Choosing the Best Polyurethane Cast Elastomer for ...€¦ · • Vacuum Casting (Wire or Fiber...
Transcript of Choosing the Best Polyurethane Cast Elastomer for ...€¦ · • Vacuum Casting (Wire or Fiber...
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Choosing the Best Polyurethane Cast Elastomer for Demanding Applications
Dr. R. Scott Archibald, Ph.D.
6 November 2018
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Polyurethane Industry
• The 2016 market for polyurethanes is estimated to be over $55 Billion.
• The 2016 diisocyanate (limited to MDI and TDI) market is estimated at $22 Billion.
• The 2016 US polyurethane market is expected to reach over $19 Billion and employ over 200,000 jobs.
*2014 UTECH Conference Website
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Overview
• Markets
• Applications
• Urethane Chemistry
• Reasons to use urethane elastomers
• Application types
• Urethane elastomer comparisons to metal, rubber, and plastic
• Urethane limitations
• Control of Urethane Properties
• Urethane general selection
• Selecting the best urethane for a new application
• Field Testing
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Major Polyurethane Markets • Construction – rigid foam insulation • Automotive – seating, vehicular interiors, facia • Bedding and Furniture • Footwear – shoe soles • Textiles – Spandex, • Adhesives and Sealants - flooring • Electronics • Machinery & Foundry • Thermoplastic Urethanes (TPU) • Coatings • CAST ELASTOMERS – 2-3%
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Major Cast Elastomer Polyurethane Applications
• Agriculture and Food Processing
• Office Machinery
• Oil and Gas Pipeline Parts
• Tire and Wheels
• Papermaking and Printer rolls
• Mining Parts
• Recreational – Golf Balls, Inline Skate wheels, Skateboard wheels, bowling balls
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Urethane Prepolymer Synthesis
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Cast Elastomer Production
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Production Supply Arrival
Prepolymer Curative / Chain Extender
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Prepolymer Preparation
• Melting in Oven
• Transfer to Machine Tank or Dispense to Pail
• Degassing
• Maintain Production Temperature
Prepolymer
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Curative/Chain Extender Preparation
• Transfer to Machine Tank for Melting or Melt enough for single pour
• Maintain Liquid State
• Degassing
• Maintain Production Temperature
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Polyurethane Processing
Mixing
(Melting), Warming & Degassing
(Melting), Warming & Degassing
Meter Streams
Molding
Demold
Finishing
Dispensing
Curing
Post-Curing
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Polyurethane Processing
Mixing
Meter Streams
Dispensing
Molding
Machine Mixing
Dispensing
Hand Batching
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Polyurethane Processing
Molding
Demold
Curing
Demolding
Curing Oven
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Polyurethane Processing
Demold
Finishing
Post-Curing
Post-Curing Oven
Finishing Tradename Printing
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Polyurethane Elastomer Think Elastic
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Urethane Elastomer Performance Advantages
• Tear Resistance
• Abrasion Resistance
• Toughness
• Load-bearing Ability
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Urethane Elastomer Cost Advantages
• Reduced Downtime in Manufacturing Processes Mining
Paper Mills
Pipelines
Machine Parts
• Lower Tooling and Equipment Costs for Small Production Runs
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Mining - Hydrocyclones
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Mining - Hydrocyclones
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Urethane Lined Hydrocyclone Distributor
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Paper Mill Rolls
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Pipeline Pigs/Spheres
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Pipeline Cleaning Pigs
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Crossover Pads
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Wheels for Forklifts and Lift Trucks
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Processing Urethane Prepolymers
• Open Casting (Most Common, low cost)
• Compression Molding (for Precision Parts)
• Centrifugal Molding (Pipelining, multi-cavity, circular molds)
• Liquid Injection Molding (low pressure bottom fill)
• Ribbon Molding (Rolls, to big to open cast)
• Spraying (High/Low pressure; No Solvent/Solvent)
• Rotational Molding (Hollow Items) • Vacuum Casting (Wire or Fiber Inserts) • Transfer Molding (Multiple Precison
Parts) • RIM – Reaction Injection Molding (High
Pressure Impingement Mixing) • B – Staging (When molds can’t hold
