Bakelite Properties

Product Bulletin

Thermoset Moulding Compounds for the Automotive Industry

For years, thermoset materials from Hexion Specialty Chemicals have been well established and indispensable in many automotive industry applications. Our thermoset moulding compounds and engineering phenolics are used in products ranging from cutting-edge technology mouldings through insulating materials and paneling to friction linings meeting the most stringent requirements. Even at the development stage, we support our customers in selecting the best possible product from the main groups of plastics.

Compounds designed for processing in automatic injection moulding machines satisfy the ambitious demands of the market with respect to • Weight savings • Cost reduction • Design flexibility • Integration capability The specific, customized properties of these materials make them an obvious choice to replace existing metals applications by innovative design solutions.

Resistance to Peak Thermomechanical Stresses With Glass Fiber-Reinforced Bakelite ® Moulding Compounds

Hexion Specialty Chemicals supplies specialty moulding compounds with high engineering demand profiles and strong growth potentials for its customers. Particularly in this field, Hexion’s aim is to exploit new applications with the aid of High Performance Materials and an excellent technical service system. The focus is on cooperative project teamwork with the final customers. In these activities, Hexion views itself as both a high-performance plastics specialist, and a component designer and provider of packaged engineering services. The product line includes • High-strength, glass fiber-reinforced phenol-formaldehyde moulding compounds for mechanically and thermally stressed housings and drive elements in the engine compartment • Carbon fiber-reinforced Carbomould ® moulding compounds designed to meet tribologic demands in frictional and sliding functional components • Electrically sophisticated, elimination product-free, glass fiber-reinforced epoxy moulding compounds for high tension insulating components in the automotive electrical system

Applications

Material Advantages

Highly demanding housings and functional components in the engineering and automotive fields

• Peak thermal stability

Bakelite High Performance Materials increasingly replace functional elements and system components that up to now have been made of metal. Such materials include the particularly robust glass fiberextended, phenol-formaldehyde moulding compounds – Bakelite ® Engineering Thermosets. These are used in fields including the automotive industry in transmissions, brake systems and engine assemblies. Moreover, the electrical and electronics industries also rely on these innovative moulding compounds to manufacture high quality, thermally resistant functional elements with high mechanical strength.

• Low density

®

• Low creep, low compression set • High chemical resistance • High modulus of elasticity • High dimensional stability • High surface hardness • High corrosion resistance • Low thermal expansion coefficient • Low shrinkage • Economical alternative to materials including PPS, PEI, PEEK, PPA and die cast aluminum

Bakelite ® Moulding Compound PF 6771 Applications • Automotive housing components exposed to high levels of mechanical stress • Air, water and oil transporting applications • Water pumps Material Description Highly glass fiber-reinforced phenolformaldehyde moulding compound

Technical Data Sheet Specifications (ISO) Property

Units

Bakelite® PF 6771

Density

g/cm3

1.69

Tensile Strength

MPa

120

Tensile Modulus of Elasticity

MPa

17,000

Bending Strength

MPa

225

Modulus in Bending

MPa

16,000

Charpy Impact Strength

kJ/m2

19

Charpy Notched Impact Strength

kJ/m2

4

HDTC deflection temperature under load

°C

170

Special Advantages • Highly complex components can be produced

Elasticity Modulus of Bakelite ® PF 6771 in the Untreated State and After Heat Treatment

• Peak strength combined with great toughness

18000

• Excellent processability

16000

• Very high ratios of flow path to wall thickness possible

] 14000 a P M 12000 [ g n i d 10000 n e B n 8000 i s u l u 6000 d o M

4000 2000 0

50

100

Temperature [ °C ]

150

200

Untreated

Heat Treated

Bending Strength of Bakelite® PF 6771 in the Untreated State and After Heat Treatment 400 350 ] a 300 P M [ h 250 t g n e r t 200 S g n i d 150 n e B

100 50 0 -50

0

Temperature [ °C ]

50

100

150 Untreated

200

250 Heat Treated

Bakelite ®-Moulding Compound PF 6501 Applications • High-strength components and housings • Pulleys for automotive and household use • Pistons, flanges and pump rotors Material Description Glass fiber-reinforced, mineral extended phenol-formaldehyde moulding compound


Units

Bakelite® PF 6501

Density

g/cm3

1.6

Tensile Strength

MPa

85


MPa

15,000

Bending Strength

MPa

185

Modulus in Bending

MPa

12,500


kJ/m2

12


kJ/m2

3.5

HDT-C deflection temperature under load

°C

170

Special Advantages • Very low compression set permits immediate assembly • Very high reverse bending fatigue strength

Bakelite ®-Moulding Compound PF 1110 Applications • Dimensionally accurate, high precision housings • High-strength components and housings • Fuel transporting applications Material Description Phenol-formaldehyde moulding compound, 80 % inorganic (silica-free) extender


