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fluoropolymer resinDuPont Tefzelfi

Properties Handbook

Table of Contents

Introduction ................................................................................................. 1Commercially Available Tefzel Fluoropolymers ........................................ 1Specifications ............................................................................................. 2Description ................................................................................................. 2

Mechanical Properties .............................................................................. 5Strength and Stiffness ................................................................................ 5Stress/Strain in Tension and Compression ................................................ 5Tensile Strength vs. Temperature .............................................................. 5Glass Fiber Orientation in Molded Structures ............................................ 7Flexural Properties .................................................................................... 7Flexural Modulus vs. Temperature ........................................................... 7Creep, Apparent Flex Modulus, and Long-Term Strain ............................. 7Flex Fatigue ............................................................................................... 9Impact Strength .......................................................................................... 9Friction and Bearing Wear ......................................................................... 11

Thermal Properties .................................................................................... 13Temperature Rating ................................................................................... 13

Electrical Properties .................................................................................. 14Environmental Effects ................................................................................ 17

Chemical Resistance ................................................................................. 17Hydrolytic Stability and Water Absorption .................................................. 17Weather Resistance ................................................................................... 17Effects of Radiation .................................................................................... 17Vacuum Outgassing ................................................................................... 17Permeability ............................................................................................... 20Flame Resistance and Smoke ................................................................... 20Effects of Heat Aging ................................................................................. 20Loss of Weight with Aging .......................................................................... 22

Optical Properties ....................................................................................... 23Fabrication Techniques ............................................................................. 24Assembly Techniques ................................................................................ 24

Screw Assemblies ...................................................................................... 24Snap-Fit ..................................................................................................... 24Press Fit ..................................................................................................... 24Cold or Hot Heading ................................................................................... 25Spin Welding .............................................................................................. 25Ultrasonic Welding ..................................................................................... 25Potting ........................................................................................................ 26Adhesive Bonding ...................................................................................... 26Melt Bonding .............................................................................................. 26

Safe Handling .............................................................................................. 26Typical Applications .................................................................................. 27

Bearings ..................................................................................................... 27Electronic Components .............................................................................. 27Fasteners ................................................................................................... 27Valve Linings .............................................................................................. 27Film Form Available ................................................................................... 27Tubing ........................................................................................................ 27Wire and Cable .......................................................................................... 27Biomedical/Labware ................................................................................... 27Pump Components .................................................................................... 27

IntroductionDuPont Tefzel fluoropolymers are melt-processible thermoplastics. They are part of theDuPont family of fluorine-based products that in-cludes Teflon PTFE, Teflon FEP, and TeflonPFA fluoropolymer resins.This handbook presents data for engineers andothers involved in materials selection and productdesign. It contains detailed information for theevaluation of Tefzel in electrical, mechanical,and chemical applications.All properties presented in this handbook should beconsidered as typical values and are not to be usedfor specification purposes. The age of this data var-ies, ranging in origin from the 1970s to the 1990s.

A variety of natural and reinforced compositions isavailable, permitting the selection of resins based onspecific applications or processing needs.A continuing program of resin development is beingconducted by DuPont. For additional technical data,information about the current line of Tefzel compo-sitions or design assistance for a particular applica-tion, please contact the DuPont office listed on theback cover.

Commercially Available DuPont Tefzel Fluoropolymers

Tefzel ETFEGrade Resin Characteristics Applications

200 General-purpose fluoropolymer resin with intermediate Electrical sleeving, coil forms,flow rate. Recommended upper service temperature sockets, connectors andis 150C. switches.

207 Special-purpose fluoropolymer resin with a higher Ideal for injection molding andflow rate but still maintains a service temperature thin wall extrusion.of 150C.

210 Special-purpose fluoropolymer resin with a higher Uniquely suitable for high speedflow rate and lower maximum service temperature. processing, especially for

extruded coatings and injectionmolding of slender, thin-walledor intricate shapes.

280 Premium fluoropolymer resin with a relatively low Components, linings and moldedflow rate, a greatly enhanced flex life, and a resistance parts for use in unusually extremeto environmental stress. thermal, mechanical, and

chemical environments.

750 Higher temperature rating, more flexible. Appliance wire Motor lead wire Wire and cable

2195 Free-flowing powder, with controlled particle size, Pump housings, vessels, columns,shape, and size distribution. elbows, tees, and pipe sections

with unusual shapes.

HT-2004 Glass-fiber reinforced resin for enhanced mechanical Injection-molded articles withproperties. unique mechanical properties.

HT-2127 Provides the general characteristics of other Tefzel Compact wire and cableresins while providing greater flexibility, improved constructions for service inretention of tensile properties at elevated demanding environments temperatures, reduced flammability and long life at airframe wiring.higher temperatures.

HT-2160 Static dissipating semiconductive resin. Extruded tubing, pipe and otherprofiles for hose.

Injection and blow-molded articlesrequiring superior electrical,chemical, and thermal properties.

1

The DuPont Oval Logo, DuPont, The miracles of science,and Tefzel are trademarks or registered trademarks ofE.I. du Pont de Nemours and Company.

Other product grades are also available for specialprocessing needs. Tefzel film is available in a widerange of thicknesses for electrical, chemical, andrelease applications. These include:Type LZ: General purpose filmType CLZ: Treated one side for improved

cementabilityType CLZ-20: Treated both sides for improved

cementability

SpecificationsThe ASTM material specification covering Tefzelis D3159.Tefzel is also called out in various industrial andmilitary specifications for tubing, molded parts,and film, as well as numerous wire and cableapplications.

DescriptionTefzel can best be described as a rugged thermo-plastic with an outstanding balance of properties.Mechanically, it is tough, has medium stiffness(1,170 MPa, 170,000 psi), impact, and abrasionresistance. Flex life depends upon the grade used,with Tefzel 280 being higher than the other grades.The glass reinforced compound (Tefzel HT-2004)has higher tensile strength (83 MPa, 12,000 psi),stiffness (6,555 MPa, 950,000 psi), and creep resis-tance than unfilled grades. However, it is still toughand impact resistant.Tefzel is typically considered to have a no loadcontinuous use temperature of 150C (302F). Incertain specific applications, Tefzel can have anupper service temperature in excess of 230C(392F). See page 13 for a more complete discus-sion of thermal rating.

2

Commercially Available DuPont Tefzel Fluoropolymers (continued)

Tefzel ETFEGrade Resin Chracteristics Applications

HT-2170 Improved stress crack resistance and flexibility Extruded tubing, pipe, and other(when compared with other static-dissipating profiles for hose.Tefzel ETFE resins). Linings of components used in the

chemical processing industries. Industrial film. Injection and blow-molded articles

requiring superior electrical,chemical, and thermal propertiesand stress crack resistance.

HT-2181 General-purpose resin. Intermediate flow rate. Films Tubing Injection-molded articles or linings Wire and cable

HT-2183 Improved stress crack resistance version of HT-2181. Tubing Injection-molded articles or linings Wire and cable

HT-2185 Higher flow rate version of HT-2181. Films Tubing Injection-molded articles or linings

HT-2202 Special-purpose resin available designed to promote Tubing, valves, containers, andadhesion between polyamide resins and ETFE fasteners.resins. Battery or instrument components.