liquid) • Pressure Casting (Pressure Chamber) • Solvent Casting (Low Viscosity for Fabric
Penetration) • Trowelling (Repairs and Special Apps) • Dipping (Long Pot life, Heat Activated)
Most Common Least Common
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Lined Steel Pipe – Centrifugal Cast
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Gaskets/Seals – Compression Molding
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Ride Wheels – Open Cast
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Big Rolls - Ribbon Molding
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Polyurethane Advantages over Metal
• Impact Resistance
• Lighter Weight
• Less Noise
• Better Wear
• Corrosion Resistance
• Low Cost Manufacturing
• Non- Sparking
• Non-Conductive
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Mining Screen Operation
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Polyurethane Working Hardness Range
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Polyurethane Advantages over Rubber • Abrasion Resistance
• Cut and Tear Resistance
• Oil Resistance
• Higher Load Bearing
• Harder Durometer Range
• Clarity; Translucence
• Non-Marking, non-Staining
• Pourable; Castable
• Ozone Resistance
• Microorganism Resistance *
• High or Low Hysteresis
• Versatility
* Polyether only
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General Comparison of Polyurethane Elastomers with Various Rubbers
General Comparison of Polyurethane Elastomers with Various Rubbers
Property Polyurethane Nitrile Neoprene Natural SBR Butyl Tensile Strength (MPa) 20.7 to 65.5 13.8+/- 20.7+/- 20.7+/- 13.8+/- 13.8+/-
Durometer 5A to 85D 40 to 95A 40 to 95A 30 to 90A 40 to 90A 40 to 75A Specific Gravity 1.10 to 1.24 1.0 1.23 0.93 0.94 0.92 Tear Resistance Outstanding Fair Good Good Fair Good
Abrasion Resistance Outstanding Good Excellent Excellent Good-Excel. Good Compression Set Good Good Fair-Good Good Good Fair
Rebound Very High to Very Low Medium High Very High Medium Very Low Gas Permeability Fair-Good Fair Low Fair Fair Very Low Acid Resistance Fair-Good Good Excellent Fair-Good Fair-Good Excellent
Aliphatic Hydrocarbons Excellent Excellent Good Poor Poor Poor Aromatic Hydrocarbons Fair-Good Good Fair Poor Poor Poor
Oil and Gas Resistance
Excellent Excellent Good Poor Poor Poor
Oxidation Resistance
Outstanding Good Excellent Good Good Excellent
Ozone Resistance
Outstanding Fair Excellent Fair Fair Excellent
Low Temperature Resistance
Excellent Good Good Excellent Excellent Good
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Polyurethane Advantages over Plastic
• Non-Brittle
• Flex Resistance
• Abrasion Resistance
• Elastomeric Memory
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Limitations of Polyurethane
• High Temperature Service
• Moist, Hot Environments
• Certain Chemical Environments
• Higher Cost versus other Polymers
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Prepolymer Chemistry Controls Polyurethane Properties
• Diisocyanate Type
TDI
MDI
Specialty (PPDI, Aliphatic, LF, etc.)
• Polyol (Prepolymer Backbone) Type
PTMG (Premium) Polyether
PPG Polyether
Polyesters (%Ethylene, %Butylene, Adipate, Succinate)
Specialty (Polycaprolactones, Polycarbonates, etc.)
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Diisocyanates
CH2N NCO C O
C15H10N2O2
250.26Methylenediphenyl Diisocyanate
N C ONCO
C8H4N2O2
160.13Paraphenylene Diisocyanate
CH3
N C O
N
C
O C9H6N2O2
174.16 Toluene Diisocyanate
CH3
N C ONCO
TDI PPDI
MDI
NN C O
CO
HDI
C8H12N2O2
168.20Hexamethylene Diisocyanate
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Prepolymer Backbones HO
OOH
PPGPolypropylene glycol
PTMEGPolytetramethylene ether glycol
PEAGPolyester
HO
OO
OH
O
O
HOO H
nn
n
HO O
O
OHn
PClPolycaprolactone
Polyethers
Polyesters
Polycaprolactone
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Physical Properties Relative Performance for MDI Systems
Material Abrasion Low Temp Hydrolysis Oxidation
Ester (standard) 3 8 6 1
Ester (high abr) 1 8 6 1
Polycaprolactone 4 4 4 1
PTMG Ether 6 1 1 4
PPG Ether 8 2 1 7
(Performance: 1 = Best, 10 = Worst)
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Hard Segment Chemistry Controls Polyurethane Properties
• Curative / Chain Extender Type Diamine (fast reactivity - used with slower TDI Prepolymers) Diol, Triol (slower reactivity - used with faster MDI
Prepolymers)
• Polyol (Prepolymer Backbone) Type Curative Ratio Temperatures (Prepolymer, Curing, Post-curing)
• Additives Plasticizers Fillers Stabilizers
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Common Curatives
Equivalent Weight is ½ Molecular Mass for Di-functional Curatives Equivalent Weight is 1/3 Molecular Mass for Tri-functional Curatives
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Tear Strength Versus Stoichiometry
360
380
400
420
440
460
480
500
520
540
560
20
30
40
50
60
70
80
90
100
110
120
40 50 60 70 80 90 100 110 120
