AvaSpire® PAEK: Introducing a New Differentiated Ultra Polymer Family 10th Annual SPE AutoEPCON Conference Jamal El-Hibri & Brian Baleno 5 May 2015.

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Presentation transcript:

AvaSpire® PAEK: Introducing a New Differentiated Ultra Polymer Family 10th Annual SPE AutoEPCON Conference Jamal El-Hibri & Brian Baleno 5 May 2015

Agenda Solvay Overview Introducing AvaSpire® PAEK Automotive application potential for AvaSpire® PAEK Summary © 2015 Solvay Specialty Polymers

Agenda Solvay Overview Introducing AvaSpire® PAEK Automotive application potential for AvaSpire® PAEK Summary © 2015 Solvay Specialty Polymers

A major global player in Chemicals and Plastics €9.9 bn NET SALES Our strengths €1,663 bn Adjusted REBITDA 90% of sales in businesses among the top 3 global leaders A balanced portfolio of activities, directed at growth regions A culture of sustainability, innovation and operational excellence A major global player in Chemicals and Plastics 117 INDUSTRIAL SITES 15 MAJOR R&I 29,400 EMPLOYEES 55 COUNTRIES Created by Ernest Solvay in 1863, Solvay is a Global company, with historical anchorage in Europe, and headquartered in Brussels.

Solar Impulse

Powertrain Efficiency Electrification Light-Weighting Emissions Reduction

Solvay’s unique solution offering to its customers further differentiates it from its competitors Aromatics Fluoropolymers High-barrier polymers X-linkable compounds LCP HPPA PPS PEEK PAI PSU PTFE PVDF PFA FKM PFPE PVDC XLCP Ryton® I don’t believe that Toray has PAI; AGC doesn’t have PVDC (it’s Asahi Kasei)

Agenda Solvay Overview Introducing AvaSpire® PAEK Automotive application potential for AvaSpire® PAEK Summary © 2015 Solvay Specialty Polymers

Spire® Ultra Polymers for Automotive Torlon® PAI KetaSpire® PEEK AvaSpire® PAEK Amorphous Crystalline © 2013 Solvay Specialty Polymers

KetaSpire Polyetheretherketone (PEEK) PEEK Chemical structure: Semi-crystalline, % Crystallinity ~ 35-45% Tg ~ 150 °C, Tm ~ 340 °C Key Attributes Thermal resistance up to 315 oC (HDT) Continuous service temperatures up to 240 oC Exceptionally good chemical resistance Hydrolytic stability Best-in-class fatigue resistance Ease of melt fabrication n Solvay Business Confidential 10

AvaSpire® PAEK: Differentiated Products vs. PEEK Proprietary products in the polyaryletherketone family Depending on grade AvaSpire can offer: Improved toughness over PEEK Higher stiffness than PEEK above 150°C Lighter color, better aesthetics More attractive economics Different AvaSpire Families: AV-600 Series AV-700 Series Customizable Grades AvaSpire = Customizable solutions to suit specific application needs Solvay Business Confidential

AvaSpire® AV-600 Series – A Balance of Properties Lower Crystallinity & Much Better Toughness vs. PEEK Attribute AV-600 Series Strength and Stiffness Comparable to PEEK Melt Processability Heat Deflection Temperature Higher than PEEK (Unfilled) Toughness and Impact Higher than PEEK Flammability More Resistant than PEEK Dimensional Stability Lower shrinkage/warpage vs PEEK Economics Usually more favorable than PEEK Chemical Resistance Slightly Lower than PEEK Solvay Specialty Polymers Business Confidential

AvaSpire® AV-600 Series Compared to PEEK Property KetaSpire KT-820 NT AvaSpire AV-621 NT Tensile Strength (MPa) 95 84 Tensile Elongation at Break (%) 20-30 50-75 Flexural Strength (MPa) 146 122 Flexural Modulus (GPa) 3.7 3.1 Izod Impact, Notched (J/m) 91 100 Izod Impact, Unnotched (J/m) No Break Heat Deflection Temperature (°C) (264 psi, Annealed) 157 187 AvaSpire 600 series  better ductility and higher temperature performance © 2015 Solvay Specialty Polymers

