Advanced engineering plastics in High Tech Applications ...
Transcript of Advanced engineering plastics in High Tech Applications ...
Advanced engineering plastics in High Tech Applications
Material selection for thermoplastics
By: Michiel de Schipper (M.Sc.Eng. In plastics)Business Development EngineerCell +31 6 51 50 24 [email protected]
Tielt / B Lenzburg / CH
Reading / USA
Vreden / D Tokyo / J
ReadingAmerican QEPP
Headquarter
Hong KongAsian QEPP
HeadquarterVreden
European QEPP Headquarter
ZurichGlobal
Headquarter
The Americas Europe International
Truly global development, supply and support capabilities
Our Worldwide Presence
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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TieltGlobal QCMS Headquarter
LenzburgGlobal QPC Headquarter
TokyoMPI/MCHC
Headquarter
Hong Kong / PRC
Quadrant EPP Market Focus
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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Chemical Processing
Construction & Heavy Equip.
Aerospace & Defence
Electronic & Semi Conductor
Food Processing & Packaging
Life Science
Alternative Energy
Radiation Shielding
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 4
6 basic steps for material selection in plastics
1. Static or dynamic use2. Temperatures during use3. Chemical exposure4. Other aspects
1. Impact resistance2. Dimensional stability3. UV / high-ionizing radiation resistance4. Flammability5. Electrical properties6. Industry-specific certifications / approvals
5. Base material selection (production process)6. Machine-ability
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 5
Dynamic (wear)Static (structural)
Step 1: Static or dynamic use
No elimination of materials yet. Select on structural properties:StrengthStiffness (allowable deformation). Loading timeTemperature
These can be enhanced by fillers:Glass fibersCarbon fibersMica / ceramics
Only choose the semi-crystalline materialsWear rateCoFPV capability
These can be enhanced by internal lubricants:Carbon fibers (!)GraphiteMoS2PTFEWaxOil
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 6
Tribological test proceduresimilar to Test Method A: “pin-on-disk”,
as described in ISO 7148-2:1999
Selection guidelines: sliding properties
Tribological test proceduresimilar to Test Method “Thrust Washer” as specified in ASTM D 3702
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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3 51
28
27
2
95 5
14
36
17
5
105
7
14
6
12
0
20
40
60
80
100
120
CELAZOLE PBI
TORLON 4
203 P
AI
TORLON 43
01 P
AI
KETRON PEEK-1
000
KETRON PEEK-H
PV
KETRON PEEK-G
F30
KETRON PEEK-C
A30
KETRON PEEK-T
X
TECHTRON HPV P
PS
RADEL PPSU 10
00
ULTEM P
EI 100
0PSU 10
00
SYMALIT P
VDF 1000
FLUOROSINT 20
7
PA 66
PET
PTFE
Wea
r ra
te (
µm/k
m)
2500 ⇑
6400 ⇑
1325 ⇑
455 ⇑
WEAR RESISTANCE OF THE QUADRANT AEP(measured on a "plastics pin on rotating steel disk " - tribo system)
1600 ⇑
at 23°C
at 150°C (*)
(*) steel disk heated to 150°C
Test conditions: - pressure: 3 MPa - sliding velocity: 0.33 m/s - surface roughness of the C35 steel mating surface: Ra = 0.70 - 0.90 µm - total distance run: 28 km - normal environment (air, 23°C/50% RH) - unlubricated operation
Wear rates including influence of temperature
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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Step 2: Temperature influences
Determine continuous use and peak temperaturesAllowable Temperature in Air Defines the maximum temperature based on thermal-oxidative
behaviour Based on 50% reduction in Tensile Strength Usually 2 values: short term (few hours) and long term (10.000
hrs) Not a constant; varies by magnitude & duration of mech load Non reversible !
