ATTRIBUTES OF PEKK CO-POLYMER BASED...
Transcript of ATTRIBUTES OF PEKK CO-POLYMER BASED...
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ATTRIBUTES OF PEKK CO-POLYMER BASED
COMPOSITES
TIMOTHY A. SPAHR
BUSINESS DEVELOPMENT MANAGER - KEPSTAN®
ARKEMA INC.
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CHARACTERISTICS OF THEPEKK CO-POLYMER
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PEKK POLYMER CHARACTERISTICS
PEKK Co-Polymers are identified by their T/I ratio:
● T/I = 80/20, Semi-Crystalline Tg = 165°C Tm = 360°C Three Viscosities
● T/I = 70/30, Semi-Crystalline Tg = 162°C Tm = 335°C Two Viscosities
● T/I = 60/40, Semi-crystalline Tg = 160°C Tm = 305°C Three Viscosities
O C
O C
O
O C
O
C
O
T & I moieties give access to a Co-Polymer system
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CHEMICAL RESISTANCE
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PEKK CHEMICAL RESISTANCE TO AEROSPACE FLUIDS
PEKK Weight Gain %
Fluid Temp DaysKEPSTAN
6002
KEPSTAN
8002
Water 71°C 14 0.30% 0.20%
Hydraulic fluid 23°C 14 -0.050% -0.03%
Hydraulic fluid 71°C 14 -0.14% -0.07%
De-icing Fluid 23°C 14 -0.20% -0.12%
Isopropanol 23°C 14 -0.24% -0.18%
JP-4 Jet Fuel 23°C 14 0% 0%
Methylene Chloride 23°C 1 15.80% 0.42%
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FLAME SMOKE TOXICITY
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PEKK FLAME & SMOKE TOXICITY
Parameter Condition Specification Unit ValueFlammability rating 0.8 mm UL 94 - V-0
Limiting Oxygen Index 1.6 mm ISO 4589-2 %O2 35 – 38*
* PEKK 60/40 = 38%, PEKK 70/30 & 80/20 = 35%
Smoke Toxicity (ASTM E800)
Gas Flaming Non-Flaming
Carbon Dioxide 2449 ppm None Detected
Carbon Monoxide 280 ppm None Detected
Hydrogen Bromide None Detected None Detected
Hydrogen Chloride None Detected None Detected
Hydrogen Fluoride None Detected None Detected
Nitrogen Dioxide None Detected None Detected
Sulfur Dioxide None Detected None Detected
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COMPOSITE PROPERTIES
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COMPARISON OF EPOXY RESINS AND PEKK 70/30
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Base Resin70/30 PEKK
Polymer
Specific Gravity 1.29
Tg – Dry 200°C to 212°C 162°C
Tg – Wet 140°C to 154°C ---
Tensile Strength 81.4 MPa to 121 MPa 110 MPa
Tensile Modulus 3.52 GPa to 4.67 GPa 3.8 GPa
Composite Fiber AS4D0°Tensile Strength: 2300 - 2450 MPA
0°Tensile Modulus: 139 - 145 GPa
0°Compression Strength: 1350 - 1400MPa
0°Compression Modulus: 124 - 125 Gpa
90°Tensile Strength 77 - 88 Mpa
90°Tensile Modulus 10 - 11 GPa
Base Polymers:
Composites
Impact Modified
Thermoset/Epoxy1.3
2068 MPa
AS4
135 MPa
1530 MPa
128 MPa
64 MPa
10 MPa
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ADVANTAGE OF PEKK COMPOSITE PROCESSING
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THERMOPLASTIC COMPOSITE CAN REDUCE THE COST COMPOSITES
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Composite Cycle Time - Autoclave time only
22°C 1°C/min 3°C/min 110°C 29 minutes 88 minutes
55 minutes 65 minutes
110°C 1°C/min 3°C/min 180°C 23 minutes 70 minutes
110 minutes 130 minutes
180°C 2°C/min 5°C/min 65°C 23 minutes 58 minutes
241 minutes 411 minutes
4.01 hrs 6.84 hrs
22°C 2.0°C/min 3.00°C/min 180°C 53 minutes 79 minutes
345 minutes 360 minutes
180°C 1.1°C/min 2.78°C/min 60°C 43 minutes 108 minutes
441 minutes 547 minutes
7.35 hrs 9.12 hrs
Typical Aerospace Thermoset Composite Curing Process #1
Typical Aerospace Composite Curing Process #2
Total
TimeCuring and resin properties control the process
Cool @ 1-3°C/min to 60°C
Heat @ 2-3°C/min to 180°C
Hold @ 180°C for 345-360 min Hold
Curing and resin properties control the processTotal
Time
Metric
Hold @ 180°C for 120 min ± 5 min
Cool @ 2-5°C/min to 60-65°C
Hold
Metric Time Max
Hold @ 110°C for 60 ± 5 min
Heat to 180°C @ 2-3°C/min
Hold
Heat @ 1-3°C/min to 110°C
Start
Temp
(Min)
Ramp
(Max)
Ramp
End
TempTime Min
Time MaxStart
Temp
(Min)
Ramp
(Max)
Ramp
End
TempTime Min
22°C 25.0°C/min 100.00°C/min 380°C 4 minutes 14 minutes
10 minutes 30 minutes
380°C 10.0°C/min 50.00°C/min 120°C 5 minutes 26 minutes
19 minutes 70 minutes
0.31 hrs 1.17 hrs
(Max)
Ramp
Typical PEKK 70/30 Thermoplastic Composite Process
Time Max
Heat @ to 380°C (at any rate)
Hold @ 380°C for 10-30 min Hold
End
TempTime Min
Cool @ 5 to 10°C/min to <120°C
MetricStart
Temp
(Min)
Ramp
Crystallinity Kinetics Control the ProcessTotal
Time
Min Max
241 minutes 547 minutes
4.01 hrs 9.12 hrs
Min Max
19 minutes 70 minutes
0.31 hrs 1.17 hrs
Thermoset/TS
PEKK
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PEKK COST REDUCING COMPOSITES
• Cost reduction of composite parts can be attained by targeting structures that the cost
of processing is greater than the cost of the composite material.
