1. Most plastics are thermoplastics. Most thermoplastics are commodity.

2. Engineering Thermoplastics The most common!! Acrylonitrile Butadiene Styrene (ABS) Polycarbonate (PC) Polyamides (PA or Nylon) JUST print out slides 1 – 30!!!

3. Polymer Materials u Engineering Resins  ABS  Nylon  Polycarbonate  Acetal  Acrylic  Cellulosics  Ionomer

4. Polymer Materials u Engineering Resins (cont)  PBT  PET  PPO

5. Acrylonitrile Butadiene Styrene ABS EXCELLENT CHEMICAL RESISITANCE!!

6. Acrylonitrile Butadiene Styrene (ABS) u This is an ethenic engineering plastic  i.e. basic monomer structure as ethylene – just modifying polystyrene by: t Adding plasticizer and copolymers of styrene butadiene and styrene acrylonitrile to produce a polystyrene terpolymer of acrylonitrile, butadiene and styrene (ABS).

7. ABS butadiene

8. ABS u Major Uses  Appliance Housings  Canoes  Typewriter Keys  Pipes & Pipe Fittings  Telephone Housings

9. ABS u Why would you want to use it?  Low to Medium Cost  Good Impact Strength  Good Chemical Resistance  High Gloss Surface Finish  Good Flexural Properties

10. ABS u Processes  Injection Molding  Extrusion  Blow Molding  Thermoforming

11. ABS u Long Term Service Temperature  Max = 135°  Min = Already below Tg

12. ABS (UNFILLED)

13. Nylon PA - Polyamide http://www.sdplastics.com/nylon.html http://www.ides.com/generics/Nylon/Nylon_typical_properties.htm HIGHEST STRENGTH THERMALPLASTIC!!

14. Basic Info u Polyamides (nylon) are polymers formed as a condensation product of an acid and amine. They all contain the characteristic amide group: CO-NH. u Types  Most Common t Nylon 6 t Nylon 6/6  Nylon 6/10  Nylon 6/12  Nylon 11  Nylon 12 ** suffixes refer to the number of carbon atoms in each reacting substances involved in condensation process. They are used as an identification factor. Nylons with a period between the numbers are homopolymers; nylons with a slash (/) between numbers are a cop0lymner (ex. Nylon 6/12 is a copolymer of nylons 6 and 12)

15. Crystalline – Yes, very flexible Hygroscopic – Yes (O and N) Glass Transition = (135 F) Flammability – Varies depending on additives, but will usually self extinguish because of N Nylon Nylon 6/6

16. Nylon u Major Uses  Structural parts!! (i.e. replacement for cast aluminum 380 series)  Electrical Connectors  Gears  Bearings  Cables, Ties, Rope  Fishing Line  Automotive Valve Covers/Oil Pans  Sports/Exercise Equipment  Tools

17. Nylon u Why would you want to use it?  High Strength – among the highest of all engineering plastics  Good candidate for structural parts  Good Heat Resistance (continuous use up to 260 F, bonded to rubber in molds up to 350 F)  Good Chemical Resistance  Excellent Wear Resistance  Good Fatigue Resistance

18. Nylon u Processes  Injection Molding  Extrusion  Blow Molding  Rotational Molding  Thermoforming

19. Nylon 6 (UNFILLED)

20. Nylon 6/6 = most common

21. More on Nylon u One of the first “engineering” plastics (30s). u Crystalline thermoplastic u Can have tensile properties comparable to soft aluminum. u Types 6 and 6/6 are the cheapest and most common (also worst for moisture absorption)!! These two grades = 90% of production in US. Also, highest strength grades. u Biggest disadvantage – tendency to absorb moisture after prolonged period (up to 10% by weight) which causes war page. u Nylon 12 – best moisture resistant grade

22. Su = 35 ksi!! **Discuss bearing plate project for RuR, show samples

23. Polycarbonates (PC) IMPACT STRENGTH!!

24. Polycarbonate Crystalline – No, too rigid Hygroscopic – Yes (O) Glass Transition – High (300 F) Flammability – No (High number of double carbon bonds will extinguish –soot)

25. Polycarbonates (PC) u Polycarbonates are amorphous linear polyesters with excellent moldability. u Good impact strength, temperature resistance. u Transparent (aka Plexiglas) u Tensile strength similar to ABS and nylon except impact strength can be 10X greater! But……Costs more and susceptible to environmental stress cracking.

26. Polycarbonates (PC) u Uses include:  Helmets (football and hard hats), face shield, power tool housings, cell phones, automotive dashboards, window cranks, small gears, etc.

