Read Ultem profile (English) text version

Strength

200 MPa 160 120 80 V1 40 0

· nt

5VA 5VB V0

Flammability

g

EN /10/2001

GE Plastics

V2 HB

Ultem 0 50

Impact

40 50 kJ/m 2 30

20

10

0

100

0 2500 5000 7500

150

200

250

300°C

Modulus

Ultem profile Ultem profile

10000 12500

Heat®

®

15000 MPa

u

overview

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Contents

Titlepage Contents

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h

............................. 1

.............................. 2

2.6 Telecom, Moulded Interconnect Devices (MIDs) . . . . . . . . . . . . . . 7 2.7 Electrical and Lighting . . . . . . . . . . . . . . . . . . . 8 2.8 HVAC / Fluid handling . . . . . . . . . . . . . . . . . . . . 8

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Markets

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3

3 Product Selection

..................... 9

............................... 4

3.1 Product description . . . . . . . . . . . . . . . . . . . . . . 9

3.1.1 Ultem 1000 series Base Polymer . . . . . . . . . 9 3.1.2 Ultem 2000 series . . . . . . . . . . . . . . . . . . . . 9 3.1.3 Ultem 4000 series . . . . . . . . . . . . . . . . . . . . 9 3.1.4 Ultem CRS 5000 series . . . . . . . . . . . . . . . . . 9 3.1.5 Ultem 6000 series . . . . . . . . . . . . . . . . . . . . 9 3.1.6 Ultem 7000 series . . . . . . . . . . . . . . . . . . . . 9

2.1 Tableware / Catering . . . . . . . . . . . . . . . . . . . . 4 2.2 Medical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.4 Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.5 Automotive Lighting . . . . . . . . . . . . . . . . . . . . . 7

g GE Plastics

Ultem ® profile Contents page 2

3.1.7 Ultem 9000 series . . . . . . . . . . . . . . . . . . . . 9 3.1.8 Siltem ® STM 1500 (PEI / siloxane copolymer) . . . . . . . . . . . . . . 9 3.1.9 Ultem HTX series (high impact) . . . . . . . . . . 9 3.1.10 Ultem ATX series (polyetherimide / polycarbonate-ester blend) . . . . . . . . . . . . 9

5 Design

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6 Processing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7 Secondary Operations

. . . . . . . . . . . . . . . . 37

3.2 Selection tree . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3 Heat - Impact - Flow comparison . . . . . . . . . . . 13 3.4 Heat - Modulus - Flow comparison . . . . . . . . . . 14 3.5 Typical properties . . . . . . . . . . . . . . . . . . . . . . . 15

P S

7.1 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7.2 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7.3 Mechanical Assembly . . . . . . . . . . . . . . . . . . . . 37 7.4 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7.5 Metallization . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.1 Thermal Properties . . . . . . . . . . . . . . . . . . . . . . 20 4.2 Flammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.3 Mechanical properties . . . . . . . . . . . . . . . . . . . 22 4.4 Electrical properties . . . . . . . . . . . . . . . . . . . . . 25 4.5 Environmental resistance . . . . . . . . . . . . . . . . . 29

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Addresses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1

Introduction Ultem ®

Polyetherimide Resins

PEI PEI + PCE PEI + SI

Ultem Polyetherimide resin, PEI, is an amorphous high performance polymer which is characterized by excellent thermal properties, good chemical resistance, inherent flame retardancy and exceptional dimensional stability. The base polymer Ultem 1000 has a transparent amber brown colour, is manufactured by polycondensation and has the following chemical structure:

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N C O O O C CH3 C CH3 O C n O O C N

· · · · ·

Key properties of the Ultem 1000 base polymer are: High long-term heat resistance exhibiting a glass transition temperature (Tg) of 217°C, HDT/Ae of 190°C and relative thermal index (RTI) of 170°C Inherent flame retardancy with low smoke evolution, meeting ABD, FAR and NBS requirements Excellent dimensional stability (low creep sensitivity and low, uniform coefficient of thermal expansion) Exceptional strength and modulus at elevated temperatures Good resistance to a broad range of chemicals such as automotive fluids, fully halogenated hydrocarbons, alcohols and aqueous solutions

g GE Plastics

Ultem ® profile 1 Introduction page 3

· · · ·

unreinforced - 1000 series

Stable dielectric constant and dissipation factor over a wide range of temperatures and frequencies Transparency to visible light, infrared light, and microwave radiation. Compliancy with FDA, EU, national food contact regulations and USP Class VI Outstanding processibility on conventional moulding equipment

Multi purpose glass reinforced - 2000 series unreinforced Wear resistant - 4000 series glass reinforced unreinforced Chemical resistant - CRS 5000 series glass reinforced High heat - 6000 series

Injection moulding Carbon fibre filled - 7000 series unreinforced Aircraft - 9000 series glass reinforced

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Injection moulding and Extrusion

Ultem

High impact - HTX series Polymer blend - ATX series Multi purpose Flexible copolymer Extrusion High impact - HTX series unreinforced - 1000 series Siltem

2

Medical Aircraft Automotive

Markets

Tableware / Catering

Automotive Lighting Telecom, Moulded Interconnect Devices (MIDs)

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Electrical and Lighting HVAC / Fluid handling

g GE Plastics

Ultem ® profile 2 Markets page 4

2.1

Tableware / Catering

High performance and design flexibility allow Ultem resin to be used for a wide variety of high quality, reusable food service applications which are fully recyclable after their service life. Examples are food trays, soup mugs, steam insert pans or gastronorm containers, cloches, microwavable bowls, ovenware, cooking utensils and re-usable airline casseroles.

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· · · ·

Ultem resin in tableware and catering offers: Temperature resistance up to 200°C for hot air ovens: Excellent infra-red and microwave transparency for fast reheating of food Reheating in combi-steamer and thermal contact heater Proven property retention through over 1000 cycles in industrial washing machines with detergents

stain resistance even with stain-prone ·Excellentlike tomato ketchup, carrots and products

· · · · · · ·

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barbecue sauce Compliancy with FDA, EU and national food contact regulations Resistance against most cooking oils and greases Long-term hydrolytic stability Practical level of impact resistance (from subzero to 200°C) Cold touch (heated Ultem trays can be easily handled by hands) Ultem ATX series for superior impact behaviour and intermediate thermal performance Ultem HTX series for superior impact behaviour and similar heat performance to Ultem 1000

2.2

Medical

Ultem resin provides value added performance for reusable medical devices like sterilization trays, stopcocks, dentist devices and pipettes.

g GE Plastics

Ultem ® profile 2 Markets page 5

2.3

Aircraft

· · · ·

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The reasons why Ultem resin is the right choice for medical applications are: Full compliance with FDA and USP Class VI Ability to withstand various sterilization methods like EtO gas, gamma radiation, autoclaving and dry heat Excellent chemical resistance against lipids, detergents and disinfectants Ultem HTX offers enhanced impact resistance and optimum property retention after repeated sterilization, proven up to 3000 autoclave cycles at 134°C

The inherently flame retardant Ultem product family is widely used in the aircraft industry in applications like air and fuel valves, food tray containers, steering wheels, interior cladding parts and (semi-)structural components.

· · · · · ·

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Ultem is chosen because it offers: The Ultem 9000 series for full compliance with aircraft industry regulations for aircraft interiors including ABD 0031, FAR 25.853, OSU 65/65 heat release tests and NBS smoke density tests The Ultem 1000, 2000, CRS 5000, 6000 and 7000 series for compliance with aircraft industry regulations such as ABD 0031, FAR 25.853, OSU 100/100 heat release tests and NBS smoke density tests Very low smoke and toxic gas emission, which makes it the material of choice for aircraft interiors Chemical resistance against most fuels and fluids Excellent processibility with a very good part reproducibility Ultem CRS 5000 series for better resistance against hydraulic aircraft fluids, such as Skydrol, compared to Ultem 1000

·Ability to manufacture Ultem based thermoplastic composites which allow increased productivity in ·

component manufacturing over traditional composite materials Ability to manufacture Ultem foam cores for tough, light-weight sandwich panels

g GE Plastics

Ultem ® profile 2 Markets page 6

2.4

Automotive

Ultem in the automotive industry provides manufacturers with a high performance, costeffective alternative to metal: strong enough to replace steel in some applications and light enough to replace aluminium in others. For applications like transmission components, throttle bodies, ignition components, sensors and thermostat housings, Ultem resin offers:

200°C, RTI ·Heat resistance up toagainst most of 170°C automotive ·Chemical resistance fuels, fluids and oils ·Excellent dimensional stability (low creep sensitivity and low, uniform coefficient of

· · ·

thermal expansion) Superior torque strength and torque retention Excellent processibility with very tight moulding tolerances Elimination of secondary operations like machining and anodizing

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2.5

Automotive Lighting

The Ultem product family has a specifically good fit in a heat dominated area like automotive lighting. Typical applications are headlight reflectors, foglight reflectors, bezels and light bulb sockets where Ultem resin provides:

·High heat resistance up to 200°C, RTI of 170°C without primer ·Metallizationsystem cost vs traditional thermoset ·Competitive materials and processing flexibility ·Design free form reflector designwhich allows typical possibilities ·Integration fixings for mounting and adjustment ·Infra-red transparency allowing heat dissipation ·Weight savings because of lighter, thinner walled reflectors than possible with traditional thermoset · ·

materials Excellent dimensional stability (low creep sensitivity and low, uniform coefficient of thermal expansion) Recyclability of Ultem versus the "traditional" materials

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g GE Plastics

Ultem ® profile 2 Markets page 7

2.6

Telecom, Moulded Interconnect Devices (MIDs)

Its unique plating capabilities make Ultem resin the material of choice for Telecom and MID applications. Ultem allows the combination of electrical functions with the advantages of injection moulded three-dimensional mechanical components in: electrical control units, computer components, mobilephone internal antenna's, rf-duplexers or microfilters and fiber optic connectors.

·Excellent dimensional stability, (low creep sensitivity and low, uniform coefficient of ·

thermal expansion) Consistent processibility and therefore reproducibility of parts

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· · · ·

Ultem resin offers: Unique plating capabilities with the chemical bonding process Significant productivity through integration of components and ease of assembly through, among others, snap fits High heat resistance up to 200°C Stable dielectric constant and dissipation factor over a wide range of temperatures (subzero to 200°C) and frequencies (1 H z - 10 10 Hz)

2.7

Electrical and Lighting

From connectors to reflectors, Ultem resin is the material of choice for today's demanding electrical and lighting applications.