AST
M D
-62
4 D
ie C
Te
ar S
tre
ngt
h (
LbF/
in)
AST
M D
-47
0 S
plit
Te
ar S
tre
ngt
h (
LbF/
in)
MOCA Concentration (% Theory)
Tear Strength Versus % Theory
ASTM D-470 Split Tear
ASTM D-624 Die C Tear
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Selection of a Polyurethane Elastomer for a Specific Application
• Properties Needed for the Job
• Most Probable Failure Mechanism
• Processing Characteristics
Pot Life
Ratio Control
Viscosity
Demold Time
Process Temperatures
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Polyurethane Elastomer Selection Guidelines
Property Greatest Least
Hardness N/A N/A
Tensile Strength Ester Ether
Elongation N/A N/A
Modulus N/A N/A
Tear Strength Ester PPG Ether
Compression Set TDI MDI
Rebound MDI Ether PPG Ether/ Ester
Low Temperature Usage MDI Ether TDI Ester
High Temperature Usage TDI MDI
Sliding Abrasion Resistance Ester PPG Ether
Impingement Abrasion Resistance MDI Ether PPG Ether
Heat Buildup Ether Ester
Hydrolysis Resistance MDI Ether TDI Ester
Oil Resistance Ester Ether
Heat Aging Ester PPG Ether
Low Cost PPG Ether Ether
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Polyurethane Elastomer Other Selection Guidelines
Property Greatest Least
Low Durometer Formulations (<60A)
TDI Ester Ether
Formulation Flexibility MDI TDI
FDA Dry Food N/A N/A
FDA Wet Food MDI Ester TDI
Low Cost PPG Ether MDI Ether
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FDA Food Contact Systems
• Wet Food regulated by 21CFR 177.2600 • Dry Food regulated by 21CFR 177.1680 • Your prepolymer supplier can determine if their
resins meet chemical standards • Wet food approval requires water extraction of
final part • Dry food approval requires abrasion test of final
part surface that contacts food • Wet food formulations chemically qualify for dry
food approval with positive abrasion test • Some catalysts, plasticizers are also allowed
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Polyurethane Elastomer Application Selection
Application Urethane Type Basis of Choice
Squeegees MDI Ester Chemical Resistance
Paper Mill Rolls TDI Ether Hydrolysis Resistance, Hardness
Stability, Dynamics
Laundry Equipment MDI Ether Hydrolysis Resistance
Sandblast Curtains MDI Ether High Resilience, Impingement
Abrasion Resistance
Hammers TDI Ester Tear Resistance, Low Resilience,
Fork Lift Tires TDI Ether (TDI Ester) Low Heat Buildup
Grain Handling Equipment MDI Ester Abrasion Resistance
Oil Pipeline Pigs TDI/MDI Ester Oil and Abrasion Resistance
Roller Skate Wheels MDI Ether High Resilience
Printing & Coating Rolls TDI Ester Solvent Resistance, Good
Physicals at Low Durometers
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Low-Free Diisocyanate Prepolymers ( <0.1% Free Diisocyanate TDI, MDI, PPDI, HMDI, etc)
• Easier Processing
Lower Viscosity
Longer Pot Life
• Better Dynamics
Less Heat Buildup
• Health & Safety
Easier Plant Engineering Controls
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Selecting a Polyurethane Elastomer for a New Application
• Decide What Properties are of Key Importance Physical Requirements and Environmental Resistance
Consider most likely Mechanism of Failure
• Select Prepolymer / Curative Systems Which are Likely Candidates
• Consider the Engineering Design of the Part
• Consult Your Suppliers for Recommendations and Further Information
• Review Your Plant/ Processing Capabilities
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Selecting a Polyurethane Elastomer for a New Application – Next Steps
• Run Whatever Preliminary Tests are Available
• Make Prototype Units of One or More Candidate Systems
• Field Test in Actual Service,
• Make Comparisons to Existing Materials
• Get Approval from Future Customers
• Gear up for Production
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Field Testing – Scrapper Blades
• Is the Scrapper Blade used outside or is in contact with water?
• Is Abrasion the most likely failure mechanism?
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Field Testing – Track Pads
• Track Pad is used outside.
• Is Impingement Abrasion Resistance or Sliding Abrasion Resistance most important?
• Is Cut and Tear resistance important?
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Field Testing – Chock Blocks
• What materials will bear the load required to keep cargo in place?
• Will the new material be tough enough to resist wear and tear?
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Review
• Applications
• Urethane Technology
• Overview
• Why use Urethane elastomers
• Types of Applications
• Comparisons to metal, rubber, and plastic
• Limitations of Urethane
• What Controls Urethane Properties
• Urethane Selection
• Selecting Urethane for a new application
• Field Testing
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Thanks for your Attention!
Obrigada pela atenção!
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