pps-014 fortron thermoplasticcompositesppt am 1013

2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Contents

Introduction to TiconaFortron PPS Chemistry

Properties

Applications

Fortron PPS Composites Background

Processing Options

Properties

Applications

Summary

2013 Celanese PPS-014 AM 10/13 Fortron PPS for Thermoplastic Composites 2

Amorphous Partially crystalline

High-PerformancePolymers (HPP)(TI1 > 150C)

EngineeringPolymers (ETP)(TI1 90 150C)

Celanese Maintains Leading Position in Engineered Materials

2013 Celanese PPS-014 AM 10/13 3

Basic Polymers

TI1 = Temperature Index

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Fortron PPS for Thermoplastic Composites

Engineering Polymers

LCP Vectra /Zenite

PPS Fortron

PCT Thermx

PET Impet

PBT Celanex

PBT Alloy Vandar

TPC-ET Riteflex

POM Hostaform/Celcon

UHMW-PE GUR

Long Fiber and Continuous Fiber Reinforced Thermoplastics*

LFRT Celstran, Factor

Compel

CFR-TP Celstran Tapes, Rods and Profiles

* with Matrix Polymers: PP, PA, PPS, PBT, POM and others on request

Fortron PPSSummary Structure and Properties


Semicrystalline Tg 85C, TM 285C

Density 1.35 g/cm

Inherently Flame Retardant: UL94-V0, LOI > 45

Chemical Resistance Dimensional Stability Fuels, oils, solvents

Water-glycol

Easy to Process Injection molding

ExtrusionPolyphenylenesulfide (PPS)Poly(thio 1,4 - phenylene)

n

Fortron PPS

Semi-crystalline thermoplastic polymer, perfectly suited for parts that have to withstand the high mechanical and thermal requirements which require A high melting point range between 280 and 290CInherently flame resistantExcellent resistance to chemicals, oils and fluidsAn ideal alternative to conventional materials such as

thermosetting polymers and metalsHigh hardness and stiffness and superb long-term creep

under load propertiesEase to injection mold, blow mold and machineWeight reduction combined with high dimensional stability


Fortron PPS Has No Known SolventBelow 200C

Chemical resistance with minimal attack or swelling even at elevated temperatures Resists: acids/bases pH 2 to 12

Resists: strong bleaches

Resists: auto fluids coolants, transmission & brake

Resists: gas & alternate fuels (methanol, ethanol)

Resists: hydrolysis


Fortron 0214C1 Matrix Material for Composites

Linear, unmodified PPS polymerHigh molecular weight / high viscosity: 140 pas For extrusion and injection molding applications

Specified for aircraft applications In use at Airbus and Boeing VIAM qualification Federal state unitary enterprise All Russian Scientific Research

Institute of Aviation Materials

Tested in regards to flammability, smoke density and smoke toxicity: ABD0031 FAR/JAR 25.853 New: DIN 5510 and ISO 5659


Fortron PPS 0214C1 Smoke DensityTested with 2 mm Plaques

Smoke density according to Airbus Standard ABD0031 Non-flaming Max. Value: 0, Average: 0 DS max. @ 4 min: 0; ABD and FAR Passed

Flaming Max. Value: 32 (6 min.), Average: 23 (6 min) DS max. @ 4 min: 15; ABD and FAR Passed

Tox-Test (ABD0031):


ABD / FAR passed Value Max. Value in ppmHydrogen Cyanide HCN: NF: 0 F: 0 150

Carbon Monoxide CO: NF: 0 F: 10 1000

Nitrous Gases NO-NO2: NF: 0 F: 0 100

Sulfur Dioxide/Hy. Sulfide SO2 - H2S: NF: 0 F: 10 100

Hydrofluoric Acid HF: NF: 0 F: 0 100

Hydrochloric Acid HCl: NF: 0 F: 0 150

Fortron 0214C1 FlammabilityTested With 2 mm Plaque


Vertical Burning Test 12 s ABD0031 Total burn time: 12 s Flame extinguish time: 0 s No. of particles: 0 Ignited particles: 0 Total burn length: 5 mm

Vertical Burning Test 60 s ABD0031 Total burn time: 60 s Flame extinguish time: 0.6 s No. of particles: 2.4 Ignited particles: 1.4 Total burn length: 44 mm

Internal UL Flammability Testing

Thin PEEK samples failed to achieve a V-Rating because of long burn times and cotton ignition

Thin PPS parts have V-0 equivalent burn times but molten polymer drips can ignite the cotton = V-2 Rating