HDT (Heat Deflection Temperature) Defines the maximum temperature up to which average
mechanically loaded parts can be used as construction material Is reversible
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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0
50
100
150
200
250
300
350
400
450
0 50 100 150 200 250 300 350
Max. allowable service temperature in air (continuo usly for min. 20,000h) - (°C)
QUADRANT 1000 PSU KETRON 1000 PEEK
KETRON HPV PEEK
ERTALYTE
ERTALON 6 SA
DURATRON T4203/4301/5530 PAI
SYMALIT 1000 PVDF
DURATRON CU60 PBI
KETRON TX PEEK
FLUOROSINT 207TECHTRON HPV PPS
KETRON GF30 PEEK QUADRANT PPSUDURATRON U1000 PEI
FLUOROSINT 500
Tem
pera
ture
of d
efle
ctio
n un
der
load
acc
. to
ISO
75
M
etho
d A
: 1.8
MP
a (
°C)
KETRON CA30 PEEK
FLUOROSINT HPV
DURATRON D7000 PIDURATRON D7015G PI
SYMALIT 1000 PFASYMALIT 1000 ECTFE
TEMPERATURE OF DEFLECTION UNDER LOAD VERSUS MAX. ALLOWABLE SERVICE TEMPERATURE IN AIR
Selection guidelines: thermal properties
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
-50 0 50 100 150 200 250 300
Temperature (°C)
Mod
ulus
of e
last
icity
(M
Pa)
KETRON 1000 PEEK
KETRON HPV PEEK
KETRON GF30 PEEK
KETRON CA30 PEEK
KETRON TX PEEK
TECHTRON HPV PPS
ERTACETAL C
STIFFNESS VERSUS TEMPERATURE (derived from DMA-curves)
Selection guidelines: structural properties AEP
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 14
0
1000
2000
3000
4000
5000
6000
7000
8000
-50 0 50 100 150 200 250 300 350
Temperature (°C)
Mod
ulus
of e
last
icity
(M
Pa)
DURATRON CU60 PBI
DURATRON D7000 PI
DURATRON D7015G PI
DURATRON T4203 PAI
DURATRON T4301 PAI
DURATRON T5530 PAI
ERTACETAL C
STIFFNESS VERSUS TEMPERATURE (derived from DMA-curves)
Selection guidelines: structural properties AEP
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Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 15
Effect of temperature (& time) on creep / relaxation of mainly unfilled plastics
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 16
Minimum service temperatures - all
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TIVAR 1000 is only materialthat can beused down to-200°C
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 17
Step 3: Chemicals
Determine chemical resistance needed: During useDuring cleaning of parts after useHydrolisis / steam sterilisation / autoclave abilityUV and radiation resistance
Always check both PH value (indicational only) but also full chemical resistance listGeneral rules: all 4P (PE, PA, POM, PET) are suitable for standard industrial
use, with reasonable chemical resistance Semi-crystalline materials show better chemical resistance
than amorphous materials.
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Slide 18 Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Thickness Loss in Oxygen Plasma – Extreme Conditions
Chamber Conditions
• 2.5 KW
• O2 2000 sccm
• 0.4 Torr
• um per hour
MPR-1000 has less than 0.8 um/hr erosion in 2.5 KW O2, 25X better than PI
Semitron® MPR-1000 OEM plasma data
Displays mass loss – All samples started approximately the same size
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 19
Semitron® MPR-1000 data
MPR -1000 much lower metal content when adjusted to mass loss in chamber
Ratio of Ionic Purity Data Adjusted for Mass Loss During Erosion
1KW 1200 sccm O3
Element UnitsMPR-1000
Vespel SP1
Ketron PEEK
Aluminum (Al) ppm 0.14 6.11 6.89Barium (Ba) ppm 0.07 0.65 0.36Calcium (Ca) ppm 2.8 0.13 145.12Chromium (Cr) ppm 2.6 0.13 8.89Copper (Cu) ppm 0.14 0.65 3.63Iron (Fe) ppm 2.3 4.68 108.84Lead (Pb) ppm 0 0.65 0.09Lithium (Li) ppm 0 0.65 0.09Magnesium (Mg) ppm 0.3 3.64 14.51Manganese (Mn) ppm 0.11 0.26 3.63Nickel (Ni) ppm 0.36 0.26 7.62Potassium (K) ppm 0.77 1.69 29.02Sodium (Na) ppm 4.4 5.72 8707.20Strontium (Sr) ppm 0.04 0.65 10.88Titanium (Ti) ppm 0.12 0.65 3.27Zinc (Zn) ppm 0 0.26 2.72
2KW 1200 sccm O3
Element UnitsMPR-1000
Vespel SP1
Ketron PEEK