Powder Resins Five grades are available covering a broad range of Ideal for when materials must beMFRs and particle sizes. The lower MFR resin dispersed in an ETFE matrix.provides a higher degree of stress crack resistance, Materials can be well dispersed inwhile the higher MFR resin is easier to process. the powder and then either

compression molded or meltmixed for additional processing.

3Table 1Typical Properties of DuPont Tefzel Fluoropolymers

ASTMProperty Method Units 210 200 280Mechanical

Melt Flow Rate D3159 g/10 min 23 7 4Ultimate Tensile Strength, 23C (73F)* D638 MPa 40 46 47

(psi) (5,800) (6,500) (6,700)Ultimate Elongation, 23C (73F)* D638 % 150300 150300 150300Compressive Strength, 23C (73F)** D695 MPa 17 17 17

(psi) (2,500) (2,500) (2,500)Flexural Modulus D790 MPa 1,200 1,200 1,200

(psi) (170,000) (170,000) (170,000)Impact Strength, 23C (73F) D256 J/m no break no break no break

(ftlb/in) no break no break no breakHardness, Durometer, Shore D D2240 63 67 72Coefficient of Friction, Metal/Film D1894 0.23 0.23 0.23Deformation Under Load, D621 % 0.2 0.3 0.2

23C (73F), 1000 psi, 24 hrLinear Coefficient of Expansion E831

0100C mm/mmC x 105 12.6 13.1 13.3100150C 17.6 18.5 20.9150200C 22.3 25.2 25.732212F (in/inF x 105) (7.0) (7.3) (7.4)212302F (9.8) (10.3) (11.6)302392F (12.4) (14.0) (14.3)

Specific Gravity D792 1.72 1.71 1.70Water Adsorption, 24 hr D570 % 0.007 0.007 0.005ElectricalSurface Resistivity D257 ohmsq >1015 >1016 >1016

Volume Resistivity D257 ohmcm >1017 same same

Dielectric Strength, 23C (73F) D1490.25 mm (10 mil) kV/mm (V/mil) 64 (1,600) 64 (1,600)3.20 mm (126 mil) kV/mm (V/mil) 15 (370) 15 (370)

Tefzel Grade

*Actual value depends on test specimen and test conditions.**Failure defined as stress at 5% strain.

(continued)

Tefzel is weather resistant, inert to most solventsand chemicals, and is hydrolytically stable. It hassubstantially better resistance to radiation thanTeflon but is not immune to damage by long-termexposure to gamma radiation, especially at elevatedtemperatures. Where specific radiation require-ments must be met, adequate testing of the pro-posed application in the radiation environment mustbe carried out to establish the suitability of Tefzelfor this application.Electrically, Tefzel is an excellent low-lossdielectric, with a uniformity of electrical propertiesnot normally found with other thermoplastics.A list of typical properties of Tefzel is shown inTable 1.

Tefzel can be extruded or injection molded easily,using conventional techniques, and thus presentsno unusual operator training problems. Corrosionresistant equipment is recommended for extendedproduction runs. Electrically heated dies are recom-mended for injection molds.Tefzel can perform successfully in applicationswhere other materials are lacking in mechanicaltoughness, broad thermal capability, ability tomeet severe environmental conditions, or limitedby fabricating problems.As is the case with all new developments, a thor-ough prototype and test program is recommendedto ensure successful performance of Tefzel compo-sitions in specific applications.

4Table 1Typical Properties of DuPont Tefzel Fluoropolymers (continued)

ASTMProperty Method Units 210 200 280

Tefzel Grade

Dielectric Constant, 22C (72F) D15311 kHz 2.6010 kHz 2.60100 kHz 2.601 MHz 2.59100 MHz 2.441 GHz 2.333 GHz 2.3113.6 GHz 2.28

Dissipation Factor, 22C (72F) D15311 kHz 0.000710 kHz 0.0011100 kHz 0.00231 MHz 0.0070100 MHz 0.02301 GHz 0.01723 GHz 0.011913.6 GHz 0.0073

Arc Resistance D495 seconds 122

ThermalMelting Point DTA C 255280

D3418 (F) (491536)Heat of Fusion DSC kJ/kg 46.7 50.7 43.8

D3417 (Btu/lb) (20.1) (21.8) (18.8)Specific Heat DSC kJ/kgK

25C (77F) cal/gC 0.25100C (212F) 0.30150C (302F) 0.34

300C (572F) (melt) 0.38Heat of Combustion D240 MJ/kg 13.7

(Btu/lb) (5,900)Thermal Conductivity W/mK 0.24

(Btuin/hft2F) (1.65)Limiting Oxygen Index (LOI) D2863 % 3032 3032 3032Heat Deflection Temperature D648 C (F )

455 kPa (66 psi) 81 (177)1620 kPa (264 psi) 51 (123)

Continuous Service Temperature C 135 150* 150*(F) (275) (302) (302)

*See page 13 for a more complete discussion of Thermal Rating.

Mechanical Properties

Strength and StiffnessTefzel is less dense, tougher, stiffer, and exhibits ahigher tensile strength and creep resistance thanTeflon PTFE and Teflon FEP fluoropolymer res-ins. It is, however, similarly ductile. Tefzel compo-sitions display the relatively nonlinear stress-strainrelationships characteristic of nearly all ductile ma-terials.

Stress/Strain in Tension andCompressionFigures 1 and 2 show stress vs. strain for Tefzel200 and Tefzel HT-2004, at room temperature, inboth tension and compression. Because of the non-linear character of the curves beyond approximatelya 1% strain, calculation of a corresponding stressbased on tangent or secant (1% offset) moduluswould be inaccurate.For this reason, it is recommended that if the calcu-lated strain exceeds 1%, the stress value should beread from the curve. For longer-term strain calcula-tions, the apparent modulus procedure should beused as presented.

Tensile Strength vs. TemperatureFigure 3 shows the effect of temperature on tensilestrength for Tefzel 200 and Tefzel 280. The effectof temperature on ultimate elongation is shownin Figure 4. These measurements were made on5" x 0.5" x 0.125" injection molded tensile bars.Thinner test specimens will result in slightly higherultimate elongation values.The effect of temperature on tensile modulus isshown in Figure 5.