Units

Bakelite® PF 1110

Density

g/cm3

2.07

Tensile Strength

MPa

140


MPa

28,000

Bending Strength

MPa

240

Modulus in Bending

MPa


kJ/m

15


kJ/m2

4

HDT-C deflection temperature under load

°C

190

25,000 2

Special Advantages • Very high dimensional stability • Very tight tolerances can be met • Thermal expansion coefficient similar to that of aluminum

Storage in FAM B Test Fuel for 250 h at 80 C °

0.8

• Very low wear in plastics machining • Isotropic properties

PF 1110 0.6

0.4

] % [

0.2

0

-0.2

-0.4 Volume Change

Thickness Change

Length Change

0.1 %

0.1 %

0,0 %

0.3 %

0.6 %

0.1 %

PF 6771

The thermal expansion coefficient is uniform along the three coordinate axes. In view of the thermal ex-pansion of 20 x 10-6 / °K, very tight fits can be accomplished in combinations with metallic materials over a wide range of temperature.

Thermal Expansion Coefficient of Bakelite ® PF 1110, 10 °C / min

2.00

] % [ A M T y b n o i s n 1.00 a p x E l a n i d u t i g n o L

0.00 100.00

200.00

Temperature [ °C ]

Normal

300.00 High

Transverse

60,00 °C

1,46 μm

18,25 x10 -6 / K

3,71 μm

18,53 x10-6 / K

1.30 μm

11.23 x10 -6 / K

80,00 °C

3,03 μm

18,94 x10 -6 / K

7,69 μm

19,21 x10-6 / K

2.60 μm

11.23 x10 -6 / K

100,00 °C

4,59 μm

19,13 x10 -6 / K

11,67 μm

19,43 x10-6 / K

3.81 μm

10.97 x10 -6 / K

120,00 °C

6,03 μm

18,84 x10 -6 / K

15,69 μm

19,59 x10-6 / K

5.06 μm

10.92 x10 -6 / K

140,00 °C

7,55 μm

18,88 x10 -6 / K

19,90 μm

19,88 x10-6 / K

6.45 μm

11.14 x10 -6 / K

160,00 °C

9,15 μm

19,06 x10 -6 / K

24,28 μm

20,21 x10-6 / K

7.82 μm

11.26 x10 -6 / K

180,00 °C

10,83 μm

19,34 x10 -6 / K

28,89 μm

20,62 x10-6 / K

9.27 μm

11.44 x10 -6 / K

200,00 °C

12,89 μm

20,14 x10 -6 / K

34,01 μm

21,24 x10-6 / K

10.77 μm

11.63 x10 -6 / K

220,00 °C

16,92 μm

23,50 x10 -6 / K

42,28 μm

23,47 x10-6 / K

13.35 μm

12.81 x10 -6 / K

Inorganically Extended Bakelite ® Moulding Compounds With Peak Thermal Resistance

Very High and Uniform Residual Strength After Ageing at Elevated Temperatures Using the Modulus of Elasticity as an Example (Bakelite ® PF 1110)

30000 ] a 25000 P M [ y t i 20000 c i t s a l E f 15000 o s u l u d o 10000 M e l i s n e T 5000

0

27500

Initial

28500

28500

28500

100 h

200 h

300 h

Storage at 180 °C

Carbon Fiber-Reinforced Carbomould ® Moulding Compounds For Enhanced Tribologic Properties Material Description High-performance plastics based on carbon fiber-reinforced phenolic moulding compounds.

Comparison of Carbon to Glass Fiber Plastics

Applications Highly demanding functional components with excellent wear resistance

Property

Units

Carbon Fiber Plastic

Glass Fiber Plastic

Density

g/cm

1.8

2.6

Modulus of Elasticity

MPa

240,000

77,000

Bending Strength

MPa

4,000

3,500

Thermal and electrical conductivity, low attrition

Insulator, high attrition

3

Further Properties

• Automotive pump parts • Bearing elements, slide bearings • Gear wheels and cams • Guide elements

Carbomould ® S, M and T

• Sliding components Material Advantages Material Advantages • Peak thermal stability • Low creep, low compression set • Grades with very low friction coefficients

Various grades of material are available to provide optimal application properties. Carbomould ® S exhibits high strength levels, Carbomould ® M offers a high modulus of elasticity and Carbomould ® T is a tribologically optimized material.

• Tribologic grades with low specific rates of wear Material Advantages

• High chemical resistance

Property

Units

Carbomould ® S High strength

Carbomould ® M Peak modulus of elasticity

Carbomould ® T Tribologic

Density

g/cm3

1.5

1.8

1.7

Tensile Strength

MPa

110

110

80


MPa

29,000

31,000

23,000

Bending Strength

MPa

250

200

180

Modulus in Bending

MPa

28,000

31,000

24,000

Compression Strength

MPa

270

250

200

• Low density • High dimensional stability and modulus of elasticity • Economical alternative to PEEK or coated aluminum • High surface hardness • High corrosion resistance

Carbon Fiber Plastics Properties • Low density • High modulus of elasticity and rigidity • High mechanical strength • Low abrasion • Low and uniform coefficient of friction

Pin-on-Disk Setup: Contact ball size: 4 mm FN t

= =

10 [N] 4 [h]

v

=

0.25 [m/s]

The contact ball wear is low.