Aluminum (Al) ppm 0.14 2.96 3.72Barium (Ba) ppm 0.07 0.32 0.20Calcium (Ca) ppm 2.8 0.06 78.40Chromium (Cr) ppm 2.6 0.06 4.80Copper (Cu) ppm 0.14 0.32 1.96Iron (Fe) ppm 2.3 2.27 58.80Lead (Pb) ppm 0 0.32 0.05Lithium (Li) ppm 0 0.32 0.05Magnesium (Mg) ppm 0.3 1.76 7.84Manganese (Mn) ppm 0.11 0.13 1.96Nickel (Ni) ppm 0.36 0.13 4.12Potassium (K) ppm 0.77 0.82 15.68Sodium (Na) ppm 4.4 2.77 4704.00Strontium (Sr) ppm 0.04 0.32 5.88Titanium (Ti) ppm 0.12 0.32 1.76Zinc (Zn) ppm 0 0.13 1.47
1KW 1200 sccm O2 2KW 1200 sccm O2
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
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Number of cyclesMaterial 0 50 100 250 500
ACETRON LSG 100 83 80 58 xErtalyte 100 100 32 28 xPSU 1000 LSG 100 x x 62 54PEI 1000 LSG 100 x x 95 94PVDF 1000 100 x x 105 100PPSU 1000 LSG 100 x x 102 102Techtron HPV PPS 100 x x 65 70Ketron PEEK 1000 LSG 100 x x 105 102
The table below shows the effect of repeated steam sterilisation on the Charpy notched impact strength (ISO 179/1eA). The values in this table show the retention of the notched impact resistance in % of the original value after a certain number of cycles
• The test results clearly show that PVDF 1000, PEI 1000 LSG, Ketron PEEK 1000 LSG and PPSU 1000 LSG are very suitable for repeated steam sterilisation
• PSU 1000 LSG and Techtron HPV PPS also offer a good autoclavability up to 500 cycles• Acetron LSG and Ertalyte can be used for parts, which will only be steam sterilised a few
times
Chemical Resistance ∾ Steam Sterilization
Slide 21
Brachy Therapy Prostate Stepper – Quadrant® LSG Naturel PPSU
Application:For treatment of cancer (Brachytherapy), a radioactive probe is positioned into the body to attack the cancer.In the case of prostate cancer, a stepper template is used to position this radioactive probe at the right spot, and its position can be checked by X-rays.After the treatment, the part is cleaned by harsh medical cleaners, plus high temperature autoclave cycle.
Why Quadrant® LSG Naturel PPSU for this application? Biocompatibility
(USP XXIII Class VI and ISO 10993-10 and -11compliant)
Excellent resistance against steam autoclaving
Excellent impact resistance Stepper templates from Nucletron B.V.
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 22
Selection guidelines: miscellaneous
Consider additional material characteristics:
Toughness and impact strength / notch sensitivity
Dimensional stability (thermal expansion and moisture absorption)
Regulatory/agency compliance (food contact, biocompatibility, …)
Flammability
Electrical properties (insulating, anti-static)
Others (UV-resistance, resistance against high ionising radiation, resistance against steam sterilisation, outgassing, …)
STEP 4
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 23
FLAMMABILITY
(*): there are no "UL File Numbers" for these stock shapes
1.5 mm 3 mm
DURATRON CU60 PBI V-0 V-0 58 DURATRON D7000 PI V-0 V-0 51 DURATRON D7015G PI V-0 V-0 47 DURATRON T4203 & T4503 PAI V-0 V-0 45 DURATRON T4301 & T4501 PAI V-0 V-0 44 DURATRON T5530 PAI V-0 V-0 50 KETRON 1000 PEEK V-0 V-0 35 KETRON HPV PEEK V-0 V-0 43 KETRON GF30 & CA30 PEEK V-0 V-0 40 KETRON TX PEEK V-0 V-0 40 TECHTRON HPV PPS V-0 V-0 44 QUADRANT PPSU V-0 V-0 38 QUADRANT 1000 PSU HB HB 30 DURATRON U1000 PEI V-0 V-0 47 SYMALIT 1000 PVDF V-0 V-0 44 SYMALIT 1000 ECTFE V-0 V-0 52 SYMALIT 1000 PFA V-0 V-0 ≥ 95 FLUOROSINT V-0 V-0 ≥ 95
OXYGEN INDEX (%) according to
ASTM D 2863 & ISO 4589
FLAMMABILITY RATING (*)according to UL 94
thickness
Selection guidelines: miscellaneous AEP
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 24
1 gray = 100 rad
106 gray = 100 Mrad
1 Mrad = 10 kJ/kg
The Radiation Index (RI) is defined as the logarithm, base 10, of the absorbed dose in grays at which theflexural stress at break or flexural strain at break of the tested material is reduced to 50% of its originalvalue, under specified conditions of irradiation (the most radiation-sensitive of these two properties ischosen as the reference critical property).