*Data as reported by Underwriters Laboratory

Material Part Thickness Unaged Sample Rating

Aged SampleRating

Unfilled Fortron PPS Control

3.0mm (0.12) V-0* V-0*

1/32 V-0 V-2

1/64 V-2 V-2

Unfilled PEEK Control

3.0mm (0.12) V-0* V-0*

1.5mm (0.059) V-0* V-0*

1/32 No V-Rating V-2

1/64 No V-Rating No V-Rating

Extremely low moisture absorption 0.02%Minimal effect of temperature CLTE 19 x 10-6 /C (6165A4)Precision molding Low shrinkage - 0.3% (6165A4)Creep resistance

Fortron PPS Dimensional Stability


For Precision Parts Even at Elevated Temperatures

00.02

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0.12

0.14

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PPS PEI PEEK

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Low PPS Water AbsorptionResults in Dimensional Stability


Automotive

EE & SensorsIndustrialSemicon

Top Fortron PPS Segments


Fibers

Composites

Inlet Tank for CAC 1140L4

Fortron PPS Automotive: Under the Hood


Throttle Body 1140L4

Crankshaft Flange 4332L6 Water Pump Impeller 1140L4

Water Pump 6165A6, 1140L6

Fuel Injection Rail

Fuel Pump Parts

Fortron PPS Automotive: Fuel Applications

Fortron PPS was selected for:


Resistance to all sorts of fuels including auto-oxidized fuels up to 120C

Excellent mechanical and impact strength at elevated temperatures

Inherently flame resistant (UL 94 V-0) Lower specific gravity than metal Simplified fabrication by eliminating

secondary operations

Fortron 1140L4 Water Pump Impellers


The challenge: Improve pump efficiency

Decrease water pump cost

Improve fuel efficiency (Lower HP requirements)

The innovation: Exotic blade shapes improve

pump efficiency by 10-20% vs. sheet metal

Fortron PPS has required chemical / hydrolysis resistance to OAT coolants

Excellent fatigue properties withstand pressure cycles

Excellent erosion resistance

Fortron PPS Industrial

Gas Furnace Tray

Instant Hot Water HeaterMedical Forceps


Washing Machine Light Fixture

Chemical Metering Pump

High Tenacity Monofilament

CPI Filter

Fortron PPS Extrusion: Film, Fiber, Netting, etc.


Aircraft CompositeFilter Netting

Stock Shapes


Fortron PPS for Thermoplastic CompositesMay 2012

Why Thermoplastic Matrix Composites?

Melt processibleCan be reformedNear infinite shelf life No refrigeration needed

Common generalized attributes: Good in fatigue Insensitive to moisture

Tough Higher temperature

Damage tolerant Excellent FST

Good chemical compatibility in aircraft fluids


Why Thermoplastic PPS Composites vs. Thermoset Composites?

Improved Properties Improved Processing

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Tougher, good fatigue performance 4x tougher than toughened epoxies

Damage tolerant Insensitive to moisture High-temperature performance Very low flammability, smoke, toxicity Low residual stress in molded parts Excellent chemical resistance

Eliminate bagging materials and labor May also eliminate kitting and debulking

steps and equipment

Eliminate autoclave possible Cost, space and bottleneck issues

Rapid processing vs. thermosets Can be reformed Simple, longer lasting tool Fusion bonding eliminates fasteners and

adhesives Reduces cost and weight

Green processing Recyclable

No VOCs in processing

Less process scrap

Fewer process energy requirements

2013 Celanese PPS-014 AM 10/13 Fortron PPS for Thermoplastic Composites

Thermoplastic Composite MatrixCost Advantage


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ProcessingMaterial

The material cost for a thermoplastic matrix might be equal or even higher

Lower cost for handling, processing, and assembly can lead to a substantial advantage in total cost

Even the High Cost Thermoplastic Polymers Offer Improved Cost Savings vs. Epoxy Based Composites

Fibers E Glass S2 Glass Carbon/

Graphite Aramid/Kevlar Polymer Boron/Ceramic

Resins PEEK PPS PEI Nylons PP Etc

Film Fabric Prepreg Dry Powder

Slurry

Hot Melt

Liquid

Comingle Tows

Fabric

Pultrusion Lamination Molding Oven

Match

Bladder

Fiber Placement Filawinding

AFP

Sheets Rods Pipes/Tubes Beams Shapes Structures

Thermoplastic Composite Value Chain


RawMaterials

IntermediateProducts

Fabrication Processes End Users

Example for Value Chain in Aircraft Industries


PlasticPellets

FilmProducer

Producer ofComposites Assembling Aircraft

Thermo-Forming-Process

Station 1: Film Production

Starting Product:


PPS Pellets Temperature stability High level of hardness and

impact strength Excellent resistance

to chemicals Broad temperature range Inherent flame resistance

Film ProductionStation 1 Lipp-Terler GmbH in Gaflenz near Linz, Austria. The pellets are converted into films with a thickness of 50 to 200 m. The film leaves the special plant in rolls of 100 kg in a flawless state, crystal clear and with the required characteristics with regard to strength and dimensional stability.