5

Figure 2. Compressive Stress vs. Strain

10,000

8,000

6,000

4,000

2,000

0 1 2 3 4 5 6 7

Stre

ss, M

PaTefzel HT-2004

Tefzel 200

Stre

ss, p

siStrain, %

0

70.0

55.2

41.4

13.8

27.6

0

Figure 3. Tensile Strength vs. Temperature

Figure 1. Tensile Stress vs. Strain

12,000

10,000

8,000

6,000

4,000

2,000

0 1 2 3 4 5 6 7

Stre

ss, p

si

Stre

ss, M

Pa

82.7

70.0

55.2

41.4

27.6

13.8

Strain, %

Tefzel HT-2004

Tefzel 200

0 0

Tens

ile S

treng

th, p

si

Tens

ile S

treng

th, M

Pa

40 0 50 100 152 200(40) (32) (122) (212) (302) (392)

Temperature, C (F)

Tefzel HT-2004

Tefzel200

Tefzel280

12,000

10,000

8,000

6,000

4,000

2,000

0

82.7

70.0

55.2

41.4

27.6

13.8

0

6Figure 4. DuPont Tefzel 200, 280, and HT-2004Ultimate Elongation vs. Temperature,5" x 0.5" x 0.125" Injection Molded Bar

Tefzel HT-2004

Tefzel 200

Tefzel 280

Ultim

ate

Elon

gatio

n, %

Temperature, C (F)

300

250

200

150

100

50

050 0 50 100 150 200

(58) (32) (122) (212) (302) (392)

Figure 5. DuPont Tefzel 200, 280, and HT-2004Tensile Modulus vs. Temperature,5" x 0.5" x 0.125" Injection Molded Bar

Tefzel 280

Tefzel 200

Tefzel HT-2004

690

552

414

276

138

0

Tens

ile M

odul

us, k

psi

Tens

ile M

odul

us, M

Pa

Temperature, C (F)

1,000

800

600

400

200

050 0 50 100 150 200(58) (32) (122) (212) (302) (392)

Glass Fiber Orientation inMolded StructuresGlass fibers in an injection molded part tend to lineup parallel to the lines of flow in filling the mold.This produces nonisotropic strength properties in thepart. Table 2 shows that the tensile strength ofTefzel HT-2004 measured perpendicular to fiberorientation is 7075% of that parallel to orientation.Thus, a design safety factor is suggested to recog-nize this phenomenon.

7

Flexural Modulus vs. TemperatureThe effect of temperature on flexural modulus, orstiffness, is shown in Figure 7.Figure 7 shows that stiffness decreases significantlyas environmental temperature increases for bothTefzel 200 and the glass filled Tefzel HT-2004.However, the glass filled Tefzel retains significantstiffness even at the upper use temperature. Whendesigning parts, these changes with temperaturemust be taken into consideration in order to achievethe desired functionality.

Creep, Apparent Flex Modulus, andLong-Term StrainAs with other plastics, ambient temperatures andduration of load are important to design variables.The usual relationship:

Stress= Modulus

Strainapplies to short-term loading of an elastic structure.When load is applied, an initial deflection occurs.If the load is not excessive (i.e., for Tefzel, a loadproducing less than 1% strain), the conventionalmodulus figure indicates the correct stress-strainrelationship, and standard engineering equationsmay be applied to predict performance.If, however, the load is maintained continuously, allmaterials deform or creep, generally at a decreasingrate with time. The apparent modulus concept isa way of mathematically describing this creep be-havior.Apparent modulus (Ea) = Stress (fixed value)(after a given time of Total strain (measuredload application at a after the given timegiven temperature) of exposure)Most creep occurs within the first year and, there-fore, the apparent modulus at 10,000 hours can beused in many calculations involving continuous load(substitute Ea for E).Apparent modulus is a function of temperatureand time. Figure 8 gives the apparent flexuralmodulus of Tefzel HT-2004 at 23C (73F) and100C (212F). To approximate apparent modulusat other temperatures, use Figure 7, which showsflexural modulus as a function of temperature.For a given use temperature, read the modulus for

Table 2Effects of Orientation of Glass Fibers on

Tensile Properties of DuPont Tefzel HT-2004

Parallel to Glass Perpendicular to GlassTensile Tensile

Strength Elongation Strength Elongation82.7 MPa 8% 57.6 MPa 8%(12,000 psi) (8,360 psi)

Figure 6. Flexural Stress vs. StrainTefzel 200and HT-2004. ASTM D790; RoomTemperature 23C (73F); Span 3"(76 mm); Specimens 0.5" (13 mm) Wide,0.175" (4 mm) High

Flexural PropertiesThe relationship between flexural stress and strainis shown in Figure 6.

0

5,000

10,000

15,000

20,000

350

700

1,050

1,400

0 1 2 3 4 5

Tefzel HT-2004

Tefzel 200

Flex

ural

Stre

ss, p

si

Flex

ural

Stre

ss, k

g/cm

2

Strain, %

0

8Figure 7. DuPont Tefzel 200 and HT-2004ASTM D790; Flex Modulus vs. Temperature,5" x 0.5" x 0.125" Injection Molded Bars

Figure 8. CreepApparent Flex Modulus vs. Time and Temperature by ASTM D674,DuPont Tefzel HT-2004

Tefzel HT-2004

Tefzel 200

Flex

Mod

ulus

, kps

i

Flex

Mod

ulus

, MPa

Temperature, C (F)

1,000

800

600

400

200

050 0 50 100 150 200

690

552

414

276

138

0

(58) (32) (122) (212) (302) (392)

1 x 106

8 10x 5

6 10x 5

54 10x

2 10x 5

00.1 1 10 100 1,000 10,000

7.0 10x 4

23C(73F)

100C(212F)

5.6 10x 4

4.2 10x 4

42.8 10x

1.4 10x 4 App

aren

t Mod

ulus

, kg/

cm 2

App

aren

t Mod

ulus

, psi

Time, hr

0

Tefzel HT-2004 from Figure 7, using a straightline through it approximating the slopes at 23C(73F) or 100C (212F) from Figure 8. The abovediscussion is related to flex modulus only. For prac-tical purposes, however, the same procedure nor-mally will give adequate design results for tensileor compressive stresses.Creep can also be presented to show actual defor-mation under load vs. time. Figures 9 and 10 showpercent strain at 23C (73F) and 100C (212F)for Tefzel 200 and Tefzel HT-2004 at two pres-sures. Curves for Tefzel 280 would be expected tobe similar to those of Tefzel 200.Flex FatigueFigure 11 gives the results of rapid flexing testsfor Tefzel 200 and Tefzel HT-2004 using aSonntag flex tester. Although Tefzel HT-2004 has

a greater fatigue limit than Tefzel 200, both arequite sensitive to stress levels. For best fatigue per-formance, stress levels below 20.7 MPa (3,000 psi)and 12.1 MPa (1,750 psi) are suggested for TefzelHT-2004 and Tefzel 200 respectively. Tefzel 280would be expected to have a greater flex fatiguelimit than Tefzel 200.Impact StrengthTefzel 200 and Tefzel 280 have high impactstrength, ranking among the highest of all plasticsover a broad temperature range. The low tempera-ture embrittlement point is below 100C (148F).Data showing the effect of temperature are pre-sented in Table 3.