6,5
5,8 6
7,1 7,1 7,1
0
1
2
3
4
5
6
7
8
RADIATION RESISTANCE(Gamma -rays)R
adia
tion
Inde
x -
Log(
gray
)
≈ ≈ ≈ ≈ 3
> > > > 7,5 > > > > 7,5≥ ≥ ≥ ≥ 7≥ ≥ ≥ ≥ 7
≈ ≈ ≈ ≈ 4
≥ ≥ ≥ ≥ 6
≈ ≈ ≈ ≈ 5
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 25
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 10 20 30 40 50 60
Test specimen thickness (mm)
Tra
nspa
renc
y (%
)
KETRON PEEK-CLASSIX LSG white
KETRON PEEK-GF30 LSG blue
KETRON PEEK LSG & PEEK-CA 30 LSG
TECHTRON HPV LSG
RADEL PPSU LSG black
PC LSG natural
ACETRON LSG
TRANSPARENCY OF THE QEPP LIFE SCIENCE GRADES TO HIG H ENERGY RADIATION AS A FUNCTION OF THE TEST PLATE THICKNESS (measured at 23°C, applying an energy level of 59 keV*)
* This energy level corresponds with the typical level used in X-ray medical diagnostic equipment (λ = 21 pm).
Life Science ∾∾∾∾ X-Ray transparency / thickness
[Surgical Instruments - Osteosythesis]
[Application: Target Devices in Osteosynthesis]Material [KETRON® PEEK CA 30 LSG and Ketron ® PEEK CC]Processes [Extrusion, Bonding, High Precision Machining]
Target devices are used to help the surgeon to fix the bone in the exact position and need to be very precise and resistant to high press ure.
Properties and benefits of the selected material:
Radiolucency of the material providing visibility during surgery Excellent mechanical strength and stiffness and creep resistance High E-Modulus (PEEK CA30 = 9,2 Gpa at 23 °C, while PEEK CC = 70GPa) &
extremely high dimensional stability Biocompatibility according to ISO 10993 and USP Class VI requirements
(suitability for body contact up to 24 hrs)
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 26
Ketron CC PEEK (PEEK + continuous carbon fiber)
Extreme stiffnessLow densityPressed in laminatesup to 2” thickness, suitable for machining
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 27
Stiffness indices
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Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 28
key properties on stiffness E/ρ
E/ρ
(indexed;
alu=100%) E^0,5/ρ
E 0,5/ρ
(indexed;
alu=100%) E^0,333/ρ
E^0,3333/ρ
(indexed;
alu=100%)
Materialstiffness [Gpa]
Density [kg/dm3]
CLTE [m/mK]
stiffness (tensile bar)
stiffness (tensile bar)
stiffness (bending beam)
stiffness (bending beam)
stiffness (bending plate)
stiffness (bending plate)
Al 70 2,7 23 25,92593 100% 3,09874 100% 1,52638 100%
Mg 44 1,74 25 25,28736 98% 3,81221 123% 2,02891 133%
Fe 220 7,87 11 27,95426 108% 1,88468 61% 0,76705 50%
PE 500 1,3 0,96 150 1,35417 5% 1,18768 38% 1,13687 74%
TIVAR UHMWPE 0,75 0,93 200 0,80645 3% 0,93121 30% 0,97695 64%
Ertacetal C POM 2,80 1,41 110 1,98582 8% 1,18675 38% 0,99961 65%
Ertalyte PETP 3,50 1,39 60 2,51799 10% 1,34592 43% 1,09229 72%
Ketron 1000 PEEK 4,30 1,31 50 3,28244 13% 1,58293 51% 1,24132 81%
Ketron CA30 PEEK 9,20 1,40 25 6,57143 25% 2,16654 70% 1,49669 98%
Ketron CC PEEK 70,00 1,53 4 45,75163 176% 5,46837 176% 2,69361 176%
bestworst
ESd Materials for Semicon by Thermal Properties
Anti Static Properties
250°°°°C
100°°°°C
tem
pera
ture
Semitron ESd 520HR(PAI)
Semitron ESd 490HR(PEEK)
Semitron ESd 480(PEEK)
Semitron ESd 420 V(PEI)
Semitron ESd 420(PEI)
Ketron CA30 PEEK
Semitron ESd 410C(PEI)
Semitron ESd 225(POM)
102
106
1010
1012 (Ω / sq.)