· · · · · · ·

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· · ·

g GE Plastics

In these markets Ultem provides: Temperature resistance up to 200°C, RTI of 170°C and ball pressure test at 125°C Excellent dimensional stability (low creep sensitivity and low, uniform coefficient of thermal expansion) Compatibility with UL file E75735 for use as insulation materials in transformers and motors of up to 600 volts Inherent flame retardancy Passes glow wire test at 960°C (1 - 3.2 mm) Low water absorption Ultem grades with F0 and F1 classification according to the French Standard for Transportation NF F 16 -101 Suitability for use with dichroic coating without primer for reflectors Siltem STM 1500 for non-halogenated flexible cable and wire coatings Ultem 6000 series for high heat connectors

Ultem ® profile 2 Markets page 8

2.8

HVAC / Fluid handling

needed because ·Weld line strength,dynamic pressuresof high temperatures and up to 90°C (KTW ·Potable water approvalproperties under approval) ·Excellent mechanical hot water conditions ·Good hydrolytic stability ·Excellent dimensional stability, (low creep sensitivity and low, uniform coefficient of thermal expansion)

In circumstances where heat and fluids are combined in an application, Ultem resin offers an ideal balance of properties. For applications like water-pump impellers, expansion valves, hot water reservoirs and heat exchange systems, Ultem is chosen because it offers: Long-term heat resistance, RTI of 170°C

·

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3

3.1

Product Selection

3.1.3 Ultem 4000 series

Product description

3.1.1 Ultem 1000 series Base Polymer

·Multi purpose ·Unreinforcedcompliant grades available contact ·FoodClass VI compliant grades available ·USP viscosity grades available ·Low and injection moulding grades ·Extrusion

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·Wear resistance of friction ·Reduced coefficient reinforced grades ·Unreinforced and glass

3.1.4 Ultem CRS 5000 series

3.1.2 Ultem 2000 series

·Superior chemical resistance over Ultem 1000 ·Better resistance against hydraulic aircraft fluids compared to Ultem 1000 ·Unreinforced and glass reinforced grades

3.1.5 Ultem 6000 series

·Glass reinforcedvs. Ultem 1000 ·Greater rigidity ·Improved dimensional stability over Ultem 1000 ·Low viscosity grades available

g GE Plastics

·Highest heat resistance of all Ultem grades

Ultem ® profile 3 Product Selection page 9

3.1.6 Ultem 7000 series

3.1.9 Ultem HTX series (high impact)

·Carbon fibre-reinforced ratio ·Exceptional strength-to-weightgrades ·Highest modulus of all Ultem

3.1.7 Ultem 9000 series

aircraft industry regulations ·FulfillsFAR, OSU and NBS) (ABD, individual lot certification ·Delivered withand glass reinforced grades ·Unreinforced injection moulding grades ·Extrusion and

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·Superior impact performance compared to Ultem 1000 ·Enhanced chemical resistance and hydrolytic stability vs. Ultem 1000 over 3000 ·Autoclavabilityretention cycles at 134°C with property contact compliant grades available ·FoodClass VI compliant grades available ·USP colours only ·Opaque and injection moulding grades ·Extrusion

3.1.10 Ultem ATX series (polyetherimide /

polycarbonate-ester blend)

3.1.8

Siltem ® STM 1500 (PEI / siloxane copolymer)

·For wire and cable ·Halogen free composition combustion ·For applications where minimal corrosion is required ·Extrusion and injection moulding grades

·Intermediate heat performance ·Ultem ATX 100 offers higher impact performance compared to Ultem 1000 ·Very high flow compared to Ultem 1000 ·Metallizable without primer available ·Food contact compliant grades

3.2

Selection tree

click on a section to jump to the related tree

multi-purpose wear resistant chemical resistant high heat

GRADE

Grade: (F): (R): Heat: Impact: Impact*: Modulus: Heat · Impact · Modulus Flammability · Flow All are injection moulding grades unless otherwise indicated. Food compliant version Improved release version HDT/Ae in °C (ISO 75) Izod Notched at 23°C in kJ/m 2 (ISO 180/1A) Izod Unnotched at 23°C in kJ/m 2 (ISO 180/1U) Flexural in MPa (ISO 178)

h

Ultem

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carbon fibre filled aircraft flexible copolymer high impact polymer blend

Flammability: Recognized at mm thickness (UL94) Flow: MVR at 360°C/5.00kg in cm 3/10min (ISO1133) Flow*: MVR at 320°C/2.16kg in cm 3/10min (ISO1133) n.t.: not tested

g GE Plastics

Ultem ® profile 3 Product Selection page 10

Ultem > multi-purpose | wear resistant | chemical resistant | high heat | carbon fibre filled |

aircraft

|

flexible copolymer

|

high impact

|

polymer blend

also Extrusion

190°C · 6 kJ/m 2 · 3300 MPa V0/0.41 - 5VA/1.60 · 13 cm 3/10min

standard

1000 (F,R)

unreinforced 1000 series

high flow

1010 (F,R)

190°C · 5 kJ/m 2 · 3300 MPa V0/0.71 - 5VA/3.00 · 25 cm 3/10min

high pigment loading

1110 (F)

185°C · 4 kJ/m 2 · 3300 MPa V0/0.74 · 21 cm 3/10min

multi-purpose

10%

2100 (R) 2200 (R) 2300 (R) 2400 (R)

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glass reinforced 2000 series standard

205°C · 30*kJ/m 2 · 4500 MPa V0/0.4 1 · 9 cm 3/10min 205°C · 30*kJ/m 2 · 6000 MPa V0/0.41 · 7 cm 3/10min 210°C · 40*kJ/m 2 · 7500 MPa V0/0.25 - 5VA/1.24 · 6 cm 3/10min 210°C · 35*kJ/m 2 · 10000 MPa V0/0.25 · 5 cm 3/10min

20%

30%

40% see charts on pages 13 and 14

Ultem > multi-purpose | wear resistant | chemical resistant | high heat | carbon fibre filled |

aircraft

|

flexible copolymer

|

high impact

|

polymer blend

multi-purpose

10%

2110 (R) 2210 (R) 2310 (R) 2410 (R)

205°C · 30*kJ/m 2 · 4500 MPa V0/0.41 · 13 cm 3/10min 205°C · 30*kJ/m 2 · 6000 MPa V0/0.41 · 10 cm 3/10min 210°C · 40*kJ/m 2 · 7500 MPa V0/0.25 - 5VA/1.24 · 8 cm 3/10min 210°C · 35*kJ/m 2 · 10000 MPa V0/0.25 - 5VA/1.57 · 7 cm 3/10min

20%

glass reinforced 2000 series high flow

30%

40%

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see charts on pages 13 and 14

milled glass

30%

2312

192°C · 20*kJ/m 2 · 7000 MPa V0/0.81 · 12 cm 3/10min

g GE Plastics

Ultem ® profile 3 Product Selection page 11

Ultem > multi-purpose | wear resistant | chemical resistant | high heat | carbon fibre filled |

aircraft

|

flexible copolymer

|

high impact

|

polymer blend

190°C · 10 kJ/m 2 · 3000 MPa V0/1.60 - 5VA/1.50 · 13 cm 3/10min

unreinforced wear resistant 4000 series glass reinforced 25%

4001

4000

205°C · 15*kJ/m 2 · 7000 MPa V0/0.84 · 5 cm 3/10min

standard

unreinforced

CRS 5001

200°C · 8 kJ/m 2 · 2500 MPa V0/1.59 · 7 cm 3/10min

high flow

CRS 5011

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200°C · 5 kJ/m 2 · 2900 MPa V0/1.60 · 20 cm 3/10min

chemical resistant CRS 5000 series 20% glass reinforced 30%

CRS 5201 (R)

205°C · 40*kJ/m 2 · 5800 MPa V0/1.59 - 5VA/1.59 · 5 cm 3/10min

CRS 5311

215°C · 35*kJ/m 2 · 8200 MPa V0/1.59 · 7 cm 3/10min

see charts on pages 13 and 14

Ultem > multi-purpose | wear resistant | chemical resistant | high heat | carbon fibre filled |

aircraft

high heat 6000 series carbon fibre filled 7000 series

|

flexible copolymer

|

high impact

|

polymer blend

215°C · 5 kJ/m 2 · 3000 MPa V0/1.57 · 6 cm 3/10min

6000

carbon fibres

25%

7801

210°C · 35*kJ/m 2 · 13500 MPa V0/1.60 · 5 cm 3/10min

standard

unreinforced aircraft 9000 series glass reinforced 30%

9075

185°C · 7 kJ/m 2 · 3000 MPa V0/1.60 · 27 cm 3/10min

extrusion

9076 AR 9300

175°C · 6 kJ/m 2 · 3000 MPa n.t. · 22 cm 3/10min 208°C · 35*kJ/m 2 · 8500 MPa n.t. · 6 cm 3/10min

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see charts on pages 13 and 14

g GE Plastics

Ultem ® profile 3 Product Selection page 12

Ultem > multi-purpose | wear resistant | chemical resistant | high heat | carbon fibre filled |

aircraft

flexible copolymer high impact HTX series

|

flexible copolymer

|

high impact

|

polymer blend

Siltem

n.t. · 25kJ/m 2 · 475 MPa V1/1.60 · 8*cm 3/10min

also Extrusion

STM 1500 HTX 1010 (F)

182°C · 15 kJ/m 2 · 2900 MPa n.t. · 18 cm 3/10min

ATX 100 (F)

polymer blend ATX series

160°C · 15kJ/m 2 · 2400 MPa HB/0.76 · 45 cm 3/10min

ATX 200 (F)

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see charts on pages 13 and 14

188°C · 5 kJ/m 2 · 3200 MPa V0/1.50 · 33 cm 3/10min

3.3

°C

Heat - Impact - Flow comparison

Ultem unreinforced multi-purpose

­ ­

standard high flow high pigment loading

210 ­ 200 ­ 190 ­ 180 1110 (F) ­ 1000 (F,R) 1010 (F,R)

Heat HDT/Ae

170 ­ 160 ­ 150 ­ 5 ­

|

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Flow Melt Volume Rate

13.3 21.6 30 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25

|

cm 3/10 min

Izod Notched Impact

kJ/m 2

g GE Plastics

Ultem ® profile 3 Product Selection page 13

°C

Ultem unreinforced non multi-purpose

­ ­ 210 ­ 200 ­ 190 ­ 180 ­ 9075 aircraft 9076 aircraft HTX 1010 (F) CRS 5011 CRS 5001 ATX 200 (F) 4001 wear 6000 high heat

wear resistant chemical resistant high heat aircraft high impact polymer blend

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Heat HDT/Ae

170 ­ 160 ­ 150 ­ ­

|

ATX 100 (F)

Flow Melt Volume Rate

5 13.3 21.6 30

|

cm 3/10 min

0

2.5

5

7.5 10 12.5 15 17.5 20 22.5 25

Izod Notched Impact

kJ/m 2

3.4

°C

Heat - Modulus - Flow comparison

­ ­

normal glass fibres 10% 20% 30%

40%

Ultem reinforced multi-purpose standard high flow milled glass

210 ­ 200 ­ 190 ­ 180 ­

2300 (R) 2100 (R) 2200 (R)

2400 (R) 2410 (R)

2310 (R) 2110 (R) 2210 (R)

2312 appearance

30% milled glass fibres

Heat HDT/Ae

170 ­ 160 ­ 150 ­ 5 ­

|

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Flow Melt Volume Rate

13.3 21.6 30 4 000 5 000 6 000 7 000 8 000 9 000 10 000 11 000 12 000 13 000 14 000

|

cm 3/10 min

Flexural Modulus

MPa

g GE Plastics

Ultem ® profile 3 Product Selection page 14

°C

­ ­

normal glass fibres 20% 25% 30%

carbon fibres 25%

Ultem reinforced non multi-purpose wear resistant chemical resistant carbon fibre filled aircraft

CRS 5311 7801 210 ­ 200 ­ 190 ­ 180 ­ CRS 5201 (R) 4000 wear AR 9300 aircraft

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Heat HDT/Ae

170 ­ 160 ­ 150 ­ 5 ­

|

Flow Melt Volume Rate

13.3 21.6 30 4 000 5 000 6 000 7 000 8 000 9 000 10 000 11 000 12 000 13 000 14 000

|

cm 3/10 min

Flexural Modulus

MPa

3.5

Typical properties

Unit

Test Method

Test Specimen

MPTS (multi purpose test specimen) as defined in ISO 3167. Smaller test specimens may be machined from MPTS. All dimensions in mm.