Tensile Stress-Strain at 23 °C: AV-621 vs. PEEK Solvay Specialty Polymers Business Confidential

DMA Modulus vs. Temperature: PEEK & AV-621 AV-621 modulus ~ 2X PEEK modulus in 160-190 oC temperature range Solvay Specialty Polymers Business Confidential

Heat Aging Stability at 200 oC (in Air) © 2013 Solvay Specialty Polymers

AvaSpire 600 Series Offer Excellent Fatigue Resistance Outstanding Fatigue Resistance Even at Elevated Temperatures © 2013 Solvay Specialty Polymers

ESCR of AV-6xx Series Almost on Par with PEEK Solvay Specialty Polymers Business Confidential

PEEK & PAEK Immersion Resistance to Common Industrial Chemicals and Solvents – 30 Days Immersion at 23 °C Environment KetaSpire PEEK AvaSpire AV-6xx PAEK Property  % Wt. Change %Ten Str. Retention % Mod. Retention Rating Hydrochloric Acid, 37% 0.26 99 101 A 0.60 103 Nitric Acid, 30% 0.25 100 0.52 98 Sulfuric Acid, 50% 0.03 0.24 95 97 Potassium Hydroxide, 45% 0.14 Acetone 0.02 0.21 93 104 Cyclohexane 0.01 0.04 Ethanol -0.02 0.10 105 Ethyl Acetate -0.03 Methylene Chloride 1.37 94 34.1 52 1 F Methyl Ethyl Ketone -0.04 0.20 Toluene 0.06 102 1,1,1-trichloroethane -0.01 Auto Transmission Fluid 0.31 Brake Fluid -0.11 0.13 Calcium Chloride Brine 0.00 0.07 Motor Oil – 10W30 0.09 0.17 Outstanding chemical resistance for both PEEK and PAEK in most environments Rating key: A = excellent, F = poor Solvay Specialty Polymers Business Confidential

Melt Viscosity vs Shear Rate: AV-6xx vs PEEK Grades Comparable Melt Processing to Standard PEEK Grades Solvay Specialty Polymers Business Confidential

AvaSpire® AV-600 Series Grade Slate Description Unreinforced AV-651 BG 15 Medium Flow, Injection Molding AV-621 NT Low Flow, Extrusion, Higher Performance than AV-651 AV-630 NT Low Flow, Extrusion, Wire Coating and Monofilament Grade Glass Fiber Reinforced AV-650 GF30 Medium Flow, Best Economics, Injection Molding AV-651 GF30 Medium Flow, Injection Molding, Slightly Better Chemical Resistance vs..AV-650 GF30 AV-621 GF30 Low Flow, Extrusion and Injection Molding Carbon Fiber Reinforced AV-651 CF30 AV-621 CF30

AvaSpire® AV-700 Series – Performance at Lower Cost Similar Performance to PEEK with Improved Economics Attribute AV-700 Series Economics More Attractive than PEEK Modulus Comparable to PEEK Chemical Resistance Strength Melt Processability Toughness, Impact Heat Deflection Temperature Long Term Use Temperature Lower than PEEK

ASTM Properties of AV-722 Comparable to PEEK Property Neat PEEK AV-722 Tensile Yield Strength (MPa) 95 88 Tensile Modulus (GPa) 3.5 3.6 Tensile Yield Elongation (%) 5.2 4.9 Tensile Break Elongation (%) 25 Flex Strength (MPa) 146 138 Flex Modulus (GPa) 3.7 Notched Izod (J/m) 91 80 HDT [264 psi] (C) 157 158 Specific Gravity 1.30 1.32 Water Absorption, 24 hr 0.1 Neat PEEK = KT-820 NT

AV-750 GF40  Strength Similar to 30% GF PEEK, 40% Higher Modulus AvaSpire® AV-750 GF40 Compared to GF PEEK Property Units AvaSpire AV-750 GF40 PEEK 30% GF Tensile Strength MPa 191 174 Tensile Elongation at Break % 1.8 2.7 Flexural Strength 253 269 Flexural Modulus GPa 14.8 10.7 Izod Impact, Notched J/m 53 112 Izod Impact, Unnotched 590 960 Heat Deflection Temperature (264 psi, Annealed) °C 285 315 AV-750 GF40  Strength Similar to 30% GF PEEK, 40% Higher Modulus