HighResistancy
Range
Dissipative Range
Conductive Range
Semitron ESd 500(PTFE)
Semitron ESd 300(PET)
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 29
Slide 30
SEMITRON ESd 420 (black) - static dissipative PEI
Application:During production of TFT screens (used in mobile phones etc), the tester itself should be fully ESd. The tester should not be too conductive (shortcut) but also not too isolating (sparks).
Why SEMITRON ESd 420 for this application? Permanent static dissipative
(106 - 109 Ohm) Good machinability High stiffness Wear resistant Non-sloughing
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 31
Further Outgassing Data on other Quadrant material s…
Outgassing Values of the Quadrant Engineering Plastic Products’ stock shapes .
In 1995, a number of Quadrant Engineering Plastic Products’ stock shapes were tested according to the European Space Agency (ESA) - specification PSS-01 -702 (“A thermal vacuum test for the screening of space materials”). Samples were heated to 125°C for 24 hours, collector plates kept at 25°C and the testing carried out in a vacuum of 0,001 Pa.
MATERIALS TML (%) RML (%) CVCM (%)
Ertalon® 66 SA 1.3 .17 .002
Ertalon® 6 PLA 1.5 .06 .005
Ertacetal® C .34 .13 .016
Ertacetal® H .47 .24 .005
Ertalyte® .33 .20 .005
Ertalyte® TX .25 .03 .003
Ketron® 1000 PEEK .26 .03 .003
Ketron® HPV PEEK .16 .02 .003
Techtron® HPV PPS .06 .02 .003
Duratron® U1000 PEI .82 .32 .002
Quadrant® 1000 PSU .49 .09 .002
Symalit® 1000 PVDF .05 .02 .006
Duratron® T4203 PAl 1.9 .93 .007
Duratron® T4301 PAl 1.4 .42 .018
Duratron® CU60 PBI 2.2 .84 .014
TIVAR® 0.14 NT 0.02
TML = Total Mass Loss RML = Recovered Mass Loss CVCM = Collected Volatile Condensed Material NT = Not Tested
Outgas s ing (ASTM E595)
%TML %CVCM %WVR
Semitron ESD 225 1,000 0,054 0,603
Semitron ESD 410C 0,458 0,000 0,170
Semitron ESD 420 1,810 0,000 0,700
Semitron ESD 500 0,004 0,000 0,000
Semitron ESD 520HR 1,380 0,000 0,470
Techtron PPS 0,038 0,000 n/a
Torlon 5530 0,927 0,000 0,220
Vespel 0,750 0,000 0,490
Ketron peek 1000 0,310 0,000 0,160
Celazole PBI 2,513 0,000 0,388
Ertalyte PET-P 0,127 0,000 n/a
ASTM testing ESA testing
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Neutron Radiation Shielding
Alpha, Beta, and Gamma radiation can be blocked with material that has a high electron density (typically high atomic number materials such as lead)
Since neutrons have no charge, they are not effected by materials with high electron densities (such as lead). To slow neutrons down, they need to collide with similar size particles (such as hydrogen).