9

Figure 9. DuPont Tefzel 200Flexural Creep, 5" x 0.5" x 0.125" Injection Molded Bars

1

2

3

4

5

6

7

0

23C, 13.8 MPa(73F, 2,000 psi)

23C, 6.9 MPa(73F, 1,000 psi)

100C, 5.5 MPa(212F, 800 psi)

St

rain

, %

Time, hr1 10 100 1,000 10,0000

100C, 2.8 MPa(212F, 400 psi)

Figure 10. DuPont Tefzel HT-2004 Flexural Creep, 5" x 0.5" x 0.125" Injection Molded Bars

Figure 11. Flex Fatigue of DuPont Tefzel 200 and HT-2004, ASTM D671Tension/Compression;1,800 Cycles/Minute, 23C (73F), 50% RH; Sample Type I, Small

10

1

2

3

0

100C, 13.8 MPa(212F, 2,000 psi)

Stra

in, %

Time, hr

100C, 6.9 MPa(212F, 1,000 psi)

23C, 27.6 MPa(73F, 4,000 psi)23C, 13.8 MPa(73F, 2,000 psi)

1 10 100 1,000 10,0000

Tefzel HT-2004

Tefzel 200

Stre

ss, p

si

Stre

ss, k

g/cm

2

4,000

3,000

2,000

104 105 106 107

280

210

140

Cycles to Failure

Friction and Bearing WearUnlike many other polymers, the addition of glassreinforcement improves the frictional and wearproperties of Tefzel. For example, the dynamiccoefficient of friction (0.69 MPa [100 psi] at10 ft/min) for Tefzel 200 is 0.4 but drops to 0.3 forTefzel HT-2004 under these conditions. The wearfactor also improves from 6,000 x 1010 to 16 x1010 in3min/ftlbhr. These improved frictional andwear characteristics, combined with outstandingcreep resistance, suggest that the glass-reinforcedresin be favored for bearing applications. TefzelHT-2004 also appears to be less abrasive on matingsurfaces than most glass-reinforced polymers.The static coefficient of friction for TefzelHT-2004 is dependent on bearing pressure.This relationship is shown in Table 4.

Dynamic friction is dependent on pressure and rub-bing velocity (PV). Figure 12 is a plot of coefficientof friction against PV for Tefzel HT-2004 againststeel.The generation of frictional heat is dependent oncoefficient of friction and the PV factor. For TefzelHT-2004, temperature buildup begins at about a PVof 10,000 and thermal runaway occurs just below aPV of 20,000. The equilibrium bearing temperaturesare shown as a function of PV in the upper right-hand corner of Figure 12. High wear rates begin ata PV above 15,000.The rate of wear depends on the type of metal rub-bing surface and on other factors such as finish,lubrication, and clearances. Lubrication, hardershaft surfaces, and high finishes all improve wearrates. Minimum diametral clearances of 0.3 to 0.5%are suggested for sleeve bearings.Table 5 gives wear factors for steel and aluminum.The wear rate of both Tefzel and the metal is muchhigher for aluminum than for steel. Therefore, ifaluminum is the mating metal, an anodized surfaceis suggested.The wear factor of Tefzel HT-2004 against steel isabout one/tenth that of 33% glass-reinforced nylon.

11

Table 3DuPont Tefzel HT-2004Effect of Temperature on Izod Impact Strength

Notched Izod Impact StrengthTest Temperature J/m ftlb/in

Tefzel 20060C (76F) no break no break23C (73F) no break no break121C (250F) no break no break204C (400F) no break no break

Tefzel 28060C (76F) no break no break23C (73F) no break no break121C (250F) no break no break204C (400F) no break no break

Tefzel HT-200460C (76F) 183.5 3.4423C (73F) 392.5 7.35121C (250F) no break no break204C (400F) no break no break

Table 4Static Coefficient of Friction,

DuPont Tefzel HT-2004

Coefficient ofpsi MPa Friction10 0.069 0.5150 0.345 0.38

100 0.69 0.31500 3.45 0.34

12

Figure 12. Frictional BehaviorDuPont Tefzel HT-2004 vs. Steel. Thrust-bearing tester, no lubricant,mating surface AISI 1080 steel, 16AA. (Wear transition temperature between 113150C [235300F])

150

100

50

300

250

200

150

C F

Coef

ficie

nt o

f Fric

tion

Tem

pera

ture

of S

teel

Mat

ing

Surfa

ce

100 (psi x ft/min)3.6 (kg/cm2 x cm/s)

1,000 (psi x ft/min)36 (kg/cm2 x cm/s)

10,000 (psi x ft/min)360 (kg/cm2 x cm/s)

PV (Bearing Compression Load x Rubbing Velocity)

0.5

0.4

0.3

0.2

0.1

Table 5DuPont Tefzel HT-2004 Bearing Wear Rate1

Pressure Velocity Wear Factor K x 1010

Mating Surface psi MPa ft/min cm/sec Tefzel Metal

Steel2 1,000 6.9 5 2.5 16 41,000 6.9 10 5.1 14 61,000 6.9 15 7.6 19 131,000 6.9 17.5 8.9 30 161,000 6.9 20 10.2 FAIL

Aluminum3 300 2.07 10 5.1 1,220 1,220100 0.69 50 25.4 480 390

1Thrust bearing tester, no lubricant, ambient air temperature, metal finish 16 microinches (406 nanometers).2Steel mating surface AISI 1018.3Aluminum mating surface LM24M (English).

Thermal PropertiesTefzel is a modified copolymer of tetrafluoro-ethylene and ethylene and, as such, has a meltingrange rather than a sharp melting point. The meltingrange of Tefzel is 255280C (491536F).Table 1 lists the thermal properties of Tefzel 200.Tefzel 210 and Tefzel 280 would be expected tobe similar.

Temperature RatingTefzel 200 and 280 are typically considered to havea no load continuous use temperature of 150C(302F). This continuous use temperature rating isbased on 10,000 hour aging tests that involve expo-sure of standard tensile test specimens and wireinsulations to a series of elevated temperatures todetermine the rate of change of various physicalproperties with time. Elongation and tensile strengthare properties that change significantly with tem-perature exposure. These data were fit to anArrhenius plot (the logarithm of the rate of changeof a physical property is a straight line when plotted

against the reciprocal of the absolute temperature ofexposure). The Arrhenius plots for elongation andtensile strength are presented in Figures 18 and 19respectively.In practice, the upper service temperature of a mate-rial depends on the specific nature of the end useapplication. According to Underwriters Laboratory,fixed property level and percent-of-unagedproperty level are two end-of-life criteria that appearto have the most significance in relation to end-useapplications. Tables 6a and 6b contain estimatedupper service temperatures depending on differentpossible end use requirements. These results areconsistent with the information provided graphicallyin Figures 18 and 19. Actual upper service tempera-tures may differ from the results in the table depend-ing on such factors as aging under load, chemicalexposure, support from substrate, etc. These upperservice temperatures should be used as guidelines.End use performance testing should be done toverify the acceptability of Tefzel for each specificapplication.

13

Table 6aEstimated Upper Service Temperatures (C), No Load Thermal Aging

End-of-Life Criterion Based on Elongation

End-of-Life Criterion Exposure Time, hr

ElongationActual Elongation Retained, % 1000 3000 10k 20k* 50k* 100k*

135% 50 210 195 172 159 143 13250% 18 ** 211 188 175 158 14725% 9 ** ** 196 182 165 153

**These estimates were extrapolated from 10,000 hour aging results.**Estimates are not available for these exposure regions.

Table 6bEstimated Upper Service Temperatures (C), No Load Thermal Aging

End-of-Life Criterion Based on Tensile Strength

End-of-Life Criterion Exposure Time, hr

TensileActual Tensile Strength Strength Retained, % 10k 20k* 50k* 100k*

3,750 psi 50 190 176 159 1472,000 psi 27 204 190 172 158

*These estimates were extrapolated from 10,000 hour aging results.

One conventional definition of upper service tem-perature is the lowest temperature at which one ofthe key physical properties is diminished by one halfafter 20,000 hours. Using Tables 6a and 6b, Tefzel200 has a 20,000 hour half-life temperature of ap-proximately 159C (318F). (For Tefzel, elonga-tion decreases faster than tensile strength, thus the20,000 hour half life for tensile strength is 176C[349F].)Another definition of upper service temperature isthe temperature at which the elongation drops to50% after 20,000 exposure hours. The expectedupper service temperature would be 175C (347F)(see Table 6a).