Typical values only. Variations within normal tolerances are possible for various colours.

ISO IEC*

DIN VDE*

ASTM other*

Mechanical

Tensile stress Tensile strain Tensile modulus Flexural stress Flexural modulus Hardness Abrasion resistance at yield (at break) at break at yield (at break) at break at yield (at break) Ball indentation Rockwell Taber, CS-17, 1 kg at 50 mm/min at 5 mm/min at 50 mm/min at 5 mm/min at 1 mm/min at 2 mm/min at 2 mm/min H 358/30 R, M or L per 1000 cycles MPa MPa % % MPa MPa MPa MPa scale mg R527 R527 R527 R527 R527 178 178 2039-1 2039-2 MPTS (150 x 20/10 x 4) MPTS MPTS 80 x 10 x 4 80 x 10 x 4 50 x 50 x 4 D785 GE*

53456

Impact

Izod Charpy notched unnotched notched unnotched at +23°C [-30°C] at +23°C [-30°C] at +23°C [-30°C] at +23°C [-30°C] kJ/m 2 kJ/m 2 kJ/m 2 kJ/m 2 180-1A 180-1C 53453 53453 80 x 10 x 4 80 x 10 x 4

P

Thermal

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Vicat A/50 B/50 B/120 HDT/Ae /Be Ball pressure Relative Temperature Index

10N (method A) 50N (method B) 50N (method B) edgewise, span 100 mm passes at °C RTI

at 50°C/h at 50°C/h at 120°C/h at 1.80 MPa at 0.45 MPa Electrical properties Mechanical properties with Impact Mechanical properties without Impact in flow direction in flow direction

Thermal conductivity Coefficient of Thermal Expansion

CTE

°C °C °C °C °C °C °C °C °C W/m°C 1/°C 1/°C

306 306 306 75 75 335-1*

110 x 10 x 4 53460 110 x 10 x 4 UL746B* UL746B* UL746B* C177 D696 D696

1)

52612 53752 53752

2)

110 x 10 x 4

Flammability

UL94 rating Limited Oxygen Index Glow wire Needle flame Hot Wire Ignition High-Current Arc Ignition flame class rating LOI passed at °C passed at 10 sec HWI HAI at mm thickness class at mm % °C at mm -- PLC PLC 4589 695-2-1* 695-2-2* UL94* D2863 125 x 13, thickness as noted 150/80 x 10 x 4

1) 3) 3)

at mm thickness at 3.2 mm Performance Level Class Performance Level Class

UL746A* UL746A*

1) 4)

Electrical

Dielectric strength Surface resistivity Volume resistivity Relative permittivity Dissipation factor Comparative Tracking Index Comparative Tracking Index Arc Resistance High Voltage Arc-Tracking Rate in oil at 0.8 mm / 1.6 mm / 3.2 mm kV/mm Ohm Ohm·cm -- -- -- V PLC PLC PLC 243* 93* 93* 250* 250* 250* 112* 0303T2* 0303T3* 0303T3* 0303T4* 0303T4* 0303T4* 0303T1* D149 D257 D257 D150 D150 D150 D3638 UL746A* UL746A* UL746A*

or Dielectric constant or Loss tangent CTI (CTI- M) CTI D-495 HVTR

at 50 Hz (at 1 MHz) at 50 Hz at 1 MHz 50 drops [M: wetting agent] Performance Level Class Performance Level Class Performance Level Class

5) 1) 4)

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Physical

Density Moisture absorption Water absorption Mould shrinkage at saturation at saturation at 23°C, 50% R.H. at 23°C, in water in flow direction g/cm 3 % % % 1183 62 62 R527 53479 D792 D570 D570 D955

6)

Rheological

Melt Volume Rate

1) 2)

MVR

at 360 °C / 5 kg

4)

cm 3/10 min

1133

6)

53735

granules

as recognized on UL yellow cards; UL recognition may differ with colour values may differ with glass fibre orientation 3 ) these ratings are not intended to reflect hazards presented by this or other material under actual fire conditions NB : not broken · ­ : not relevant · n.t.: not tested

measured at 3 - 3.2 mm thickness - values may differ for other thicknesses 5 ) values may differ with pigmented materials

only typical data for material selection purposes - not to be used for part/tool design; for glass reinforced grades: values may differ with glass fibre orientation

g GE Plastics

Ultem ® profile 3 Product Selection page 15

multi purpose unreinforced

Typical values only. Not to be used for specification purposes.

glass reinforced high pigment loading 10% high flow 20% high flow

page 17

standard high flow

Mechanical

Tens. stress Tens. strain y (b) b y (b) b 50 5 50 5

Unit

MPa MPa % % MPa MPa MPa MPa scale mg

1000 (F,R)

105 (85) ­ 6 (60) ­ 3200 160 (­) 3300 140 M109 10

1010 (F,R)

105 (85) ­ 6 (60) ­ 3200 160 (­) 3300 140 M109 10

1110 (F)

110 (80) ­ 6 (10) ­ 3500 140 (­) 3300 145 n.t. 10

2100 (R)

­ (­) 115 ­ (­) 4 6000 ­ (185) 4500 140 M109 15

2110 (R)

­ (­) 115 ­ (­) 4 6000 ­ (185) 4500 140 n.t. 15

2200 (R)

­ (­) 140 ­ (­) 2 7600 ­ (210) 6000 150 M114 17

2210 (R)

­ (­) 140 ­ (­) 2 7600 ­ (210) 6000 150 M114 17

Tens. modulus Flex. stress y (b) Flex. modulus Hardness Ball Rockwell Abrasion Taber

Impact

Izod notch. unnotch. Charpy notch. unnotch. 23° (-30°) C 23° (-30°) C 23° (-30°) C 23° (-30°) C kJ/m 2 kJ/m 2 kJ/m 2 kJ/m 2 6 (6) ­ (­) 4 (4) ­ (­) 5 (5) ­ (­) n.t. (n.t.) ­ (­) 4 (4) ­ (­) n.t. (n.t.) ­ (­) ­ (­) 30 (30) ­ (­) 35 (35) ­ (­) 30 (30) ­ (­) 35 (35) ­ (­) 30 (30) ­ (­) 35 (35) ­ (­) 30 (30) ­ (­) 35 (35)

P S C W

Thermal

Vicat A/50 B/50 B/120 HDT/ Ae 1.80 MPa / Be 0.45 Mpa Ball Pressure RTI Electrical Mech. with Impact without Impact Thermal conductivity CTE flow flow °C °C °C °C °C °C °C °C °C W/m°C 1/°C 1/°C 215 211 212 190 200 125 170 170 170 0.24 5.0·10 -5 5.0·10 -5 215 211 212 190 195 125 170 170 170 0.24 5.0·10 -5 5.0·10 -5 210 200 205 185 200 125 n.t. n.t. n.t. 0.26 5.0·10 -5 5.0·10 -5 223 212 217 205 210 125 170 170 170 0.25 2.6·10 -5 6.0·10 -5 223 212 217 205 210 125 170 170 170 0.25 2.6·10 -5 6.0·10 -5 223 212 218 205 210 125 170 170 170 0.28 2.5·10 -5 6.0·10 -5 223 212 218 205 210 125 170 170 170 0.28 2.5·10 -5 6.0·10 -5

Flammability

UL94 LOI Glow wire Needle flame HWI - PLC HAI - PLC class at mm % °C at mm -- PLC PLC V0/0.41 5VA/1.60 47 960/1.0-3.2 1.0 1 3 V0/0.71 5VA/3.00 47 960/1.0-3.2 1.0 1 3 V0/0.71 5VA/3.00 47 960/1.0-3.2 n.t. ­ ­ V0/0.41 n.t. 46 960/1.0-3.2 1.0 1 4 V0/0.41 n.t. 46 960/1.0-3.2 1.0 1 4 V0/0.41 n.t. 46 960/1.0-3.2 1.0 1 4 V0/0.41 n.t. 46 960/1.0-3.2 1.0 1 4

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm Surface resistivity Volume resistivity Rel. permitt. 50 Hz (1 MHz) Dissipation f. 50 Hz 1 MHz CTI (CTI-M) CTI Arc D-495 HVTR kV/mm Ohm Ohm·cm -- -- -- V PLC PLC PLC 33 / 25 / 16 >10 15 >10 15 2.9 (2.9) 0.0005 0.006 150 (100) 4 5 2 33 / 25 / 16 >10 15 >10 15 2.9 (2.9) 0.0005 0.006 150 (100) 4 5 2 ­/ ­ / 17 >10 15 >10 15 3.5 (­) 0.0016 ­ 175 (125) ­ ­ ­ 34 / 27 / 15 >10 15 >10 15 3.0 (2.9) 0.0009 0.0025 150 (100) 4 6 2 34 / 27 / 15 >10 15 >10 15 3.0 (2.9) 0.0009 0.0025 150 (100) 4 6 2 34 / 26 / 16 >10 15 >10 15 3.1 (3.0) 0.0008 0.0025 150 (100) 4 6 2 34 / 26 / 16 >10 15 >10 15 3.1 (3.0) 0.0008 0.0025 150 (100) 4 6 2

P S C W

Physical

Density Moisture abs. 23°C Water abs. 23°C Mould shrink. flow g/cm 3 % % % 1.27 0.7 1.25 0.5-0.7 1.27 0.7 1.25 0.5-0.7 1.37 0.65 1.20 0.4-0.6 1.34 0.6 1 0.4-0.6 1.34 0.6 1 0.4-0.6 1.42 0.55 1 0.3-0.5 1.42 0.55 1 0.3-0.5

Rheological

MVR cm 3/10 min 13 25 21 9 13 7 10

1000 (F,R)

1010 (F,R)

1110 (F)

2100 (R)

2110 (R)

2200 (R)

2210 (R)

NB : not broken · ­ : not relevant · n.t.: not tested

g GE Plastics

Ultem ® profile 3 Product Selection page 16

page 16 page 16

Typical values only. Not to be used for specification purposes.

multi purpose glass reinforced 30% high flow 40% milled glass high flow

Mechanical

Tens. stress Tens. strain y (b) b y (b) b 50 5 50 5

Unit

MPa MPa % % MPa MPa MPa MPa scale mg

2300 (R)

­ (­) 165 ­ (­) 2 9500 ­ (225) 7500 165 M114 20

2310 (R)

­ (­) 165 ­ (­) 2 9500 ­ (225) 7500 165 M114 20

2312

­ (­) 85 ­ (­) 3 7000 ­ (145) 7000 160 n.t. 35

2400 (R)