DMA of Unfilled AV-722 vs. PEEK and PPS © 2013 Solvay Specialty Polymers

ESCR of AV-700 Series: Same or Better than PEEK   KetaSpire PEEK AvaSpire AV-722 PAEK Critical Strain, % Critical Stress, psi (Mpa) Reagent Aqueous Acids and Bases Sulfuric Acid, 20% >2.0 NE 10,600 (73) >10,600 (73) Sulfuric Acid, 50% Hydrochloric Acid, 37% Potassium Hydroxide, 45% Organic Solvents Acetone 1.03 SC 5,500 (38) Cyclohexane Ethanol Ethyl Acetate 0.97 SC 5,100 (35) Methyl Ethyl Ketone Toluene 1,1,1-trichloroethane 10.600 (73) Notes: 24 hr exposure under stress at 23 °C NE = No effect up to up to the maximum available strain of 2.0% SC = Very slight crazing confined to surface Critical Stress = Minimum stress required to induce failure © 2013 Solvay Specialty Polymers

AV-722 Resistance to Brake Fluid and ATF at 150 oC Automotive Brake Fluid Property Control 1000 hr 2000 hr 3000 hr Tensile Yield Strength (MPa) 94 95 91 Tensile Modulus (GPa) 3.7 4.0 4.2 Tensile Yield Elongation (%) 5.0 4.3 3.9 Tensile Break Elongation (%) 20.3 16.1 19.6 16.9 Automatic Transmission Fluid Property Control 1000 hr 2000 hr 3000 hr Tensile Yield Strength (MPa) 94 101 103 Tensile Modulus (GPa) 3.7 3.9 Tensile Yield Elongation (%) 5.0 4.6 4.7 Tensile Break Elongation (%) 20.3 12.3 13.8 16.4 AvaSpire 700 Series  Outstanding Resistance to Automotive Fluids

DMA: AV-750 GF40 vs. 30% GF PEEK and 40% GF PPS © 2013 Solvay Specialty Polymers

AV-750 GF40 :Flex Modulus & Strength at Elevated Temps Flexural Modulus (GPa) Flexural Strength (MPa) © 2015 Solvay Specialty Polymers

Rheology of AV-700 Series Comparable to PEEK Temperature: AV-700: 380 oC, KetaSpire PEEK: 400 oC

AvaSpire® AV-700 Series Grade Slate Description Unreinforced AV-722 BG20 Standard Flow, Extrusion and Injection Molding 40% Glass Fiber Reinforced AV-750 GF40 High Flow, Best Economics, Injection Molding 30% Carbon Fiber Reinforced AV-722 CF30 Wear Resistant AV-755 SL45 High Limiting PV in Lubricated Environments

Agenda Solvay Overview Introducing AvaSpire® PAEK Automotive application potential for PAEK Summary © 2015 Solvay Specialty Polymers

AvaSpire® Automotive Application Considerations Powertrain Applications Push-pull cables (transmission) Bearing cages (engine, transmission) Fuel injectors Ignition coils Pump vanes Automotive Electronic Applications Electrical film insulation Magnet Wire insulation Electronic terminals Cable ties High temperature connectors

Summary Solvay Specialty Polymers offers the broadest range of ultra performance to the automotive industry including PAEK, PEEK, and PAI AvaSpire® PAEK is a differentiated ultra polymer with unique benefits compared to PEEK Approximately 25 active commercial grades of AvaSpire® PAEK AvaSpire ® PAEK can be considered in a range of automotive applications © 2013 Solvay Specialty Polymers

Powertrain Efficiency Light-Weighting Emissions Reduction Electrification Powertrain Efficiency If interested to discuss further please contact us! Brian Baleno Global Automotive Business Development Manager Solvay Specialty Polymers Brian.Baleno@Solvay.com