Fortron PPS Pellets

Station 2: Composite Production

Starting Product:

Laminate Production


Basic Matrix of PPS / Carbon Fiber Fabric

Station 2 Ten Cate Advanced Composites BV, Nijverdal, Netherlands. The carbon fiber fabric and PPS film are bonded together in a press, under high pressure and high temperature, into high-strength, dimensionally stable and resistant composites in the desired layer thickness.

Fortron PPS Film

e. g. Carbon Fiber

Station 3: Thermoforming


ShapingStation 3 Fokker Special Products, Hoogeveen, Netherlands.The composite plates are pre-heated and subsequently shaped into the desired form under pressure and high temperature.

Composite Plate

Positive Form

Negative FormStarting Product: Composite plates in the required size

Station 4: Assembly


Front Wing Portion

AssemblyStation 4 AirbusThe completed construction element is mounted at the intended location.

Starting Product: Front wing portion (Weight of the parts is 20 percent less than aluminum)

Technology Breakthrough: Fixed Wing Leading Edge Airbus

Welded structure Low weight and low cost monolithic design


Fortron PPS Success in the Aviation Industry

Safe, efficient, environmentally friendlyModern design Licensed for aircraft constructionNew applications from Fortron PPS


Thermoplastic Composite Processing Technologies

PultrusionContinuous laminatingCompression moldingThermoformingAutomated tape laying/fiber placementBladder molding


Relative Cost

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Pultrusion

DiaphragmForming

Sheet Forming:Stamping,Roll Forming

In-SituFilament Winding,Tape Placement

Prepreg MoldingCompression Molding,Autoclave

ContinuousMolding

Source: Composite Market Reports

Process Cost vs. Part Complexity for Continuous Fiber Reinforced Parts


Continuous Fiber TPC Processes

Rods/Profiles/Sheets Pultrusion Continuous/Semi-continuous molding Batch molding (press, autoclave)

Tubes/Pipes Fiber/Tape placement (In situ) Table roll/oven molding (2 Step) Table roll/bladder molding (2 Step)

Complex Geometries (draws, bends, etc.) Automated tape lay-up/fiber placement Mold processing (compression, bladder) Diaphragm, matched metal, thermoforming/folding, et al


Additional Thermoplastic CompositeManufacturing Processes


Automated Dynamics Fiber Placement

FiberForge Compression MoldingLingol Thermoforming

Advantages of Thermoplastic Composite Automation Processes

Accurate fiber placement at any angleMaterial savings Labor savingsQuality improvementAutomatic debulkingReduced manufacturing spaceReduced assembly costs


Environmental Attributes for Thermoplastic Composites

Reduced Energy RequirementsReduced Scrap and Reusability/RepairabilityReduced VOCs and Toxic Cure By-Products


Reduced Scrap and Reusability/ Repairability

Thermosets Thermoplastics

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Prepreg Shelf Life Scrap Ends in Landfill Rework can be Difficult

No Prepreg Shelf Life All Scrap can be Reused e.g., Pelletized for Injection Molding

Rework is easier since Thermoplastics can be Melted and Reformed


Reduced Process Energy Example for TP vs TS Composites


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Assemble part in tool Match Mold Process Cycle (1+ hours) Cool, removal

Assemble part in tool Stamp /Thermoform Cycle (minutes) Subsequent part can be stamped

immediately

Energy Required Per Part Can Be Less Than a Factor of 10 for TP vs. TS with Match Metal Molding of Simple Parts

Additional Savings: No Need for Prepreg Freezers Reduced Facility HVAC Costs


Reduced VOCs and Toxic Products


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Prepregs usually Contain Solvents (VOCs) for Tackiness

Cure By-Products can be Complex Organic Compounds

Halogenated Additives Are Typically Used to Reduce Flammability But Toxicity is Increased

Prepregs Do Not Contain Solvents No Cure By-Products No Halogenation Necessary for Most