­ (­) 180 ­ (­) 2 11500 ­ (240) 10000 170 M125 20

2410 (R)

­ (­) 180 ­ (­) 2 11500 ­ (240) 10000 170 M125 20

Tens. modulus Flex. stress y (b) Flex. modulus Hardness Ball Rockwell Abrasion Taber

Impact

Izod notch. unnotch. Charpy notch. unnotch. 23° (-30°) C 23° (-30°) C 23° (-30°) C 23° (-30°) C kJ/m 2 kJ/m 2 kJ/m 2 kJ/m 2 ­ (­) 40 (40) ­ (­) 40 (40) ­ (­) 40 (40) ­ (­) 40 (40) ­ (­) 20 (20) ­ (­) 25 (25) ­ (­) 35 (35) ­ (­) 40 (40) ­ (­) 35 (35) ­ (­) 40 (40)

P S C W

Thermal

Vicat A/50 B/50 B/120 HDT/ Ae 1.80 MPa / Be 0.45 Mpa Ball Pressure RTI Electrical Mech. with Impact without Impact Thermal conductivity CTE flow flow °C °C °C °C °C °C °C °C °C W/m°C 1/°C 1/°C 225 213 220 210 215 125 180 170 180 0.3 2.0·10 -5 6.0·10 -5 225 213 220 210 215 125 180 170 180 0.3 2.0·10 -5 6.0·10 -5 220 211 213 192 206 125 170 170 170 0.3 2.3·10 -5 2.7·10 -5 230 217 225 210 215 125 170 170 170 0.33 1.5·10 -5 4.5·10 -5 230 217 225 210 215 125 170 170 170 0.33 1.5·10 -5 4.5·10 -5

Flammability

UL94 LOI Glow wire Needle flame HWI - PLC HAI - PLC class at mm % °C at mm -- PLC PLC V0/0.25 5VA/1.24 48 960/1.0-3.2 1.0 1 4 V0/0.25 5VA/1.24 48 960/1.0-3.2 1.0 1 4 V0/0.81 n.t. n.t. 960/1.0-3.2 1.0 1 3 V0/0.25 n.t. 48 960/1.0-3.2 1.0 0 4 V0/0.25 5VA/1.57 48 960/1.0-3.2 1.0 0 4

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm Surface resistivity Volume resistivity Rel. permitt. 50 Hz (1 MHz) Dissipation f. 50 Hz 1 MHz CTI (CTI-M) CTI Arc D-495 HVTR kV/mm Ohm Ohm·cm -- -- -- V PLC PLC PLC 35 / 26 / 15 >10 15 >10 15 3.3 (3.4) 0.0016 0.0023 150 (100) 4 6 3 35 / 26 / 15 >10 15 >10 15 3.3 (3.4) 0.0016 0.0023 150 (100) 4 6 3 ­/­/­ >10 15 >10 15 n.t. (3.4) n.t. n.t. 150 (n.t.) 4 7 0 35 / 26 / 16 >10 15 >10 15 3.5 (3.1) 0.0025 0.0019 150 (100) 5 5 4 35 / 26 / 16 >10 15 >10 15 3.5 (3.1) 0.0025 0.0019 150 (100) 5 5 4

P S C W

Physical

Density Moisture abs. 23°C Water abs. 23°C Mould shrink. flow g/cm 3 % % % 1.51 0.5 0.9 0.2-0.4 1.51 0.5 0.9 0.2-0.4 1.51 0.5 0.9 0.2-0.4 1.61 0.4 0.8 0.1-0.3 1.61 0.4 0.8 0.1-0.3

Rheological

MVR cm 3/10 min 6 8 12 5 7

2300 (R)

2310 (R)

2312

2400 (R)

2410 (R)

NB : not broken · ­ : not relevant · n.t.: not tested

g GE Plastics

Ultem ® profile 3 Product Selection page 17

wear resistant unreinforced

Typical values only. Not to be used for specification purposes.

chemical resistant unreinforced glass reinforced 20% 30%

high heat

carbon fibre filled

glass reinforced 25%

standard

high flow

25%

Mechanical

Tens. stress Tens. strain y (b) b y (b) b 50 5 50 5

Unit

MPa MPa % % MPa MPa MPa MPa scale mg

4001

95 (75) ­ 6 (30) ­ 3000 125 (­) 3000 130 M110 2

4000

­ (­) 90 ­ (­) 1 9900 ­ (120) 7000 140 M85 30

CRS 5001

100 (95) ­ 8 (50) ­ 3200 110 (105) 2500 135 R123 10

CRS 5011

100 (85) n.t. 8 (50) n.t. 2900 110 (n.t.) 2900 n.t. n.t. n.t.

CRS 5201 (R)

­ (­) 135 ­ (­) 3 7200 (­) 180 5800 145 n.t. n.t.

CRS 5311

­ (­) 160 ­ (­) 2 10000 (­) 210 8200 165 n.t. n.t.

6000

110 (95) ­ 7 (15) ­ 3100 140 (­) 3000 160 M110 n.t.

7801

­ (­) 200 ­ 1.5 16000 ­ (260) 13500 180 n.t. 20

Tens. modulus Flex. stress y (b) Flex. modulus Hardness Ball Rockwell Abrasion Taber

Impact

Izod notch. unnotch. Charpy notch. unnotch. 23° (-30°) C 23° (-30°) C 23° (-30°) C 23° (-30°) C kJ/m 2 kJ/m 2 kJ/m 2 kJ/m 2 10 (8) ­ (­) 11 (9) ­ (­) ­ (­) 15 (15) ­ (­) ­ (­) 8 (8) ­ (­) n.t. (n.t.) ­ (­) 5 (5) ­ (­) n.t. (n.t.) ­ (­) ­ (­) 40 (40) ­ (­) ­ (­) ­ (­) 35 (35) ­ (­) ­ (­) 5 (5) ­ (­) n.t. (n.t.) ­ (­) ­ (­) 35 (35) ­ (­) 35 (35)

P S C W

Thermal

Vicat A/50 B/50 B/120 HDT/ Ae 1.80 MPa / Be 0.45 Mpa Ball Pressure RTI Electrical Mech. with Impact without Impact Thermal conductivity CTE flow flow °C °C °C °C °C °C °C °C °C W/m°C 1/°C 1/°C 215 208 210 190 200 125 170 170 170 0.26 3.9·10 -5 4.0·10 -5 225 215 220 205 210 125 n.t. n.t. n.t. 0.43 1.5·10 -5 5.0·10 -5 225 220 222 200 210 125 n.t. n.t. n.t. 0.29 5.0·10 -5 6.0·10 -5 220 215 215 200 210 125 n.t. n.t. n.t. n.t. 5.5·10 -5 5.5·10 -5 225 220 222 205 210 125 n.t. n.t. n.t. n.t. 2.0·10 -5 5.0·10 -5 228 220 222 215 215 125 n.t. n.t. n.t. 0.33 2.0·10 -5 7.0·10 -5 235 222 230 215 220 125 n.t. n.t. n.t. n.t. 4.5·10 -5 4.5·10 -5 225 215 220 210 220 125 n.t. n.t. n.t. 0.36 0.7·10 -5 6.0·10 -5

Flammability

UL94 LOI Glow wire Needle flame HWI - PLC HAI - PLC class at mm % °C at mm -- PLC PLC V0/1.60 5VA/1.50 48 960/1.0-3.2 3.2 n.t. n.t. V0/0.84 n.t. 48 960/1.0-3.2 1.0 n.t. n.t. V0/1.59 n.t. 47 960/1.0-3.2 1.0 0 0 V0/1.60 n.t. 49 960/3.2 n.t. n.t. n.t. V0/1.59 n.t. 47 960/1.0-3.2 1.0 0 4 V0/1.59 5VA/1.59 n.t. 960/1.0-3.2 1.0 0 4 V0/1.57 n.t. 47 960/1.0-3.2 1.0 0 4 V0/1.60 n.t. n.t. 960/1.0-3.2 1.0 n.t. n.t.

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm Surface resistivity Volume resistivity Rel. permitt. 50 Hz (1 MHz) Dissipation f. 50 Hz 1 MHz CTI (CTI-M) CTI Arc D-495 HVTR kV/mm Ohm Ohm·cm -- -- -- V PLC PLC PLC n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 150 (n.t.) n.t. n.t. n.t. n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 200 (100) 4 n.t. n.t. n.t. / 26 / 16 >10 15 >10 15 3.2 (3.0) 0.0016 0.0043 175 (125) 4 5 3 n.t. / n.t. / 18.1 >10 15 2.5·10 15 3.2 (n.t.) 0.0021 n.t. 150 (100) n.t. n.t. n.t. n.t. / 26 / 16 >10 15 >10 15 3.2 (3.0) 0.0016 0.0043 150 (100) 4 5 4 n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 150 (100) 4 5 4 n.t./29/18.6 >10 15 >10 15 3.2 (n.t.) 0.0015 n.t. 150 (100) n.t. n.t. n.t. ­/­/­ ­ ­ ­ (­) ­ ­ ­ (­) ­ ­ ­

P S C W

Physical

Density Moisture abs. 23°C Water abs. 23°C Mould shrink. flow g/cm 3 % % % 1.33 0.6 1.10 0.6-0.8 1.68 0.3 0.7 0.1-0.3 1.28 0.6 1.20 0.6-0.8 1.28 0.2 1.20 0.5-0.7 1.43 0.2 1.00 0.3-0.5 1.52 0.15 0.9 0.2-0.4 1.3 0.8 1 0.4-0.6 1.37 0.5 0.9 0.2-0.4

Rheological

MVR cm 3/10 min 13 5 7 20 5 7 6 5

4001

4000

CRS 5001

CRS 5011

CRS 5201 (R)

CRS 5311

6000

7801

NB : not broken · ­ : not relevant · n.t.: not tested

g GE Plastics

Ultem ® profile 3 Product Selection page 18

aircraft unreinforced

Typical values only. Not to be used for specification purposes.

flexible copolymer glass reinforced 30%

high impact

polymer blend

standard

extrusion

Siltem

Mechanical

Tens. stress Tens. strain y (b) b y (b) b 50 5 50 5

Unit

MPa MPa % % MPa MPa MPa MPa scale mg

9075

90 (75) ­ 6 (25) ­ 3200 125 (120) 3000 127 n.t. 15

9076

95 (70) n.t. 6 (50) n.t. 3000 135 (n.t.) 3000 145 n.t. n.t.

AR 9300

­ (­) 165 ­ (­) 2 9500 (­) 225 8500 160 n.t. n.t.

STM 1500

20 (25) ­ (­) 15 (110) ­ (­) 590 20 (18) 475 ­ ­ 1) 60

HTX 1010 (F)

97 (80) ­ (­) 6 (15) ­ (­) 3100 122 (­) 2900 115 ­ 15

ATX 100 (F)

68 (55) ­ (­) 7 (30) ­ (­) 2350 90 (­) 2400 111 ­ n.t.