Electrical PropertiesTefzel exhibits high resistivity and low losses.Tefzel has a dielectric constant of 2.52.6 at fre-quencies below 10 MHz. At higher frequencies, the

value decreases to approximately 2.3 at 10 GHz.The dissipation factor is below 0.001 at low fre-quencies but gradually increases to a peak at about0.023 at approximately 100 MHz, after which itdecreases to below 0.01 at 10 GHz. The changes areshown graphically in Figures 13 and 14. The effectsof both frequency and temperature on both dielectricconstant and dissipation for Tefzel 200 are shownin Figures 15 and 16. Values for Tefzel 280 andTefzel 210 are similar.The dielectric breakdown strength at various thick-ness levels is shown in Figure 17.The addition of glass reinforcement raises the lossesof Tefzel HT-2004 as would be expected.As with other materials, exposure to radiation raisesthe losses.

14

Figure 13. DuPont Tefzel 200 Dielectric ConstantRoom Temperature

2 4 6 8 10

10k 1M 100M 10G 1k 100k 10M 1G

Die

lect

ric C

onst

ant

Log Frequency, Hz

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.0

3.0

15

Figure 14. DuPont Tefzel 200Dissipation FactorRoom Temperature

Figure 15. DuPont Tefzel 200Dielectric ConstantElevated Temperature

00.0020.0040.0060.0080.0100.0120.0140.0160.0180.0200.0220.0240.0260.0280.030

2 4 6 8 10

1M 100M 10G10M 1G

Dis

sipa

tion

Fact

or

Log Frequency, Hz

2 4 6 8 10

1k 100k 10M 1G10k 1M 100M 10G

Die

lect

ric C

onst

ant

Log Frequency, Hz

22C (72F)

150C (302F)

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

3.0

2.0

16

Figure 16. DuPont Tefzel 200Dissipation FactorElevated Temperature

Figure 17. Dielectric Breakdown Strength at Various Thickness Levels for DuPont Tefzel 200 and 280

0

0.010

0.020

0.030

0.040

0.050

2 4 6 8 10

1M 100M 10G10M 1G

Dis

sipa

tion

Fact

or

22C (72F)

Log Frequency, Hz

150C (302F)

Thickness, mil (mm)

300

400

500

600

700800900

1,000

2,000

Die

lect

ric S

treng

th, V

/mil

5 25 45 65 85 105 125(0.125) (0.625) (1.125) (1.625) (2.125) (2.625) (3.125)

17

Environmental EffectsEnvironmental behavior refers to the reaction ofTefzel when exposed to chemicals, sunlight, mois-ture, radiation (gamma or electron beam), or theeffects of temperature aging.

Chemical ResistanceTefzel has outstanding resistance to attack bychemicals and solvents that often cause rapid dete-rioration of other plastic materials. It is surpassedonly by Teflon in resistance to chemicals. Tefzelis inert to many strong mineral acids, inorganicbases, halogens and metal salt solutions. Carboxylicacids, anhydrides, aromatic and aliphatic hydrocar-bons, alcohols, aldehydes, ketones, ethers, esters,chlorocarbons, and classic polymer solvents havelittle effect on Tefzel. Under highly stressed condi-tions, some very low surface tension solvents tend toreduce the stress-crack resistance of the lower mo-lecular weight products. Very strong oxidizing acidssuch as nitric, organic bases such as amines, andsulfonic acids at high concentrations and near theirboiling points will affect Tefzel to varying degrees.Tefzel HT-2004 shows chemical resistance similarto the base fluoropolymer, except in cases wherereinforcing glass may be attacked by the chemicalmedia. There is evidence that strong oxidizingagents, particularly at high temperatures, will attackthe bond between the glass and polymer causing areduction in reinforcement.Table 7 presents data on the effect of variouschemicals on the tensile properties of Tefzel andthe weight gain, if any, during exposure.

Hydrolytic Stability and WaterAbsorptionHydrolytic stability is indicated by lack of deteri-oration in physical properties after long periods ofexposure to boiling water.Using room temperature tensile strength and elonga-tion as control properties, Tefzel 200 is essentiallyunaffected after 3,000 hours exposure to boilingwater. Tefzel 280 behaves similarly.Tefzel HT-2004 shows a decrease in tensilestrength of 2535% after 3,000 hours exposure

to boiling water. The composition loses its rein-forcement characteristics but the actual polymerdoes not appear to be affected. Data are shown inTable 8.Water absorption for unfilled Tefzel is less than0.03% by weight as determined by ASTM D570.

Weather ResistanceTefzel has excellent resistance to outdoor weather-ing. Long-term outdoor exposures show little detri-mental effects.

Effects of RadiationTefzel is much more resistant to electron beamand gamma radiation than is Teflon fluoropolymerresin. Tests have shown that both elevated tempera-tures and the presence of oxygen have a deleteriouseffect on physical properties when Tefzel is ex-posed to gamma radiation. The effect on physicalproperties is significantly decreased in an inertatmosphere, such as nitrogen.Tefzel appears to be degraded much less withelectron beam radiation than with gamma radiationat equivalent levels of total exposure. The differ-ence is probably due to the much higher dosagerate under electron beam conditions. The higherdosage rate apparently allows crosslinking reac-tions to predominate while the much slower rateunder gamma radiation apparently allows compet-ing oxidation and degradation reactions to predomi-nate. Controlled exposure to low levels of electronbeam radiation, especially in inert atmospheres,appears to result in a low level of cross-linkingwith an inherent improvement in some properties.However, exposure beyond the low level controlledconditions results in detrimental effects on physicalproperties. As with gamma radiation, oxidationreactions are inhibited under inert atmospheres.

Vacuum OutgassingUnder vacuum conditions, Tefzel 200 and Tefzel280 give off little gas at recommended maximumuse temperatures. Values for Tefzel are compa-rable to Teflon. Data are given in Table 9.