Friction Coefficient Curve at 90 °C, 0.25 m/s and 43 N/mm

2

1.0 0.9 0.8 t 0.7 n e i c i f f 0.6 e o C 0.5 n o i t 0.4 c i r F

0.3 0.2 0.1 0 3 Time [ h ]

6

9

12

15

18

Bakelite® Carbomould®

21

24

Standard Material

Glass Fiber-Reinforced Epoxy and Polyester Moulding Compounds for Electrical Insulation of CurrentCarrying Parts Bakelite® Epoxy Moulding Compound EP 8412 Applications • High-tension carrying ignition system components • Spark plug connectors Material Advantages • High thermal resistance


Units

EP 8412

EP 8416

UP 802

Density

g/cm3

1.85

1.85

2

Tensile Strength

MPa

55

70

-


MPa

13,000

15,000

-

Bending Strength

MPa

120

120

100

Modulus in Bending

MPa

14,500

14,500

13,500


kJ/m2

8.5

8.0

7


kJ/m2

3.5

2.5

3.5

• Low viscosity grades • Free of shrinkage and elimination products

Spark Plug Connectors, Distributor Rotors and Caps

• Peak chemical resistance

Requirements High electrical stability, stress-free with metallic inserts

• No stress corrosion cracking • Electrically sophisticated Additional Advantages • Embedding of sensitive electronics possible • Encapsulation of mechanically sensitive components • Crack-free enclosure of metallic inserts even at low wall thicknesses • Environmentally friendly (free of aromatics and amines)

Hexion not only offers you the most appropriate material for your application, but also supports your efforts to combine cost advantages with innovative solutions. 1. New design concept, system design 2. Feasibility study 3. Simulation 4. Prototyping 5. Sampling 6. Tests, specifications 7. Series production

Material Options Polyester moulding compound UP 802 Epoxy moulding compound EP 8416 Material Description Glass fiber-extended thermosets (epoxy and polyester GF 15) and thermoplastic polyester (PBT GF 30)

H2 / H4 Lamp Sockets Requirements Gas tightness Low fogging Long-term thermal stability Special types for manufacture of small components Material Options Epoxy moulding compound EP 8412 for H2 Polyester moulding compound UP RW 1411 for H4 Material Description Mineral and glass fiber-extended epoxy and unsaturated polyester moulding compounds for compression moulding

The Global Leader in Thermoset Resins As the world’s largest producer of thermoset resins and the leader in adhesive and structural resins and coatings, Hexion Specialty Chemicals meets customers’ specific application needs with a total solutions approach of products and services. Hexion offers the broadest range of thermoset resin technologies and unmatched technical support – and provides them around the globe. With our extensive research and development capabilities and applications know-how, we are uniquely able to work in partnership with customers to co-develop better products and systems. Plus, Hexion’s worldwide production network facilitates assured supply and prompt delivery wherever our customers do business.

World Headquarters / North America: Hexion Specialty Chemicals, Inc. 180 East Broad Street Columbus, OH 43215-3799 +1 614 225 4000

Regional Headquarters: Asia Hexion Specialty Chemicals Trading Co., Ltd. Lippo Plaza # 3701 222 Central Huai Hai Road Shanghai 200021 China +86 21 3318 4800 Australia Hexion Specialty Chemicals Australia Pty. 2- 8 James Street Laverton North Victoria 3026 Australia +61 39 369 2377 Europe Hexion Specialty Chemicals B.V. Koddeweg 67 3194 DH Hoogvliet Rotterdam, The Netherlands +31 10 295 4000 Latin America Hexion Química Indústria e Comércio Ltda. Rua Cyro Correa Pereira, 2525 Area-Sul – CIC 81450-090 Curitiba, Brazil +55 41 212 1600

Hexion Specialty Chemicals B.V. Koddeweg 67 3194 DH Hoogvliet Rotterdam, The Netherlands +31 10 295 4000 Hexion Specialty Chemicals GmbH Gennaer Straße 2-4 58642 Iserlohn Germany +49 2374 925 0 ® and TM Licensed trademarks of Hexion Specialty Chemicals, Inc.

For worldwide locations visit hexion.com © 2006 Hexion Specialty Chemicals, Inc. HCI-500 11/06 Prin ted in Germany.

The information provided herein was believed by Hexion Specialty Chemicals ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be reliable, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safe handling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and conditions of sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANY PURPOSE OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothing contained herein constitutes an offer for the sale of any product.

Bakelite Properties

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