ATX 200 (F)

98 (75) ­ (­) 7 (21) ­ (­) 3100 130 (­) 3200 130 ­ 20

Tens. modulus Flex. stress y (b) Flex. modulus Hardness Ball Rockwell Abrasion Taber

Impact

Izod notch. unnotch. Charpy notch. unnotch. 23° (-30°) C 23° (-30°) C 23° (-30°) C 23° (-30°) C kJ/m 2 kJ/m 2 kJ/m 2 kJ/m 2 7 (5) ­ (­) 7 (6) ­ (­) 6 (6) n.t. (n.t.) 6 (6) n.t. (n.t.) ­ (­) 35 (35) ­ (­) 40 (40) 25 (15) ­ (­) n.t. (n.t.) ­ (­) 15 (9) ­ (­) 15 (14) ­ (­) 15 (13) ­ (­) 19 (15) ­ (­) 5 (5) ­ (­) 4 (4) ­ (­)

P S C W

Thermal

Vicat A/50 B/50 B/120 HDT/ Ae 1.80 MPa / Be 0.45 Mpa Ball Pressure RTI Electrical Mech. with Impact without Impact Thermal conductivity CTE flow flow °C °C °C °C °C °C °C °C °C W/m°C 1/°C 1/°C 210 200 200 185 200 125 n.t. n.t. n.t. 0.23 5.0·10 -5 5.0·10 -5 210 200 200 175 195 125 n.t. n.t. n.t. 0.26 5.5·10 -5 5.5·10 -5 220 211 215 208 212 125 n.t. n.t. n.t. 0.3 1.7·10 -5 4.2·10 -5 n.t. 75 78 ­ ­ 75 n.t. n.t. n.t. n.t. 11·10 -5 9·10 -5 215 210 212 182 197 125 n.t. n.t. n.t. n.t. n.t. n.t. 182 169 176 160 168 125 n.t. n.t. n.t. n.t. 6.0·10 -5 5.9·10 -5 207 200 202 188 204 125 n.t. n.t. n.t. 0.22 4.7·10 -5 4.5·10 -5

Flammability

UL94 LOI Glow wire Needle flame HWI - PLC HAI - PLC class at mm % °C at mm -- PLC PLC V0/1.60 n.t. n.t. 960/1.0-3.2 n.t. n.t. n.t. n.t. n.t. 50 960/3.2 n.t. n.t. n.t. n.t. n.t. n.t. 960/1.0-3.2 n.t. n.t. n.t. V1/1.60 n.t. 48 960/1.0-3.2 n.t. n.t. n.t. n.t. n.t. n.t. 960/1.0-3.2 n.t. n.t. n.t. HB/0.76 n.t. n.t. 960/3.2 n.t. n.t. n.t. V0/1.50 n.t. n.t. 960/3.2 n.t. n.t. n.t.

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm Surface resistivity Volume resistivity Rel. permitt. 50 Hz (1 MHz) Dissipation f. 50 Hz 1 MHz CTI (CTI-M) CTI Arc D-495 HVTR kV/mm Ohm Ohm·cm -- -- -- V PLC PLC PLC n.t./n.t./n.t. n.t. n.t. n.t. (n.t.) n.t. n.t. n.t. (n.t.) n.t. n.t. n.t. n.t./n.t./ 18 >10 15 >10 15 2.9 (2.8) n.t. 0.005 150 (n.t.) n.t. n.t. n.t. n.t./n.t./n.t. n.t. n.t. n.t. (n.t.) n.t. n.t. n.t. (n.t.) n.t. n.t. n.t. ­ / ­ / 19 >10 15 >10 15 3 (n.t.) n.t. n.t. 175 (100) ­ ­ n.t. n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 125 (n.t.) ­ ­ n.t. n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 175 (n.t.) ­ ­ n.t. n.t./n.t./n.t. >10 15 >10 15 n.t. (n.t.) n.t. n.t. 150 (n.t.) ­ ­ n.t.

P S C W

Physical

Density Moisture abs. 23°C Water abs. 23°C Mould shrink. flow g/cm 3 % % % 1.32 0.7 1.25 0.6-0.8 1.30 0.7 1.25 0.6-0.8 1.49 n.t. n.t. 0.2-0.4 1.18 n.t. n.t. 1.2-1.4 1.27 0.7 n.t. 0.5-0.7 1.21 n.t. n.t. 0.5-0.7 1.26 0.7 n.t. 0.5-0.7

Rheological

MVR cm 3/10 min 27 27 6 8 2) 18 45 33

9075

1) 2)

9076

AR 9300

STM 1500

Siltem

HTX 1010 (F)

ATX 100 (F)

ATX 200 (F)

Shore D hardness according to ISO 868 of Siltem STM 1500 is 69 MVR of Siltem STM 1500 at 320°C/2.16 kg

NB : not broken · ­ : not relevant · n.t.: not tested

g GE Plastics

Ultem ® profile 3 Product Selection page 19

4

4.1

Properties *

Thermal Properties

Heat deflection temperature and continuous use ratings

An outstanding property of Ultem resin is its ability to withstand long-term exposure to elevated temperatures. This high heat performance, combined with excellent flammability ratings and Underwriters' Laboratory, UL, recognition, qualifies Ultem for demanding high temperature applications.

In recognition of its inherent thermal stability, UL has granted the Ultem 1000 base polymer a relative thermal index (RTI) of 170°C, according to UL746B. The polymer's high glass transition temperature (Tg) of 217°C coupled with its high heat deflection temperature (HDT/Ae 1.80 MPa) of 190°C contributes to its excellent retention of physical properties at elevated temperatures.

P S C W

* Typical values only.

In all cases extensive testing of the application under the working conditions is strongly recommended. The actual performance and interpreting of the results of end-use testing are the end-producer's responsibility.

g GE Plastics

Ultem ® profile 4 Properties page 20

s

F I G U R E 1 shows the ability of Ultem resin to

maintain this high heat deflection temperature with increased stress, an important consideration to the design engineer.

225

s

FIGURE 1

Heat deflection temperature of Ultem 1000 vs. applied stress

Heat deflection temperature (°C)

200

175

P S C W

150

125 0 1 2 3 4 5 6 7 8 9 10 Applied stress (MPa)

s

F I G U R E 2 compares the high heat deflection

temperature of Ultem 1000 with those of other high performance engineering thermoplastics.

250

s

FIGURE 2

Heat Deflection Temperature (HDT/Ae 1.80 MPa)

Heat deflection temperature (°C)

200

150

100

Ultem ATX100 Polyethersulfone Ultem ATX200

Ultem ® profile 4 Properties page 21

Ultem 2100 (10% GF)

Ultem 2400 (40% GF)

P S C W

g GE Plastics

Coefficient of thermal expansion

s

TA B L E 1

Another important design consideration is the thermal expansion of a material, particularly in applications where plastic parts are mated with metal parts or have metal inserts. s TA B L E 1 lists the coefficient of thermal expansion for the family of Ultem grades and demonstrates the capability of matching the values of several metals.

Coefficient of linear thermal expansion

Material Flow direction (10 -5 /°C) Cross flow direction (10 -5 /°C)

Ultem 1000 Ultem 2100 Ultem 2200 Ultem 2300 Ultem 2312

High heat polycarbonate

Ultem 1000

Polysulfone

5 2.6 2.5 2 2.3 1.5 5.6 3.6 7.5 1.6-1.8 2.7 2.2 1.2-1.5

5 6 6 6 2.7 4.5

4.2

Flammability

Flame resistance

Ultem 2400 Polysulfone Polysulfone 10% GF High Heat Polycarbonate Brass Zinc Aluminium

P S C W

Ultem resin exhibits exceptionally good flame resistance without the use of additives. For example, Ultem 1000 has been rated V0 at 0.41 mm under UL94, and 5VA at 1.6 mm. In addition, as seen in s F I G U R E 3 , it has a limited oxygen index of 47, the highest of any commonly used engineering thermoplastic.

Combustion characteristics

A key factor in determining the relative safety of a polymeric material is its smoke generation under actual fire conditions. Measured against

Steel

s

FIGURE 3

s

FIGURE 4

Oxygen index

Smoke evolution by NBS test Dmax 20 min

50 Oxygen index (%) Smoke density (Dmax)

Ultem 1000 Polyethersulfone Polysulfone High heat polycarbonate

240

40

180

30

120

20

60

10

0

Ultem 1000 Polyethersulfone Polysulfone

P S C W

other engineering thermoplastics, Ultem resin exhibits extremely low levels of smoke generation as demonstrated by the NBS smoke evolution test results shown in s F I G U R E 4 . Furthermore, the products of combustion of Ultem resin have been shown to be no more toxic than those of wood.

g GE Plastics

Ultem ® profile 4 Properties page 22

Aircraft industry regulations

s

TA B L E 2

Ultem resin is widely used in aircraft applications because of its compliance with aircraft industry regulations. s TA B L E 2 lists the performance of the different Ultem series according to these regulations.

Aircraft regulation compliance according to ABD 0031, FAR 25.853, OSU

Material + Grade FAR 25.853 OSU Smoke Ds 4min Toxicity

Ultem 1000 series Ultem 2000 series Ultem CRS 5000 series

a(60s) a(60s) a(60s) a(60s) a(60s) a(60s)

100/100 100/100 100/100 100/100 100/100 65/65

< 50 < 50 < 50 < 50 < 50 < 50

pass pass pass pass pass pass

4.3

Mechanical properties

Strength

P S C W

At room temperature, Ultem resin exhibits strength well beyond that of most engineering thermoplastics, with a tensile stress at yield of 105 MPa (ISO R527)and a flexural strength at yield of 160 MPa (ISO 178). Even more impressive is the retention of strength at elevated temperatures. At 190°C, a temperature well beyond the useful range of most other engineering thermoplastics, Ultem resin retains approximately 50 MPa tensile stress (ISO R527), as illustrated in s F I G U R E 5 .

Ultem 6000 series Ultem 7000 series Ultem 9000 series

ABD 0031 contains requirements for smoke, toxicity and FAR 25.853. FAR 25.853 classifies materials for flammability. OSU (Ohio State University) calorimeter requirements for larger parts.

s

FIGURE 5

Tensile stress (MPa)

Ultem

250 200 150 100 50 0 -50 0 50 100 150 200 Temperature (°C)

Tensile stress as a function of temperature

2400 2300 2200 2100 1000 CRS5001

s

F I G U R E 6 demonstrates the higher tensile

P S C W

stress of Ultem 1000 compared to other high performance engineering materials. The outstanding inherent strength of Ultem resin is further enhanced through reinforcement with glass fibres, as shown in s F I G U R E 7 which compares Ultem 2200 (20% glass reinforced grade) with other glass reinforced engineering thermoplastics.

g GE Plastics

Ultem ® profile 4 Properties page 23

s

FIGURE 6

s

FIGURE 7

Tensile stress (23°C) at yield (50mm/min)

Tensile stress (23°C) at break (5mm/min)

Tensile stress (MPa)

Tensile stress (MPa)

Ultem ATX100 Polyethersulfone Ultem ATX200 High heat polycarbonate Ultem 1000 Polysulfone

110 100 90 80 70 60 50 40

140 120 100 80 60 40

Ultem 2200 20% GF Polyethersulfone 20% GF Polysulfone 20% GF

P S C W

30

Modulus

Another outstanding mechanical property of Ultem is its high modulus. The 3300 MPa flexural modulus (ISO 178) of Ultem 1000 is one of the highest room temperature moduli of any high performance engineering plastic. In load bearing applications where deflection is a primary consideration, unreinforced Ultem

10 11

s

resin provides structural rigidity approaching that of many glass reinforced resins. In addition, the flexural modulus of Ultem resin remains exceptionally high at elevated temperatures, as shown in s F I G U R E 8 . For example, at 175°C the modulus of Ultem 1000 is higher than that of most engineering plastic at room temperature.