High Performance Thermoplastics Excellent FST Performance


Thermoplastic Composite Properties

Tg, CHigh Load

Continuous use Temperature, C

Approx.Resin Cost,

$/lb

Approx. Carbon Reinforced

prepreg Cost, $/lb

Fortron PPS 90 85 5.00 30.00

PEI 217 115 10.00 45.00

PEEK 143 138 60.00 90.00


Fortron PPS High-Performance, Low-Cost Solution

Fortron PPS Carbon Fiber Composite Properties Thermo-Lite 1466P


Mechanical Property Data1Laminate Property Fiber Orientation Test Data

Tensile Strength Ksi (MPa)0 297 (2,045)

90 7.2 (50)

Tensile Modulus Msi (GPa)0 18.5 (127)

90 1.3 (8.8)Compression Strength Ksi (MPa) 0 162 (1,117)Compression Modulus Msi (GPa) 0 17.2 (118)Flexural Strength Ksi (MPa) 0 243 (1,672)Flexural Modulus Msi (GPa) 0 16.3 (112)Shear Strength (4 Point) Ksi (MPa) 0 11.1 (77)

1 Typical mechanical properties at room temperature, dry condition

Physical Property DataFiber Type AS-4 Resin Type PPSFiber Weight % 663 Resin Weight % 343Fiber Volume % 593 Resin Volume % 413Fiber Areal Weight 150 g/m2 Total Areal Weight 227 g/m2

Density 0.58 lb/in3 (1.61 g/cm3)Thickness/Ply 0.0056 (0.14 mm) Tape Width 12 (30.5 cm)

Fortron PPS Carbon Fiber Composite Properties Thermo-Lite 4268P


Mechanical Property Data1Laminate Property Fiber Orientation Test DataTensile Strength Ksi (MPa) 0 162 (1,118)

45 19.5 (135)90 6.7 (46)

Tensile Modulus Msi (GPa) 0 6.3 (44)45 2.1 (14.5)90 2.0 (13.8)

Open Hole Tensile Strength Ksi (MPa) 0/ 45/ 90 30 (207)Open Hole Tensile Modulus Msi (GPa) 0/ 45/ 90 2.7 (18.6)Compression Strength Ksi (MPa) 0 161 (1,111)Compression Modulus Msi (GPa) 0 6.0 (41)Open Hole Compression Strength Ksi (MPa) 0/ 45/ 90 44 (304)Open Hole Compression Modulus Msi (GPa) 0/ 45/ 90 3.4(23.5)In Plane Shear Modulus (Iosipescu) Ksi (MPa) 0 8.9 (61)In Plane Shear Modulus (Iosipescu) Msi (GPa) 0 0.8 (5.5)Flexural Strength Ksi (MPa) 0 174 (1,201)Flexural Modulus Msi (GPa) 0 6.2 (43)Shear Strength (4-point) Ksi (MPa) 0 9.1 (63)

1 Typical mechanical / physical properties

Physical Property DataFiber Type E-Glass Resin Type PPSFiber Weight % 683 Resin Weight % 323Fiber Volume % 533 Resin Volume % 473Fiber Areal Weight 260 g/m2 Total Areal Weight 382 g/m2Density 0.072 lb/in3 (2.0 g/cm3)Thickness/Ply 0.0076 (0.19 mm) Tape Width 12 (305 mm)

Fortron PPS Carbon Fabric Composite Physical Property Data

High Quality prepreg made by film infusion of fabric Excellent wetout of fabric by resin Reproducible and uniform No shelf life


Physical/Thermal (nominal values) T300 5HS/pps with double sided Amcor foil

Mass of fabric 8.26 oz/yd2 280 g/m2

Mass of fabric + resin 14.33 oz/yd2 486 g/m2

Resin content by volume 50 % 50 %

Resin content by weight 43 % 43 %

Moisture pick up 0.1 % 0.1 %

Ply thickness 0.0122 In 0.31 mm

Specific gravity 96.7 lb/ft3 1.55 g/cm3

Tg (DSC) (amorphous) 194 F 90 C

Tg (DSC) (crystalline) 248 F 120 C

TM 536 F 280 C

* TenCate CETEX Data CETEX is a registered trademark of TenCate Advanced Composites, BV

