
400/
-20
200/
1420
0
Flex
ural
stre
ngth
MPa
ISO
178
dry/
cond
.32
0/25
537
0/29
741
0/31
831
6/21
836
0/-
435/
290
Char
py u
nnot
ched
impa
ct s
treng
th, +
23 °
CkJ
/m2
ISO
179
/1eU
dry/
cond
.65
/79
80/8
586
/89
76/8
388
/86
91/-
92/9
380
/-
Char
py u
nnot
ched
impa
ct s
treng
th, -
30°C
kJ /m
2IS
O 17
9 /1
eUdr
y55
/52
70/6
570
/71
58/6
178
/72
72/8
6
Char
py n
otch
ed im
pact
stre
ngth
, +23
°CkJ
/m2
ISO
179
/1eA
dry/
cond
.28
/28
37/3
737
/37
26/2
632
/32
37/-
35/3
625
/-
Chap
ry n
otch
ed im
pact
stre
ngth
, -30
°CkJ
/m2
ISO
179
/1eA
dry
28/2
837
/37
43/4
226
/26
33/3
337
/38
Izod
notc
hed
impa
ct s
treng
th, +
23°C
kJ /m
2IS
O 18
0 /A
dry/
cond
.24
/24
35/3
537
/36
26/2
531
/45
Izod
notc
hed
impa
ct s
treng
th, -
30°C
kJ /m
2IS
O 18
0 /A
dry
26/2
635
/-37
/36
24/2
431
/-
Tens
ile m
odul
usM
PaIS
O 52
7-1/
-2dr
y (8
0°C)
9300
1100
013
400
8000
9400
1240
0
Stre
ss a
t yie
ld (v
=50
mm
/min
), st
ress
at b
reak
(v =
5 m
m/m
in)
MPa
ISO
527-
1/-2
dry
(80°
C)14
317
015
712
114
014
8
Stra
in a
t yie
ld (v
=50
mm
/min
), st
rain
at b
reak
(v =
5 m
m/m
in)
%IS
O 52
7-1/
-2dr
y (8
0°C)
2.4
2.5
1.9
2.8
2.9
2
Ther
mal
pro
pert
ies
Heat
dis
torti
on te
mpe
ratu
re u
nder
1.8
MPa
load
, (HD
T A)
°CIS
O 75
-1/-
2dr
y (8
0°C)
260
260
260
218
218
18
For your notes
ww
w.4
maG
abrie
l.de
Selected Product Literature for Ultramid®: Ultramid® - Product Brochure Ultramid® - Product Range Ultramid®, Ultradur®, Ultraform® - Resistance against Chemicals
® =
regi
ster
ed tr
adem
ark
of B
ASF
SEKT
EM 1
305
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Note
The data contained in this publication are based on our current knowledge and
experience. In view of the many factors that may affect processing and application
of our product, these data do not relieve processors from carrying out own investi-
gations and tests; neither do these data imply any guarantee of certain properties,
nor the suitability of the product for a specific purpose. Any descriptions, drawings,
photographs, data, proportions, weights etc. given herein may change without prior
information and do not constitute the agreed contractual quality of the product. It
is the responsibility of the recipient of our products to ensure that any proprietary
rights and existing laws and legislation are observed. ( July 2013 )
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