The process of slowing fast moving neutrons by collisions is called attenuation or thermalization
Once neutrons have been slowed down, they are called thermal neutrons can be absorbed by the surrounding materials atoms
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 32
Neutron Particle Through A High Electron Density Material (lead)
Since the nuclei of high electron density materials are significantly larger than the nucleus of the neutron particle, the neutron particle will not transfer a large amount of energy to the material particles when they collide.
Neutron Particle
Neutron Particle
Neutron Particle Through A High Hydrogen Density Material (PolyEthylene)
Since the neutron particle is a similar size to the hydrogen nucleus, every time they collide a significant amount of energy is transferred from the fast moving neutron to the surrounding hydrogen rich material.
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 33
Thermal Neutrons
After neutrons are slowed, they are absorbed by the surrounding material. This capture process generally leads the release of high-energy gamma rays (which are dangerous to humans).
If elemental boron is added to the shielding material, it can absorb these slow neutrons and significantly reduces the amount of gamma radiation released.
The most cost effective way to add elemental boron to shielding is to use Borontrioxide (also known as Boric Oxide or B2O3)
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 34
• Shielding
material
• Etx.
TIVAR Borotron® - Improved material technologyLife Science &
nuclear medicine
• Neutron Radiation shielding
material
• Low density and weight
• Neutron absorbing
Nuclear industryIn addition to existing sales in Borotron®, Quadrant has long-term experience in manufacturing and supply of PE-HMW and PE-UHMW products to one of the most sensitive radiation shielding applications:
Polyethylene shielding rods and lids in transportation casks for nuclear spent fuel and waste
extremely stringent quality and process control
validated processes
extensive application basedtesting (e.g. CLTE)
one-stop shop: - compression-molding- annealing under N2- machining- inspection and testing
Polyethylene based shielding material in transporta tion cask for nuclear spent fuel and waste (custom formulation) – 2 layers of rods as neutron shielding
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 35
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 37
Step 6: Production technology of part- machining
Annealing / tempering of base materials. Anticipate on expected internal stress levels.Add rough-machining step if tighter tolerances are requiredTolerances achieved: Total tolerance field = 0,1 – 0,2% of nominal size, with minimum 0,05 mm For Example: diameter 200: 0,2-0,4 mm total field. Best is: dia 200 +0,1 / -0,1 mm
Determine the machine-ability of the selected materialsCoolants:can lead to breakage (amorphous materials)Filled materials (glass, carbon, etc): more abrasive to cutting tools more sensitive for breaking
Special diamond tooling required (Duratron materials)
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 38
Very best tolerances possible (Technology Center)Best possible tolerances TC Tielt
0,00
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,10
0,11
0,12
0,13
0,14
0,15
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Dimension (mm)
Tot
al to
lera
nce
field
(m
m)
HD PE
standaard / PVDF
PA / POM / F207
PET / PC / PEEK / F500 / PPS / PEI / PPSU / PSU
gevulde PEEK
PAI / PBI
Default tolerance field
These better
tolerances only
possible at extra cost
Slide 39
Duratron® T4203 – Tracking detector clamps in proton collider
Application: Within the Atlas detector at CERN, the path of the particles, which are created during the collision, is measured by many surrounding sensors. These carbon sensors are mounted on a socket, which is made of Duratron T4203. Also the mounting rings on the Printed Circuit Board are made of Duratron T4203.
Material: Duratron® T4203.(plastic part 10 – 20 mm) Dimensional stability
High radiation resistance, and does not disturb measurements
Good mechanical properties (no metal inserts needed around screws)
No interference with protons (transparent)
Low outgassing at vacuumTuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 40
Reducing internal stresses
See on right: Extruded full rod Badly tempered rod cut over
length Quadrant tempered rod cut over
lengthInternal stress level difficult to measure & quantifyWhen ignored, result of machined part can be disasterousQuadrant focusses on lowest-stress materials for machining parts. The extra cost of fully tempered material is quickly regained by saving machining time
Some can do it cheaper... But at what cost?
Slide 41Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Tuesday 16 june 2015
Lecture by MdS: Advanced Engineering Plastics in High Tech applications
Slide 42
High Performance in Plastics
You inspire … we materialize®