FIGURE 8

Flexural modulus (Pa)

PPS 40% GF

Ultem

Flexural modulus of Ultem at different glass ratios as a function of temperature vs. PPS 40%GF

10 10

2400 1000

10 9

P S C W

10 8

10 7 -120 -80

-40

0

40

80

120 160 200 240 280 Temperature (°C)

g GE Plastics

Ultem ® profile 4 Properties page 24

P S C W

Ultem ATX100

Polyethersulfone

High heat polycarbonate

Ultem ATX200

Polysulfone

Ultem 1000

Thus, Ultem resin offers designers the opportunity to achieve desired stiffness with none of the sacrifices associated with glass reinforced materials, such as increased machine and tool wear and decreased flow. s F I G U R E 9 compares the flexural modulus of the Ultem 1000 base polymer with that of other high performance engineering thermoplastics. Where greater stiffness is required, the glass reinforced Ultem 2000 series or the carbon fibre reinforced Ultem 7000 series provide additional performance with flexural moduli as high as 13500 MPa (ISO 178) at room temperature.

s

FIGURE 9

Flexural modulus (23°C) 2 mm/min

Flexural Modulus (MPa)

3400 3200 3000 2800 2600 2400 2200 2000

Ductility

Fatigue endurance

In addition to its unique combination of high strength and modulus, Ultem resin exhibits outstanding ductility. Its tensile elongation at yield affords the freedom to incorporate snap fit designs for ease of assembly. Even with the addition of 10% glass reinforcement, Ultem 2100 retains ductility over a temperature range from subzero to 200°C.

Impact strength

Fatigue is an important design consideration for parts subjected to cyclical loading or vibration. In such applications, an uniaxial fatigue diagram (see s F I G U R E 1 0 ) could be used to predict product life. These curves can be used to determine the fatigue endurance limit, or the maximum cycle stress that a material can withstand without failure.

Creep behaviour

P S C W

Ultem 1000 exhibits excellent practical impact resistance. Since Ultem resins display notch sensitivity, adherence to standard design principles is recommended. Stress concentrators such as sharp corners should be minimized to provide the maximum impact strength in moulded parts. Ultem HTX and Ultem ATX100 have been developed specifically for applications where high impact performance is required. The Izod notched impact strength of these series goes up to 15 kJ/m2.

When considering the mechanical properties of any thermoplastic material, designers must recognize the effects of temperature, stress level and load duration on material performance. Ultem resin displays excellent creep resistance even at temperatures and stress levels which would preclude the use of many other thermoplastics.

g GE Plastics

Ultem ® profile 4 Properties page 25

160

s

FIGURE 10

Stress (MPa)

Ultem

Uniaxial fatigue test of Ultem at different glass ratios

140 120 100 80 60 40 20 0 10 2 10 3 10 4 10 5 10 6 10 7 Cycles to failure

2400 2300 2200 2100 1000

P S C W

4.4

Electrical properties

Ultem resins exhibit excellent electrical properties which remain stable over a wide range of environmental conditions. This stability, together with outstanding thermal and mechanical properties, make Ultem resins ideal for highly demanding electrical and electronic applications.

Relative permittivity

Although either low or high absolute values of the relative permittivity may be desirable depending upon the application, it is more important that the values remain stable over the entire service temperature and/or frequency range. s F I G U R E S 1 1 and 1 2 demonstrate the stability of Ultem 1000 over varying temperatures and frequencies.

3.20

s

FIGURE 11

Relative permittivity of Ultem 1000 vs. temperature at 50% RH

Dielectric constant

10 3 Hz 10 6 Hz

3.15 3.10 3.05 3.00 2.95 0 50 100 150 200 Temperature (°C)

P S C W

g GE Plastics

Ultem ® profile 4 Properties page 26

3.20

s

FIGURE 12

Relative permittivity of Ultem 1000 vs. frequency at 50% RH

Dielectric constant

23°C 82°C

3.15 3.10 3.05 3.00 2.95 1 10 10 2 10 3 10 4 10 5 10 6

P S C W

10 7 10 8 10 9 10 10 Frequency (Hz)

Dissipation factor

As shown in s F I G U R E 1 3 , Ultem 1000 exhibits an exceptionally low dissipation factor over a wide range of frequencies, particularly in the kilohertz (10 3 Hz) and gigahertz (10 9 Hz) ranges. In addition, this low dissipation factor remains

0.007

s

FIGURE 13

Dissipation factor

Dissipation factor of Ultem 1000 vs. frequency at 50% RH

0.006 0.005 0.004 0.003 0.002 0.001 0 1 10 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 Frequency (Hz) 10 10

82°C 49°C 23°C

P S C W

constant over the resin's entire useful temperature range. This behaviour is of prime importance in applications such as computer circuitry and microwave components where the resin provides a minimum loss of electrical energy in the form of heat.

g GE Plastics

Ultem ® profile 4 Properties page 27

s

F I G U R E S 1 4 and 1 5 demonstrate the superior

performance of Ultem over other thermoplastic resins traditionally considered for these electrotechnical applications. The dissipation factor peak around megahertz (10 6 Hz) is caused by moisture in the material and therefore depends on the ambient conditions.

0.018

s

FIGURE 14

Dissipation factor

0.016 0.014 0.012 0.010 0.008 0.006 0.004 0.002 0 1 10 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 Frequency (Hz)

Dissipation factor vs. frequency at 23°C, 50% RH

P S C W

Ultem 1000 Polyethersulfone Polysulfone

10 10

0.010

s

FIGURE 15

Dissipation factor vs. temperature at 2.45 x 10 9 Hz

Dissipation factor

Polysulfone Ultem 1000

0.008 0.006 0.004 0.002 0 0 50 100 150 200 250 Temperature (°C)

P S C W

g GE Plastics

Ultem ® profile 4 Properties page 28

Dielectric strength

An excellent electrical insulator, Ultem resin exhibits a dielectric strength of 25 kV/mm at 1.6 mm (in oil). The effect of thickness on dielectric strength for Ultem 1000 is shown in s F I G U R E 1 6 .

s

FIGURE 16

Dielectric strength (kV/mm)

Ultem 1000

250 200 150 100 50 0 0.01

Dielectric strength of Ultem 1000 as a function of thickness

P S C W

0.1

1 10 Thickness (mm)

4.5

Environmental resistance

In an effort to further enhance the inherent chemical resistance of Ultem resin, a chemical resistant Ultem CRS 5000 series has been developed. These amorphous materials combine the chemical resistance characteristics often associated with crystalline and specialty materials with the excellent processing characteristics typical of Ultem resins.

Cleaning and degreasing

Chemical resistance

P S C W

Unlike other amorphous resins, Ultem polyetherimide demonstrates unusually good resistance to a wide range of chemicals. s TA B L E 3 lists the performance of Ultem 1000 and Ultem CRS 5000 series in a variety of common environments at several stress levels. In applications requiring prolonged immersion, finished part performance should always be evaluated on the actual part under actual service conditions. Ultem resin displays excellent property retention and resistance to environmental stress cracking when exposed to most commercial automotive and aircraft fluids, fully halogenated hydrocarbons, alcohols and weak aqueous solutions. Exposure to partially halogenated hydrocarbons and strong alkaline environments should be avoided.

Cleaning or degreasing of Ultem resin finished parts can be performed using methyl or isopropyl alcohol, soap solutions, heptane, hexane or naphtha. The parts should not be cleaned with partially halogenated hydrocarbons or with ketones such as MEK or strong bases, such as sodium hydroxide.

g GE Plastics

Ultem ® profile 4 Properties page 29

s

TA B L E 3

Chemical compatibility of Ultem 1000 and Ultem CRS 5001

Media

Alcohols 1 ) Temp (°C) Immersion (days) Strain (%) Ultem CRS 5001 Ultem 1000

Methanol

23 60

21 21 21 21

0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a.

n.a. n.a. n.a. n.a.

Aqueous Detergents 2 ) & Cleaners

Domestic Detergent

23 60

P S C W

1 2

21 21 21 21 21 21 21 21

0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.

n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.

Key to performance

Bleach (10%)

23 60

n.a. f. c. sv.c. s.c. ­

no attack failure / ruptured crazing severe crazing slight crazing not tested

) Other examples of alcohols include ethyl, propyl and some glycols ) Other examples of aqueous detergents include hypochlorite bleaches and phosphate cleaners

>

s

TA B L E 3 ( continued)

Temp (°C) Immersion (days) Strain (%) Ultem CRS 5001 Ultem 1000

Media

Water

Steam

100

21 21 21 21

0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a.

n.a. f. (216 hrs.) n.a. n.a.

Distilled Water

Chlorinated Solvents 3 )

23

1,1,2 Trichloroethylene

23

2 hrs. 2 hrs. 21 21

0.25 0.5 0.25 0.5

sv.c. sv.c. n.a. n.a.

f. f. n.a. f. (24 hrs.)

1,1,1 Trichloroethylene Chloroform

Esters

23

Dibutylphtalate

23 85

21 21 21 24 hrs.

0.25 0.5 0.25 0.5

n.a. c. n.a. c.

n.a. f. (24 hrs.) f. f.

Key to performance

Aromatic Hydrocarbons 4 )

P S C

Toluene

23 85

21 48 hrs.

0.25 0.5 0.25 0.5

n.a. c. c. (48 hrs.) c. (48 hrs.)

f. (48 hrs.) f. (2 hrs.) f. f.

n.a. f. c. sv.c. s.c. ­

no attack failure / ruptured crazing severe crazing slight crazing not tested

3

W

4

) Other examples of chlorinated solvents include methylene chloride and ethylene chloride ) Other examples of aromatic hydrocarbons include benzene, xylene and gasoline

>

g GE Plastics

Ultem ® profile 4 Properties page 30

<

Media

Ketones and Aldehydes 5 ) Temp (°C) Immersion (days) Strain (%) Ultem CRS 5001 Ultem 1000

Methyl Ethyl Ketone (MEK)

23 75

21

0.25 0.5 0.25 0.5

n.a. c. (48 hrs.) s.c.(48 hrs.) c. (48 hrs.)

f. (2 hrs.) f. (2 hrs.) f. f.

Aircraft Fluids

Skydrol 500B Hydraulic Fluid

23 85

21 21 21

0.25 0.5 0.25 0.5

n.a. n.a. n.a. c. (24 hrs.)

n.a. f. (72 hrs.) f. f.

Automotive Fluids

Gasoline ASTM Fuel C

73 60

P S C W

Brake Fluid Diesel Fuel

21 21 21 21 5

0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a. ­ ­ n.a. n.a. n.a. f.

n.a. n.a. n.a. f. n.a. n.a. n.a. n.a. f. (168 hrs.) f.