Table 7Actual Laboratory Tests on

Chemical Compatibility of DuPont Tefzel with Representative Chemicals

Boiling TestPoint Temperature

Chemical C F C F DaysAcid/AnhydridesAcetic Acid (Glacial) 118 244 118 244 7 82 80 3.4Acetic Anhydride 139 282 139 282 7 100 100 0Trichloroacetic Acid 196 384 100 212 7 90 70 0Aliphatic HydrocarbonsMineral Oil 180 356 7 90 60 0Naphtha 100 212 7 100 100 0.5Aromatic HydrocarbonsBenzene 80 176 80 176 7 100 100 0Toluene 110 230 110 230 7 Functional AromaticsO-Cresol 191 376 180 356 7 100 100 0AminesAniline 185 365 120 248 7 81 99 2.7Aniline 185 365 120 248 30 93 82 Aniline 185 365 180 356 7 95 90 N-Methyl Aniline 195 383 120 248 7 85 95 N-Methyl Aniline 195 383 120 248 30 100 100 N, N-Dimethyl Aniline 190 374 120 248 7 82 97 n-Butylamine 78 172 78 172 7 71 73 4.4Di-n-Butylamine 159 318 120 248 7 81 96 Di-n-Butylamine 159 318 120 248 30 100 100 Di-n-Butylamine 159 318 160 320 7 55 75 Tri-n-Butylamine 216 421 120 248 7 81 80 Tri-n-Butylamine 216 421 120 248 30 100 100 Pyridine 116 240 116 240 7 100 100 1.5Chlorinated SolventsCarbon Tetrachloride 78 172 78 172 7 90 80 4.5Chloroform 62 144 61 142 7 85 100 4.0Dichloroethylene 77 170 32 90 7 95 100 2.8Methylene Chloride 40 104 40 104 7 85 85 0Freon 113 46 115 46 115 7 100 100 0.8EthersTetrahydrofuran 66 151 66 151 7 86 93 3.5Aldehyde/KetonesAcetone 56 132 56 132 7 80 83 4.1Acetophenone 201 394 180 356 7 80 80 1.5Cyclohexanone 156 312 156 312 7 90 85 0Methyl Ethyl Ketone 80 176 80 176 7 100 100 0Estersn-Butyl Acetate 127 260 127 260 7 80 60 0Ethyl Acetate 77 170 77 170 7 85 60 0Polymer SolventsDimethylformamide 154 309 90 194 7 100 100 1.5Dimethylformamide 154 309 120 248 7 76 92 5.5Dimethylsulfoxide 189 373 90 194 7 95 90 1.5Other OrganicsBenzyl Alcohol 205 401 120 248 7 97 90 Benzoyl Chloride 197 387 120 248 7 94 95 Benzoyl Chloride 197 387 120 248 30 100 100 Decalin 190 374 120 248 7 89 95 Phthaloyl Chloride 276 529 120 248 30 100 100

Retained Properties, %Tensile Weight

Strength Elongation Gain

(continued)

18

Table 7Actual Laboratory Tests on

Chemical Compatibility of DuPont Tefzel with Representative Chemicals (continued)

Boiling TestPoint Temperature

Chemical C F C F Days

Retained Properties, %Tensile Weight

Strength Elongation Gain

AcidsHydrochloric (Conc) 106 223 23 73 7 100 90 0Hydrochloric (Conc) 106 223 106 223 7 96 100 0.1Hydrobromic (Conc) 125 257 125 257 7 100 100 Hydrofluoric (Conc) 23 73 7 97 95 0.1Sulfuric (Conc) 100 212 7 100 100 0Sulfuric (Conc) 120 248 7 98 95 0Sulfuric (Conc) 150 302 * 98 90 0Aqua Regia 90 194 * 93 89 0.2Nitric25% 100 212 100 212 14 100 100 Nitric50% 105 221 105 221 14 87 81 Nitric70% (Conc) 120 248 23 73 105 100 100 0.5Nitric70% (Conc) 120 248 60 140 53 100 100 Nitric70% (Conc) 120 248 120 248 2 72 91 Nitric70% (Conc) 120 248 120 248 3 58 5 Nitric70% (Conc) 120 248 120 248 7 0 0 Chromic 125 257 125 257 7 66 25 Phosphoric (Conc) 100 212 7 Phosphoric (Conc) 120 248 7 94 93 0HalogensBromine (Anhy) 59 138 23 73 7 90 90 1.2Bromine (Anhy) 59 138 57 135 7 99 100 Bromine (Anhy) 59 138 57 135 30 94 93 3.4Chlorine (Anhy) 120 248 7 85 84 7BasesAmmonium Hydroxide 66 150 7 97 97 0Potassium Hydroxide (20%) 100 212 7 100 100 0Sodium Hydroxide (50%) 120 248 7 94 80 0.2PeroxidesHydrogen Peroxide (30%) 23 73 7 99 98 0Salt-Metal EtchantsFerric Chloride (25%) 104 220 100 212 7 95 95 0Zinc Chloride (25%) 104 220 100 212 7 100 100 0Other InorganicsSulfuryl Chloride 68 115 68 155 7 86 100 8Phosphoric Trichloride 75 167 75 167 7 100 98 Phosphoric Oxychloride 104 220 104 220 7 100 100 Silicon Tetrachloride 60 140 60 140 7 100 100 Water 100 212 100 212 7 100 100 0MiscellaneousSkydrol 149 300 7 100 95 3.0Aerosafe 149 300 7 92 93 3.9A-20 Stripper Solution 140 284 7 90 90 *Exposed for 6 hours.NOTES: Change in properties -15% is considered insignificant. Samples were 1015 mil microtensile bars. TS/E and wt. gain

determined within 24 hours after removal from exposure media.

19

PermeabilityTests measured on 4 mil thick film per ASTMD1434 at 25C (77F) show the followingpermeabilities:

Permeability,Material cm3/100 in224 hatm/mil*Carbon Dioxide 250Nitrogen 30Oxygen 100*Multiply by 15.5 to obtain cm3/m2dayatm

Water vapor transmission by ASTM E96 is1.65 g/100 in224 h/mil.

Flame Resistance and SmokeTefzel is rated UL94 V-0 for unpigmented resinsdown to 0.062 in thick. Its limiting oxygen index(LOI) is 30 by ASTM D2863, which means that anatmosphere containing at least 30% oxygen is re-quired to maintain combustion in a downward burn-ing flame. By ASTM D635, Tefzel has an averagetime of burning (ATB) of less than 5 seconds and anaverage length of burn (ALB) of 10 mm (0.39 in).

Effects of Heat AgingMost polymeric materials are affected to some de-gree when exposed to elevated temperatures for longperiods of time.Figure 19 shows how room temperature tensilestrength is affected by exposure time and tempera-tures. These data were obtained on specimens ex-posed to no mechanical stress during aging and soare directly pertinent only to a device, e.g., a wire,which is exposed to temperature with little or noload, and then is mechanically stressed at room tem-perature.To demonstrate the use of Figure 19, determinewhat exposure at 135C (275F) will reduce tensilestrength to 3,000 psi. From these data, the answer isover 30 years. At 180C (356F), the time is justover 2 years. At the rated temperature of 150C(302F), the time is over 10 years.Figure 18 is a similar graph for room-temperatureelongation and is used in the same fashion as thetensile data in Figure 19.

Table 8Resistance to Boiling WaterDuPont Tefzel 200 and HT-2004

Product psi MPa Elongation, %

Tefzel 200 (no exposure) 5,800 40 1453,000 hours boiling water 5,790 40 135

Tefzel HT-2004 (no exposure) 11,890 82 71,000 hours exposure* 8,960 60 52,000 hours exposure* 8,360 57.6 53,000 hours exposure* 8,110 55.8 5*Measured at 23C (73F) after immersion in boiling water

Tensile Strength

Table 9Vacuum Outgassing

DuPont Tefzel 200 and Tefzel 280*

Weight Loss, %Maximum 0.12

Generally accepted maximum 1%Minimum 0.04Average 0.07

Volatile Condensable Material Weight (VCMW), %Maximum 0.02Minimum 0.00Average 0.01

*Tests consist of exposing 30 mil thick specimens for 24 hours ina hard vacuum at 149C (300F) and measuring weight loss andthe volatile gases that are collected in liquid air traps.