Fortron PPS Carbon Fabric Composite Mechanical Property Data*


* TenCate CETEX Data

Mechanical Properties 73F (23C)/50% RH 7781/PPSTensile strength warp 49.3 ksi 340 MPaTensile strength weft 48.3 ksi 333 MPaTensile modulus warp 3.1 Msi 22 GPaTensile modulus weft 2.9 Msi 20 GPaCompression strength warp 61.6 ksi 425 MPaCompression strength weft 42.8 ksi 295 MPaCompression modulus warp 3.7 Msi 26 GPaCompression modulus weft 3.5 Msi 24 GPaFlexural strength warp 74.2 ksi 511 MPaFlexural strength weft 56.6 ksi 390 MPaFlexural modulus warp 3.3 Msi 23 GPaFlexural modulus weft 2.9 Msi 20 GPaIn plane shear strength 11.6 ksi 80 MPaIn plane shear modulus 538.5 ksi 3714 MPaOpen hole tensile strength 23.0 ksi 158 MPaOpen hole compression strength 26.5 ksi 183 MPaCompression after impact 24.8 ksi 171 MPaBearing strength yield 46.1 ksi 318 MPaBearing strength ultimate 74.8 ksi 516 MPa

T300 3K Carbon Fabric/Fortron PPSComposite Property Data*


Steady and Stable Across Use Temperature


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CompressiveStrength

FlexuralStrength

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Open HoleTensile

Open HoleCompressive

CompressionAfter Impact

-55C

23C

80C

Values are in ksi Warp direction data Average values - Tested per Mil-R-17

T300 3K Carbon Fabric/Fortron PPS Composite Property Data*


Steady and Stable Across Use Temperature


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Tensile Modulus, msi Compressive Modulus,msi

Flexural Modulus, msi In Plane Shear Modulus,msi

-55C

23C

80C

Values are in msi Warp direction data Average values - Tested per Mil-R-17

Working Togetherin the Aviation Industry


Technology Validation Carbon/PPS:Fokker 50 Undercarriage Door

Final step in a dedicated 10-year programPress-formed ribs and sparsWelded assembly Qualified carbon / PPS materialCertified by the

Airworthiness AuthoritiesFlown on a KLM aircraft for 3.5 years


Technology Breakthrough: Fixed Wing Leading Edge Airbus A340-500/600

Welded structure Low weight and low

cost monolithic designStrong partnering with

Airbus UK and TenCateTechnology is now

state of the art current application Airbus A380


Metal Substitution with Linear PPS Composite Resulted in 2050% Lighter Components


Multi-technology concept Panels and spars

Thermoset Prepreg lay-up TP ribs and angles Aluminum and titanium brackets

Keel Beam Application

KB WP: 18m, 2.5 tons Main Ribs (L&R)

240 Parts per Airframe

A330/340 Family: Common Aileron

A318A319A320A321

A330-200

A330-300

A340-300

A340-500

A340-600

A380-800


Leading EdgeRibs, Angles & Panels

Edge Ribs Main Ribs

Edge Rib

Airbus A340 500/600 AileronThermoplastic Composite Parts


Part Description: Panel of the Pylon Forward Second Structure 22 per Aircraft

Dimensions: L = 700 1400 mmW = 200 400 mmThickness 2.8 mmDouble-Curvature Shape

Material: PPS / Carbon Fiber Bronze Mesh Top-layer for EMI Shielding

Airbus A340 500/600Thermoplastic Composite Components


Leading Edge Airbus A380

8 assemblies / wingWing length: 26 meters 16 segments, 52-meter length 400 kg total weight


Aluminum 280 g Fortron 150 g

46% Lighter Seat Parts Due to Metal Substitution

Product innovations for Composites

Weight Reduction The VisionFortron PPS in Aircraft Interior


Weight Reduction The VisionLinear PPS for Aircraft Interiors

Fortron PPS is the prime candidate for several aircraft interior efforts

Applications include seat frames, brackets, beams, ducts

Lower cost vs. PEI and PEKK


Common Aileron for A330-340 Family

240 CETEX Parts in Ailerons


Summary

Fortron PPS is a demonstrated, producible, low-cost, high-performance thermoplastic for composite applications Aircraft interior and exterior applications

Down hole applications

Corrosion resistant environments

High-temperature usage

The low-cost, green alternative

Industrial thermoplastics composites manufacturing is a demonstrated production process Proven success in aerospace

Ticona technical personnel will work with you to meet your composites needs


DisclaimerThis publication was printed on 1 October 2013 based on Celaneses present state of knowledge, and Celanese undertakes no obligation to update it. Because conditions of product use are outside Celaneses control, Celanese makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Nothing herein is intended as a license to operate under or a recommendation to infringe any patents.

Copyright 2013 Celanese or its affiliates. All rights reserved.


Contact Information

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Customer Servicet: +1-800-526-4960 t: +1-859-372-3214e: [email protected]

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e: [email protected]

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Customer Servicet: +86 21 3861 9266 f: +86 21 3861 9599e: [email protected]

Thank you.For more information:1-800-833-4882info-engineeredmaterials-am@celanese.comcelanese.com/engineered-materials


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