Key to performance

23

23 85

21 21 21

n.a. f. c. sv.c. s.c. ­

no attack failure / ruptured crazing severe crazing slight crazing not tested

5

) Other examples of ketones and aldehydes include acetone, acetealdehyde and formaldehyde

>

s

TA B L E 3 ( continued)

Temp (°C) Immersion (days) Strain (%) Ultem CRS 5001 Ultem 1000

Media

Automotive Fluids

Transmission Fluid

23 120

5 7

0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5

­ ­ ­ ­ n.a. n.a. n.a. f. (72 hrs.) n.a. n.a. n.a. n.a.

n.a. n.a. n.a. n.a. n.a. n.a. f. f. n.a. n.a. f. (168 hrs.) f. (168 hrs.)

Key to performance

Antifreeze (75%)

23 150

21 21 21

Mineral Oil

23 140

21 21 21 21

Acids

6)

Sulphuric Acid (37%) Inorganic

23 90

P S C W

6

21 21 21 21

0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a.

n.a. n.a. n.a. n.a.

n.a. f. c. sv.c. s.c. ­

no attack failure / ruptured crazing severe crazing slight crazing not tested

) Other examples of acids include hydrochloric, phosphoric and glacial acetic

>

g GE Plastics

Ultem ® profile 4 Properties page 31

<

Media

Acids 6 ) Temp (°C) Immersion (days) Strain (%) Ultem CRS 5001 Ultem 1000

Acetic Acid (20%) Organic

23 90

21 21 21 21

0.25 0.5 0.25 0.5

n.a. n.a. n.a. n.a.

n.a. n.a. n.a. n.a.

Strong Bases 7 )

Sodium Hydroxide (30%)

23 90

21 21

0.25 0.5 0.25 0.5

n.a. n.a. f. f.

n.a. n.a. f. f.

Key to performance

Weak Bases 8 )

Ammonium Hydroxide (10%)

23 90

21 21

P S

6

0.25 0.5 0.25 0.5

n.a. n.a. f. f.

n.a. n.a. f. f.

n.a. f. c. sv.c. s.c. ­

no attack failure / ruptured crazing severe crazing slight crazing not tested

C W

) Other examples of acids include hydrochloric, phosphoric and glacial acetic ) Other examples of strong bases include other metal hydroxides and some amines 8 ) Other examples of weak bases include dilute forms of metal hydroxides and some amines

7

Aqueous solutions

Chemical (concentration)

Ultem resin is resistant to mineral acids, mineral salt solutions and dilute bases (pH less than 9) as shown in s TA B L E 4 . This property, together with high temperature performance and transparency, qualifies the resin for applications such as laboratory ware and automotive heat transfer systems.

% Retention of Tensile Stress

% Weight Gain

Deionized water Zinc chloride (10%)

94 96

1.25 1.13 0.85 1.05 1.06 0.61 0.99 0.89 0.73 1.29 1.07 1.15 1.55 1.79 1.00 1.10

Potassium carbonate (30%) 97 Tin chloride (10%) Citric acid (40%) Hydrochloric acid (20%) Phosphoric acid (20%) Sulphuric acid (20%) Chromic acid (15%) Formic acid (10%) Nitric acid (20%) Acetic acid (20%) 97 96 99 97 97 94 94 96 95

P

s

Potassium hydroxide (10%) 97

S C W

TA B L E 4

Ammonium hydroxide (10%) 68 Sodium hydroxide (10%) Cyclohexylamine (1%) 97 97

Chemical Resistance of Ultem 1000 to Aqueous Solutions at 23°C, no stress applied (100 day immersion)

g GE Plastics

Ultem ® profile 4 Properties page 32

Hydrolytic stability

s

Ultraviolet exposure

F I G U R E 1 7 depicts the excellent tensile stress

retention of Ultem 1000 after 10 000 hours of immersion in water at 100°C. In addition, tests show that Ultem resin's physical properties remain virtually unchanged after repeated cycling from steam pressure to drying in vacuum at room temperature. Therefore Ultem resin is a very good material for repeated autoclavability.

s

Ultem resin is resistant to UV radiation without the addition of stabilizers. Properties like tensile stress, modulus and Izod notched impact show a negligible change after long-term exposure to UV. However, care should be taken, since colour changes and loss of Izod unnotched impact performance might occur after longterm exposure.

23°C 100°C

FIGURE 17

Tensile stress (MPa)

Effect of water exposure on tensile stress of Ultem 1000

P S C W

120 100 80 60

0

1 month

2000

4000

6000

8000

1 year

10000

Time (hours)

Radiation resistance

Parts moulded in Ultem resin demonstrate excellent resistance to gamma radiation, as shown in s F I G U R E 1 8 . A loss of less than 6% tensile strain (ISO 527) was observed after cumulative exposure to 500 megarads at the rate of one megarad per hour using Cobalt 60.

Tensile stress (MPa)

s

FIGURE 18

111 104 97 90 83 76 69

80 70 60 50 40 30 20 10 0 100 200 300 400 500 600 6 rads) Radiation exposure level (10

(1 Megarad/hour of Co60 Exposure rate)

Effect of gamma radiation exposure on tensile properties of Ultem 1000

P S C W

g GE Plastics

Agency recognition

Ultem resins have been tested and comply with a number of agency regulations and specifications. Ultem's heat stability and flammability characteristics make it an excellent choice for numerous applications which require Underwriters Laboratory, UL, approval. Several grades of Ultem resin are also recognized by, or otherwise comply with, regulations such as FDA, EU, USP, DIN, VDE, FAR,ABD and military regulations.

P S C W

Tensile strain (%)

Tensile stress % Strain ultimate % Strain of yield

Ultem ® profile 4 Properties page 33

5

Design *

Moulded-in stress in parts can be minimized by: Avoiding thin walls and sharp corners Avoiding large and sharp transitions in wall thickness Ensuring balanced and uniform part filling Properly designing ribs and coring to increase stiffness without increasing wall thickness Ultem resin is ideally suited to the design of long-term high temperature and mechanically stressed applications as confirmed by the uniaxial fatigue diagram in s F I G U R E 1 0 on page 25 of this brochure.

To extract the maximum performance from Ultem resin, the designer should strive to take full advantage of the excellent physical properties of the material as well as the design freedom offered by the injection moulding process. The designer should minimize moulded-in stress in Ultem applications because the higher the stress level in a finished part, the more susceptible it is to chemical attack.

· · · ·

P S C W

* In all cases extensive testing of the application

under the working conditions is strongly recommended. The actual performance and interpreting of the results of end-use testing are the end-producer's responsibility.

g GE Plastics

Ultem ® profile 5 Design page 34

The most important material property to be able to design for stiffness and strength is the stress-strain curve of the material. In s F I G U R E 1 9 , the curves of unreinforced Ultem 1000 base polymer and reinforced Ultem 2100, 2200, 2300, 2400 and 7801 are depicted.

210

s

Note General information on designing with engineering thermoplastics can be found in the GE Plastics `Design guide'.

FIGURE 19

Stress (MPa)

Ultem

Stress-strain curve (23°C)

P S C W

180 150 120 90 60 30 0 0 0.8 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2

7801 2400 2300 2200 2100 1000

Strain (%)

6

Processing

The excellent processing characteristics of Ultem resin make it ideal for precision injection moulding of close-tolerance parts. Optimum moulding results for Ultem resin depend upon a balance of melt and mould temperatures, pressures, part geometry, mould design and equipment.

·Reinforced 2000 series

4000 CRS 5201, CRS 5311 6000* 7801 AR9300 The Ultem grades which are used for Extrusion are: 1000 (F) Siltem STM 1500

·

P S C W

·

The Ultem grades for Injection Moulding are: Unreinforced 1000(F,R), 1010(F,R), 1110(F) 4001 CRS 5001/5011 Blends 9075 ATX 100(F), ATX 200(F) HTX 1010(F)

* Although Ultem 6000 is an unreinforced material,

it has to be processed like a reinforced material.

g GE Plastics

Ultem ® profile 6 Processing page 35

Pre-drying of Ultem resins

· · · · ·

P S C W

Ultem resin must be thoroughly dried to achieve optimum properties and part appearance. It is therefore recommended that the following pre-drying guidelines are used: Dry air dryers are preferable with a dry air dewpoint of -30°C or below 4 to 6 hours drying at 150°C for unreinforced and reinforced injection moulding grades and Ultem 1000 for extrusion Minimum 4 hours drying at 130°C for blends (Injection moulding grades) Minimum 5 hours drying at 105°C for extrusion grade Siltem STM 1500 Maximum allowable moisture content of 0.02% for all Ultem grades

Purging of the barrel

· · · ·

Purging of the barrel is required when changing material. Contamination by foreign or degraded resins can cause problems including appearance defects such as delamination and/or black specks and actual degradation of the material, resulting

in poor part behaviour. Ultem resin tends to adhere on metal, thus purging must be done carefully. The processing temperature range of Ultem resin is 370°C to 400°C. Since this is well above the degradation level of most other thermoplastics, it is essential that all traces of other polymers are removed to avoid contamination. The following purging guidelines are therefore recommended: The best purging material for Ultem resin is glass-filled or unfilled poly-carbonate. HDPE can also be used Drying of the purging material is not required Purging should be started at the processing temperature of Ultem Purging should then proceed for 10 to 15 minutes before dropping temperature settings. Temperatures can be lowered then and purging can be completed with HDPE

Mould temperature

· · ·

Ultem resin should always be moulded in temperature-controlled moulds. High mould temperatures are advisable as they provide: Better material flow during moulding Reduced amounts of moulded-in stress in final parts Optimum surface appearance of mouldings

s

s

FIGURE 20

Melt temperature 370 - 400 °C Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper

Typical moulding temperatures for Ultem unreinforced: · 1000 (F,R) · 1010 (F,R) · 1110 (F) · 4001 · CRS 5001/5011

450 400 350 300 250 200 150 100 50

F I G U R E S 2 0 , 2 1 and 2 2 depict the typical

moulding temperatures for the various grades of Ultem resin. There are different conditions for the unreinforced grades, the reinforced grades and the blend grades.