20

Figure 20 shows the effect of heat aging of TefzelHT-2004 on tensile properties aged at 204C(400F) and 230C (392F) with tensile measure-ments being made at both room temperature and150C (302F).The effect of heat aging on the impact strength ofTefzel HT-2004 is shown in Table 10.

Short-term exposure at 150C (302F) causes nomeasurable loss of impact strength while such expo-sure at 180C (356F) does cause a small decrease.

21

Figure 19. Retention of Room Temperature TensileStrength After AgingDuPont Tefzel 200

Figure 18. Retention of Room Temperature TensileElongation After AgingDuPont Tefzel 200

TEMP. VS. TIME

6 Mos.

1 Yr.

2 Yrs.

5 Yrs.

10 Yrs.

20 Yrs.

50 Yrs.Ex

posu

re, h

r

EXPOSURE TEMP. VS. TIMEINITIAL ELONG. = 275%

NO LOAD DURING AGINGABSCISSAE PLOTTED ON 1/ K SCALE

Exposure Temperature, C (F)

102

104

106

105

2 Mos.

1 Mo.

ELONGATION ATROOM TEMP. AT END OF AGING, %

2550

75100125150175200

225

250

135(275)

140(284)

150(302)

160(320)

170(338)

180(356)

190(374)

200(392)

103

TEMP. VS. TIME

6 Mos.

1 Yr.

2 Yrs.

5 Yrs.

10 Yrs.

20 Yrs.

50 Yrs.

Expo

sure

, hr

EXPOSURE TEMP. VS. TIMEINITIAL T.S. = 7,500 PSI

NO LOAD DURING AGINGABSCISSAE PLOTTED ON 1/ K SCALE

ROOM TEMPERATURETENSILE STRENGTH, PSIAT END OF AGING PERIOD

2,0003,0003,7505,000

6,000

1,000500

Exposure Temperature, C (F)

103135

(275)140

(284)150

(302)160

(320)170

(338)180

(356)190

(374)200

(392)

104

105

106

22

Figure 20. Effect of Heating of DuPont Tefzel HT-2004 (All values of elongation between 5 and 10%regardless of test temperature) (no load during aging)

14,000

12,000

10,000

4,000

2,000

TensileStrength

Measuredat 23C(73F),

psi

TensileStrength

Measuredat 150C(302F),

psi

980

840

700

280

140

10 100 1,000 10,000

TensileStrengthat 23C(73F),kg/cm2

TensileStrengthat 150C(302F),kg/cm2

Aged at204C (399F)230C (446F)

Same Curves for Aging at150 230C (302 446F)

Exposure Time, hr

Loss of Weight with AgingThe weight loss of Tefzel below the melting pointis from 0.1 to 0.3% most of which is moisture.The weight loss above 300C (572F) is shown inTable 11.

Table 10Effect of Temperature Aging on Izod Impact Strength, DuPont Tefzel HT-2004

Temperature Izod Impact Strength

C F Aging J/m ftlb/in

23 73 as molded 491 9.123 73 168 hours at 150C (302F) 491 9.123 73 168 hours at 180C (356F) 416 7.7

Table 11Initial Weight Loss of DuPont Tefzel Resins

Above 300C (572F)

Tefzel 200C F wt loss, %/hr

300 572 0.05330 626 0.26350 662 0.86370 698 1.60

Temperature

24

Figure 21. Infrared Scan of DuPont Tefzel, 0.025 mm (1 mil)

Table 12Transmittance vs. Wavelength Data Normalized

to 0.025 mm (1.0 mil) Films (Beers Law)Tefzel Film

Wavelength, nm Transmittance, %*Ultraviolet Range

200 91.5250 92300 92350 93400 94

Visible Range500 94600 94700 95800 95

* Hitachi Model V-3210 spectrometer with 60 mm diameter,151-0030 integrating sphere, scan speed 60 mm/min

Optical PropertiesData on percent transmittance vs. wavelength isgiven in Table 12. Figure 21 shows a typical infra-red scan of Tefzel films.

Wave Number, cm1

Tran

smitt

ance

, %

4,000 3,300 2,600 2,050 1,700 1,350 1,000 825 650 4000

6.9

13.8

20.7

27.6

34.5

41.5

Fabrication TechniquesTefzel, as a thermoplastic polymer, can be pro-cessed by most techniques applicable to this type ofresin. Included are: Injection molding Compression molding Rotational molding ExtrusionTefzel can also be formed, machined, colored, andprinted upon using techniques described in appropri-ate processing bulletins.

Assembly TechniquesThe success of many applications depends on theability of Tefzel to be economically assembledusing one or more of a variety of assembly tech-niques. Some of these techniques suitable forTefzel compositions are described below. Moreinformation or assistance in evaluating these for usein specific projects involving Tefzel is availablethrough your DuPont representative.

Screw AssembliesSelf-tapping screws are used for joining parts ofTefzel. Either of two types (the thread cutting,which taps a mating thread as the screw is driven,or the thread forming that mechanically displacesmaterial as the screw is driven) can reduce assemblycost.

A rule of thumb is that the boss diameter should beabout 2-1/2 times the screw diameter for maximumholding power. Lubricants should be avoided formaximum stripping torque.Threaded inserts are also used. They can be moldedin place, pressed in, or driven in ultrasonically.

24

Snap-FitThe advantage of snap-fit joints is that the strengthof the joint does not diminish with time becauseof creep. The lower ductility of Tefzel HT-2004suggests that other assembly methods be used forthis product, although snap-fits are possible at lowstrains.Two types of snap-fits are:1. A cylindrical snap-fit for joining a steel shaft

and a hub of Tefzel.2. A cantilevered lug snap-fit for inserting a

Tefzel part into another part.In a cylindrical snap-fit joint (Figure 22), the maxi-mum strain at the inside of the hub is the ratio ofinterface (I) to diameter (Ds) (x 100 for percent).A maximum strain of about 5% is suggested.

Max. Strain = I/Ds x 100 - 5%For the cantilevered lug snap-fit joint, the maximumstrain is expressed by the equation:

Max. Strain = 3Yh/2L2 x 100 < 5%Again, a 5% maximum strain is suggested.

Press FitPress fit joints are simple and inexpensive, however,the holding power is reduced with time. Creep andstress relaxation reduce the effective interference asdo temperature excursions particularly when materi-als with different thermal expansions are joined.With Tefzel joined to Tefzel, the press fit jointmay be designed with an interference resulting instrains of 67%.

Strain = Interference (on diameter) x 100Shaft Diameter

Shaft DiameterIf a part of Tefzel and one of metal are to bejoined, lower strain levels may be used.Assembly can often be made easier by inserting acooled part into a heated hub.

Cold or Hot HeadingRivets or studs can be used in forming permanentmechanical joints. The heading is accomplishedwith special tools and preferably with the rivet atelevated temperatures.Formed heads tend to recover part of their originalshape if exposed to elevated temperatures, so jointscan become loose. Forming at elevated tempera-tures tends to reduce recovery.

25

Spin WeldingSpin welding is an efficient assembly techniquefor joining circular surfaces of similar materials.The matching surfaces are rotated at high speedrelative to each other (one surface is fixed) and thenbrought into contact. Frictional heat melts the inter-face and when motion is stopped, the weld is al-lowed to solidify under pressure.