27. Acetal DONE!! Rest is just for reference!!!

28. Polyoxymethylene (Acetal or POM) Crystalline – Yes, very flexible Hygroscopic – Yes (O) Glass Transition – Low (-100 F) Flammability – Yes (only C and O bonds)

29. Acetal u Major Uses  Gears  Bearings  Faucet Components  Fuel Pump Components  Refrigerator Clips  Zippers

30. Acetal u Why would you want to use it?  Low to Medium Cost  Good Chemical Resistance  High Strength  Excellent Fatigue  Good Creep Resistance  Lubricity  Dimensional Stability at High Temperature

31. Acetal u Processes  Injection Molding  Extrusion  Blow Molding  Rotomolding

32. Acetal u Long Term Service Temperature  Max = 200°  Min = ~ -100

33. Acetal

34. u Material Suppliers  DuPont  Hoechst Celanese  BASF  LNP

35. Acrylic PMMA

36. Polymethylmethacrylate (Acrylic) Crystalline – No, too rigid (dual methyl groups) Hygroscopic – Yes (O) Glass Transition – High (220 F) Flammability – Yes (only C-H and C=O bonds)

37. Acrylic u Major Uses  Sheet t Windows t Displays  Signs  Surgical Instruments

38. Acrylic u Why would you want to use it?  Low Cost  Good Chemical Resistance  Hardness  Good Creep Resistance  Transparency  Best Polymer for Weatherability

39. Acrylic u Processes  Casting  Injection Molding  Extrusion  Thermoforming

40. Acrylic u Long Term Service Temperature  Max = 80°  Min = Already below Tg

41. Acrylic

42. u Material Suppliers  AtoHaas  Continental  DuPont  ICI

43. Cellulosic

44. u Major Uses  Tool Handles  Safety Glasses  Tooth Brush Handles  Automotive and Furniture Trim  Toys  Tubing  Writing Instruments

45. Cellulosic u Why would you want to use it?  Low Cost  Medium Chemical Resistance  Hardness  Transparency  Rigid

46. Cellulosic u Processes  Casting  Injection Molding  Extrusion

47. Cellulosic u Long Term Service Temperature  Max = 220°  Min = Already below Tg

48. Cellulosic

49. u Material Suppliers  Albis  Eastman  Kleer  Rotuba

50. Ionomer

51. u Major Uses  Golf Ball Covers  Automotive Bumper Pads  Film for Food and Drugs

52. Ionomer u Why would you want to use it?  Good Resilience  Good Flexibility  Abrasion Resistance  Good Chemical Resistance

53. Ionomer u Processes  Injection Molding  Extrusion

54. Ionomer u Long Term Service Temperature  Max = 100°  Min = -40

55. Ionomer

56. u Material Suppliers  Amoco  BASF

57. THERMOSETS:

58. Polymer Materials u Thermoset  EPOXY  Melamine  Urea  Phenolic  Polyester  Vinyl Ester

59. EPOXY

60. u Major Uses  Encapsulating Electronic Components  Bobbins for Coil Windings  Adhesives

61. Epoxy u Why would you want to use it?  High Mechanical Strength  Outstanding Adhesive Properties  Good Resistance to Heat  Good Chemical Resistance

62. Epoxy u Processes  Compression/Transfer Molding  Injection Molding

63. Epoxy

64. u Material Suppliers  Ciba-Geigy  Dow  Shell

65. Melamine (Amino)

66. Melamine u Major Uses  Molded Dinnerware  Electric Shaver Housings  Buttons  Ashtrays  Connector Bodies

67. Melamine u Why would you want to use it?  High Surface Hardness  Good Heat Resistance  Good Flame Resistance  Resists Chipping and Breaking

68. Melamine u Processes  Compression/Transfer Molding  Injection Molding

69. Melamine (Alpha Cellulose)

70. Melamine u Material Suppliers  American Cynamid  BIP  Bud Co.

71. Urea (Amino)

72. Urea u Major Uses  Control Housings  Wiring Devices  Control Buttons  Knobs

73. Urea u Why would you want to use it?  High Surface Hardness  Good Heat Resistance  Good Flame Resistance  Resists Chipping and Breaking

74. Urea u Processes  Compression/Transfer Molding  Injection Molding

75. Urea (Alpha Cellulose)

76. Urea u Material Suppliers  American Cynamid  BIP  Bud Co.

77. Phenolic

78. u Major Uses  Electrical Products  Connectors  Cooking ware (recall plate)  Ashtrays  Utensil Handles  Elecrtic Motor Components  Knobs

79. Phenolic u Why would you want to use it?  Good Heat Resistance  Good Flame Resistance  Good Rigidity  Good Creep Resistance

80. Phenolic u Processes  Compression/Transfer Molding  Injection Molding

81. Phenolic (Wood Floor)

82. Phenolic u Material Suppliers  Amoco Electronic  Rogers  Plenco

83. Vinylester

84. u Major Uses  Pipe  Electrical Equipment  Grating  Exhaust Stacks  Washer Drums  Chemical Tanks

85. Vinylester u Why would you want to use it?  Good Heat Resistance  Excellent Bonding to Fibers  Good Chemical Resistance  Good Rigidity  Good Creep Resistance

86. Vinylester u Processes  Hand Lay-Up  Compression/Transfer Molding  Injection Molding

87. Vinylester (15% Glass Fiber)

88. Vinylester u Material Suppliers  Premix  Glastic  Reichold