• The graph below charts data from the previous slide.
• This graph does not include consumables or material disposal due to shelf life.
Smaller LargerPart Size
Rela
tive C
ost
Process MaterialDominate Cost
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ASSEMBLY AND REPAIR BY INDUCTIVE & RESISTIVE WELDING
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PEKK INDUCTIVE WELDING
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Induction heating:● contactless heating method using induction coil
There are two mechanisms of heating using Induction Coils (Inductor). (www.fluxtrol.com)● Eddy current for heating electrically conductive bodies● Hysteresis heating for heating magnetic materials. ● Both are mechanisms present in any inductive coil.
Carbon Fibers are Electrically conductive:● Carbon fiber will absorb inductive energy and will heat up during an inductive welding process.
The use of energy concentrators (Susceptors):● A specially made energy concentrators (susceptor) can be placed in the joint area of the mating composites to assist welding● Susceptors are formulated to be more efficient in absorbing energy from an inductive coil than carbon fiber.● Susceptors are specially compounded with either ferrous or non-ferrous metallic particulates.
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PEKK RESISTIVE WELDING
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.Inductive Welding:
Resistive welding utilizes heating circuits made using resistive wire, thick film or metal mesh that are placed between thermoplastic composite parts.
Thermoplastic composites, such as the composites made with the PEKK copolymer, can be resistance welded.
These circuits are flexible and can be designed to accommodate complex joining surfaces.
A flexible heating circuit made using thick film heating circuit sandwiched between layers of the PEKK Co-polymer is illustrated below
Flexible Circuit Heater
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PRESS FORMED AND INSERT/OUTSERT MOLDING
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PRESS FORMED 70/30 PEKK BASED FABRIC, OVERMOLDED WITH 80/20 PEKK W/30% CHOPPED CARBON FIBER
1717
Demonstrator Box:
70/30 PEKK fabric laminate
Press Formed and overmolded
in one tool and in one process
by Cogit, France
80/20 PEKK w/30% carbon fiber
ribs and sides overmolded on to
the Press Formed 70/30 PEKK
based composite
Press Formed 70/30
PEKK based composite
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SUMMARY
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SUMMARY
Polyetherketoneketone (PEKK) is a unique member of the PAEK polymer family
PEKK is a copolymer, identified by its T/I ration, is three distinct polymer types:● T/I = 80/20, Semi-Crystalline Tg = 165°C Tm = 360°C● T/I = 70/30, Semi-Crystalline Tg = 162°C Tm = 335°C● T/I = 60/40, Semi-crystalline Tg = 160°C Tm = 305°C
PEKK:
● Has excellent Chemical Resistance
● Is naturally UL94 V0
● Has low Smoke Toxicity
● Is utilized in aerospace composites
PEKK based composites:
● Can be a cost reduction to thermoset composite parts
● Can be repaired and bonded using inductive and resistive welding.
● Are easily thermoformed
● Can be overmolded using injection molding practices.
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CONTACT INFORMATION & ACKNOWLEDGEMENTS
Tim Spahr
Business Development Manager
Arkema Inc
W17878 Silver Creek Rd
Galesville, WI 54630
USA
P: +1-608-582-2829
C: +1-608-738-9151
F: +1-610-878-6298
Email: [email protected]
Website: www.arkema.com
Americas:Fábio L.F. Paganini
Business Development Manager - South America
Arkema Brasil
Av. Ibirapuera, 2033 - 4º andar
Ibirapuera, São Paulo
Brasil - CEP 04029-901
P: 0055 11 3891-1025
C: 0055 11 99-108-4905
Email: [email protected]
Customer Service Brasil: 0055 11 2148-8570
Brasil:
Jerome Pascal, Arkema SA. France Jason Lyons, Arkema Inc, USA Bruce Clay, Arkema Inc, USA
Julien Jouanneau, Arkema Inc, USA Matt Perrone, Barrday Composite Solutions Robert Goldstein, Fluxtrol, USA
Acknowledgements
The statements, technical information and recommendations contained herein are believed to be accurate as of the date hereof. Since the conditions and methods of use of the product and of the information referred to herein are beyond our control, Arkema expressly disclaims any and all liability as to any results obtained or arising from any use of the product or reliance on such information; NO WARRANTY OF FITNESS FOR ANY PARTICULAR PURPOSE, WARRANTY OF MERCHANTABILITY, OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, IS MADE CONCERNING THE GOODS DESCRIBED OR THE INFORMATION PROVIDED HEREIN. The information provided herein relates only to the specific product designated and may not be applicable when such product is used in combination with other materials or in any process. The user should thoroughly test any application before commercialization. Nothing contained herein constitutes a license to practice under any patent and it should not be construed as an inducement to infringe any patent, and the user is advised to take appropriate steps to be sure that any proposed use of the product will not result in patent infringement. © 2016 Arkema Inc.