Ultrasonic WeldingThe ultrasonic welding of Tefzel has been demon-strated with weld strengths up to 80% of thestrength of the base resin. The success of develop-ments involving this technique depends upon jointdesign and the experimentally-determined weldingparameters of contact time and pressure. Typicalwelding conditions are 25 psi contact pressure andone- or two-second cycle time. Both employ a smallinitial contact area to concentrate and direct thehigh-frequency vibrational energy.

Figure 22. Snap-Fit Joints

Ds

I2

45

30 LeadAngle

Shaft

Return Angle

Ds Dh

LeadAngle

Hub

y

L

h

LeadAngle

Cantilevered Lug Snap-Fit Joint

ReturnAngle

Cylindrical Snap-Fit JointReturn Angle

PottingPotting of wires insulated with Tefzel has beenaccomplished with the aid of a coating of a colloidalsilica dispersion using various polysulfide pottingcompounds. Such pretreatment tends to increase thepull-out strengths by 25 to 50%.

Adhesive BondingBecause of the outstanding chemical resistance ofTefzel, surface treatment is required to allow adhe-sive bonding. Chemical etch, corona, or flame treat-ments can be used to make surfaces of Tefzel morereceptive to adhesives. Polyester and epoxy com-pounds are suitable adhesives when surfaces areproperly prepared.

Melt BondingTefzel responds well to melt bonding. It has beenbonded to untreated aluminum, steel, and copperwith peel strengths in excess of 20 lb/in. It can alsobe melt bonded to itself using such techniques as hotplate welding.The bond is achieved by heating the materials to270275C (520530F), then pressing the partstogether during cooling.

Safety PrecautionsWARNING!

VAPORS CAN BE LIBERATED WHICHMAY BE HAZARDOUS IF INHALED.Before using Tefzel, read the detailed information inthe Guide to the Safe Handling of FluoropolymerResins, latest edition, published by the Fluoro-polymers Division of The Society of the PlasticsIndustryavailable from DuPont.Open and use containers only in well-ventilatedareas using local exhaust ventilation (LEV). Vaporsand fumes liberated during hot processing, or fromsmoking tobacco or cigarettes contaminated withTefzel, may cause flu-like symptoms (chills, fever,sore throat) that may not occur until several hoursafter exposure and that typically pass within about24 hours. Vapors and fumes liberated during hotprocessing should be exhausted completely from thework area; contamination of tobacco with polymersshould be avoided.Mixtures with some finely divided metals, such asmagnesium or aluminum, can be flammable or ex-plosive under some conditions.

26

27

Typical ApplicationsNo other plastic resin comes as close to thefluoropolymers in chemical and electrical propertieswhile providing a high level of mechanical rugged-ness and easy, economical processing. Tefzelallows a range of opportunities for design engineersto achieve better product performance in manyapplication areas.

BearingsGlass-reinforced Tefzel is suited for load bearingapplications in abusive environments. A low wearfactor (one-tenth that of reinforced nylon) andgood creep resistance make it an excellent bearingmaterial.

FastenersCable and hydraulic line clamps, cable straps, andother fasteners molded of Tefzel perform in hightemperature, corrosive environments. Nuclearapplications are possible because of the radiationresistance of Tefzel. Moisture absorption is low,providing uniformity of mechanical propertiesregardless of humidity. High impact strength andUV resistance are additional advantages.Outstanding electrical properties, solvent resistance,an SE-O flammability rating,* and excellent hightemperature aging characteristics make Tefzel anideal material for high performance electrical com-ponents. Coil forms, connectors, encapsulated parts,sockets, and insulators are typical applications.

Valve LiningsTefzel has replaced other polymers and glass as avalve lining. The outstanding resistance of Tefzelto acids, bases, and solvents over a broad tempera-ture range, combined with abrasion resistance andease of processing, results in a durable and economi-cal valve.

Film Form AvailableFilm of Tefzel can be heat sealed, thermoformed,welded, heat laminated, and coated to make pres-sure-sensitive tapes, flexible printed circuits, liquidpouches, and other constructions where strength,thermal resistance, and electrical integrity arerequired.

TubingHeat-shrinkable, plain, and corrugated tubing isavailable in a wide range of thicknesses and di-ameters. It is being used at high temperatures aselectrical insulation and in service with strongchemicals.Heat-shrinkable tubing conforms to electricalterminations, hose connections, and other compo-nents to insulate, guard against abrasion, andprevent corrosion.

Wire and CableTough insulation of Tefzel is being used on con-ductors ranging from AWG #30 for wrapped com-puter terminations to 535 MCM for heavy powercircuits. Tefzel is performing well on steel millcables, airframe wire, down-hole oil well loggingcable, rapid transit car and locomotive control wire,and other rugged service wire and cable. It is receiv-ing special consideration for use in nuclear powerplants and other areas where exposure to radiationmay be encountered.

Biomedical/LabwareHigh impact strength, chemical resistance, resis-tance to high heat sterilization, and ease of process-ing are properties needed for biomedical andlabware applications. Oxygen respirator compo-nents, blood analyzer valves, evaporating dishes,and centrifuge tubes are examples.

Pump ComponentsChemical resistance, dimensional stability, andstructural strength make Tefzel a candidate forpump impellers, vanes, gears, and bodies.

* Numerical flame spread ratings are not intended to reflect hazardspresented by this or any other material under actual fire conditions.

(11/03) RWJ223 Printed in U.S.A.[Replaces: H-96518]Reorder No.: H-96518-1

For more information on Fluoroproducts: (302) 479-7731DuPont FluoroproductsP.O. Box 80713Wilmington, DE 19880-0713www.teflon.com

EuropeDuPont de Nemours Intl SADuPont Fluoroproducts2, chemin du PavillonP.O. Box 50CH-1218 Le Grand-SaconnexGeneva, Switzerland(022) 7175111

JapanDuPont MitsuiFluorochemicals Co., Ltd.Chiyoda Honsha Building518, Sarugaku-cho 1-chomeChiyoda-ku, Tokyo 101 Japan81-3-5281-5872

Asia PacificDuPont China, Limited26/F., Tower 6, The Gateway9 Canton Road, TsimshatsuiKowloon, Hong Kong(852) 27341948Tim-S.T.Leung@hkg.dupont.com

CanadaDuPont Canada, Inc.DuPont FluoroproductsP.O. Box 2200, Streetsville7070 Mississauga RoadMississauga, Ontario, CanadaL5M 2H3(905) 821-5194

South AmericaDuPont do Brasil S/AFluoropolymersAlameda Itapecuru, 50606454-080 - AlphavilleP.O. Box 263Barueri, Sao Paulo, Brazil0800-171715Produtos.Brazil@bra.dupont.com

The information set forth herein is furnished free of charge and is based on technical data that DuPont believes to be reliable. It is intended for use by personshaving technical skill, at their own discretion and risk. The handling precaution information contained herein is given with the understanding that those usingit will satisfy themselves that their particular conditions of use present no health or safety hazards. Because conditions of product use are outsideour control, we make no warranties, express or implied, and assume no liability in connection with any use of this information. As with any material,evaluation of any compound under end-use conditions prior to specification is essential. Nothing herein is to be taken as a license to operateunder or a recommendation to infringe any patents.

CAUTION: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, see DuPontMedical Caution Statement, H-50102.