P S C W

· ·

General remarks when injection moulding Ultem resin: Some colourants may show discolouration above melt temperatures of 375°C Residence times of material in the barrel should never exceed 15 minutes

hopper temperatures should not ·Machine than 100°C: moisture condensation be lower might cause splay in parts

g GE Plastics

Ultem ® profile 6 Processing page 36

s

FIGURE 21

Melt temperature 370 - 410 °C Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper

s

FIGURE 22

Melt temperature 320 - 380 °C Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper

Typical moulding temperatures for Ultem reinforced: · 2000 series · 4000 · CRS 5201 · CRS 5311 · 6000 · 7801 · AR 9300

450 400 350 300 250 200 150 100 50

Typical moulding temperatures for Ultem blends: · 9075 melt temp 380°C · ATX 100(F) melt temp 330°C · ATX 200(F) melt temp 350°C · HTX 1010(F) melt temp 330°C · HTX 2000(F) melt temp 330°C

450 400 350 300 250 200 150 100 50

P S C W

·Melt temperatures higher than 390°C may degrade blends exceed ·Screw surface speeds should not and reinforced 200 -250 mm/s for unreinforced ·

resins, and should not exceed 150 -200 mm/s for blends A machine back pressure of 5 bar is recommended

Note General information on the processing of engineering thermoplastics can be found in the following GE Plastics brochures: Injection Moulding guide Engineering Thermoplastics in the Extrusion Industry

· ·

7

Secondary Operations

Welding ·InductionWelding is not recommended due ·Hot Plateresin sticking at melt temperatures, to Ultem (±400°C)

Although most Ultem parts are moulded as finished components, the design and ultimate use of certain parts may require machining, assembly or finishing operations. Ultem resin makes a wide variety of secondary operations available to the design engineer. General recommendations for these operations are as follows:

7.2

Adhesives

7.1

P S C W

Welding

· ·

Welding is a commonly used permanent assembly technique for engineering thermoplastics. Ultem resin can be welded by using different processes: Vibration Welding Ultrasonic Welding, at amplitudes above 30 µm (0-peak)

Ultem parts can be bonded together or to dissimilar materials using a wide variety of commercially available adhesives. Because adhesive bonding involves the application of a chemically different substance between two parts, the end use environment of the assembled unit is important in selecting an adhesive.

g GE Plastics

Ultem ® profile 7 Secondary Operations page 37

· · · ·

Recommended adhesive types for Ultem are: Epoxy adhesives Polyurethanes adhesives Silicones adhesives Care should be taken with cyanoacrylates and acrylic systems which are aggressive for Ultem. Exposure to these solvents might lead to stress cracking

forming or thread cutting. ·Screws by threadscrews with low flank angle Thread forming for reduced radial stresses are preferred. Hole (0.85 times screw diameter) and screw should be circular (not trilobular/square). Boss diameter should be 2.5 times screw outer diameter All types of rivets can be used; be aware of high stresses with some pop rivets Staking is possible, with ultrasonic staking being more practical than heat staking Snap fit assembly

7.3

Mechanical Assembly

P S C W

·

Mechanical assembly techniques are widely used with Ultem parts. For unreinforced Ultem grades, the classical rules for amorphous engineering thermoplastics apply. For highly reinforced Ultem grades, the use of special thread cutting screws is advised because of the low elongation at break. The different mechanical assembly techniques that can be used can be summarized as follows: Inserts, installation by heat or ultrasonics are the preferred techniques. Press and expansion inserts give radial stresses. Overmoulding and external threaded inserts are also possible

· · ·

7.4

Painting

A wide variety of colours and textures can be applied to Ultem using commercially available organic paints and conventional application processes. Painting is an economical means of enhancing aesthetics and providing colour conformity. General recommendations for painting Ultem are: part with cleaning agents ·Handwashing theor aliphatic hydrocarbons based on alcohol

Pre-treatment

·Coatings can also help to minimize colour degradation against ·Conductive coatings offer shielding or radio frequency interference (RFI) · ·

electromagnetic interference (EMI) A variety of conventional and waterborne paints can be successfully applied to Ultem resin. Generic types are: Acrylic, Alkyd, Epoxy, Polyester, Polyimide, Polyurethane If the Ultem resin application is working under high temperature conditions, the selected paint must offer equal high temperature performance.

Paint solvents

·

P S C W

or: Power washing the part with cleaning agents based on detergents dissolved in water, acidic by nature, neutral or alkaline

Paint selection

·Paint selection is determined by the desired decorative effect, specific functional needs

and the application technique to be employed

It is important that solvent formulations are considered when selecting a paint for use with Ultem resin. It can be extremely difficult to achieve an ideal match between solvent and substrate.

g GE Plastics

Ultem ® profile 7 Secondary Operations page 38

7.5

Metallization

The best method is to keep the mouldings clean and to metallize the parts as soon as possible after moulding, or store them in clean containers.

Metallization of plastics is normally undertaken for decorative or functional reasons. Properties usually associated with metals such as reflectiveness, abrasion resistance, electrical conductivity and decorative surfaces can be added through metallization. General recommendations for the metallization of Ultem resin are:

Pre-treatment

P S C W

·Vacuum metallization through Physical Vapour Deposition. Physical Vapour Deposition is the ·

depositing of an evaporated metal, mostly aluminium, on a substrate. To achieve evaporation, the pure metal is heated in a deep vacuum. Vacuum metallization through sputtering, (Plasma Enhanced Chemical Vapour Deposition, PE-CVD). Sputtering or PE-CVD also takes place in a vacuum. With high voltage equipment, a field is created between the sample's earthed carrier and a negative electrode: the metal target that has the function of a metal or an alloy donor.

Metallization methods

Typically unreinforced Ultem resin does not need a basecoat or lacquer primer layer before metallization because of the good surface quality of Ultem after moulding. However, a surface activation pre-treatment is required in most cases. Cleaning with cloth or solvents is not recommended because of sensitivity to scratches that can be seen after metallization.

·Plating be done either by electro-less plating This can

without the addition of current to the galvanic process and/or followed by electroplating where current is used to effect an electrolytic deposition of metals coming from a dissolved metal salt. Electroless plating A non-conductive plastic is coated with a continuous metallic film by etching the plastic. This creates micro cavities which make interlocking possible. Chemical bond plating is a special etching technique which is particularly suitable for use with Ultem. In this technique, a permanganate etch opens the Ultem molecule imide ring, and allows copper to enter the molecule. A very high level of adhesion can be established with this technology. This technique is often used for EMI shielding and for Moulded Interconnect Devices, MIDs. For EMI shielding an electroless copper layer of 1 -2 µm is applied with a finish of 0.5 µm of electroless nickel. For a MID application where the moulded part becomes a circuit board, an additional copper layer is applied by electroplating.

·

Electroplating After the application of a conductive metal layer on the plastic, a further electrolytic deposition of selected metals on top of this layer can be done. Most frequently used metals are either chrome, nickel or gold in varying thicknesses. Dichroic coating Ultem resin is very suitable for use with dichroic coatings which reflect visible light but allow the transmission of infra-red rays. By applying multiple coating layers with different refraction indices, light with specific wavelengths can be filtered. The dichroic coating process also takes place in a vacuum vessel, and is used in high heat generating lamps such as small halogen lamps and dentist lamp reflectors.

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Ultem ® profile 7 Secondary Operations page 39

After treatment

· ·

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Due to the reactive nature of aluminium to humidity, and the ultra-thin layer thickness, aluminium must be protected against environmental influences. There are two systems that are most commonly used to provide this protection: Plasil/Glipoxan top layer: this silicon-based monomer layer is applied in the vacuum Clear coat top layer

· · · ·

Note General information on Secondary Operations like welding, mechanical assembly, bonding painting and metallization of engineering thermoplastics can be found in the following GE Plastics brochures: Assembly guide Design guide Painting guide Metallization guide

Addresses

More information relative to this Ultem profile ·www.geplastics.com/resins/materials/ultem.htmlcan be found on:

®

·Visit GE Plastics on: www.geplastics.com/resins

GE Plastics in Europe

European Headquarters General Electric Plastics B.V. 1 Plasticslaan, PO Box 117 NL-4600 AC Bergen op Zoom The Netherlands Tel. (31) (164) 29 29 11 Fax (31) (164) 29 29 40 Headquarters Sales Region General Electric Plastics B.V. Gagelboslaan 4 NL-4623 AD Bergen op Zoom The Netherlands Tel. (31) (164) 29 23 91 Fax (31) (164) 29 17 25 Benelux Sales Region General Electric Plastics B.V. Gagelboslaan 4 NL-4623 AD Bergen op Zoom The Netherlands Tel. (31) (164) 29 11 92 Fax (31) (164) 29 17 25 United Kingdom GE Plastics Limited Old Hall Road, Sale Cheshire M33 2HG United Kingdom Tel. (44) (161) 905 50 00 Fax (44) (161) 905 51 19 Germany General Electric Plastics GmbH Eisenstraße 5 D-65428 Rüsselsheim Germany Tel. (49) (6142) 6010 Fax (49) (6142) 65746 France General Electric Plastics France S.à.R.L. Z.I. St. Guénault B.P. 67 F-91002 Evry-Cedex France Tel. (33) (1) 60 79 69 00 Fax (33) (1) 60 77 56 53

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Italy General Electric Plastics Italia S.p.A. Viale Brianza, 181 I-20092 Cinisello Balsamo (Milano) Italy Tel. (39) (02) 61 83 41 Fax (39) (02) 61 83 42 11 Russia General Electric International A/O Kosmodamianskaia Nab, 52 Building 1 113054 Moscow, Russia Tel. (7) (095) 935 7312 Fax (7) (095) 935 7317 Spain General Electric Plastics Ibérica S.A Avenida Diagonal, 652-656 Edificio D. Planta 3 SP-08034 Barcelona, Spain Tel. (34) (93) 252 16 00 Fax (34) (93) 280 26 19 Sweden GE Plastics Limited Box 1242, Skeppsbron 44 S-11182 Stockholm, Sweden Tel. (46) (8) 402 40 24 Fax (46) (8) 723 12 92 Turkey GE Plastics Turkey Dudullu Organize Sanayi Bolgesi 2.Cadde No 173 81250 Umraniye, Istanbul, Turkey Tel. (90) (216) 365 1565 (pbx) Tel. (90) (216) 365 4959 (pbx) Fax (90) (216) 365 0115

Ultem ® profile Addresses page 40

Brazil GE Plastics South America S.A. Av. Nações Unidas, 12995 20° andar - Cep 04578.000 São Paulo - SP, Brazil Tel. (55) 11 5505 2800 Fax (55) 11 5505 1757

GE Plastics in South Africa GE Plastics in the Americas

Worldwide Headquarters GE Plastics United States 1 Plastics Avenue Pittsfield, MA 01201, USA Tel. (1) (413) 448 7110 Fax (1) (413) 448 7493 Canada GE Plastics Canada Ltd. 2300 Meadowvale Boulevard Mississauga, Ontario L5N 5P9, Canada Tel. (1) (905) 858 5774 Fax (1) (905) 858 5798 Mexico GE Plastics - Mexico S.A. de C.V. Av. Prolongacion Reforma #490, 4o. piso Colonia Santa Fe 01207 Mexico, D.F. Tel. (11) 525 257 6060 Fax (11) 525 257 6070 GE Plastics South Africa General Electric South Africa (Pty) Ltd. 15th floor Sandton Office Tower Sandton 2146 Johannesburg, South Africa Tel. (27) 11 784 2108 Fax (27) 11 784 2216

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GE Plastics in India

GE Plastics India Ltd. 405-B, Sector 20 Udyog Vihar Phase - III Gurgaon, Haryana - 122 016, India Tel. (91) 124 341 801 to 806 Fax (91) 124 341 817 or 815

GE Plastics in the Pacific

Pacific Headquarters GE Plastics Pacific Pte. Ltd. 240 Tanjong Pagar Road GE Tower #09-00, Singapore 0208 Tel. (65) 326 3301 Fax (65) 326 3303/(65) 326 3290 Australia GE Plastics Australia 175 Hammond Road Dandenong, Victoria 3175, Australia Tel. (61) 3 794 4201 Fax (61) 3 794 8563 China GE Plastics China Beijing, 3rd floor, CITIC Bldg. No.19 Jian Guo Men Wai Avenue Beijing 100004, China Tel. (86) (21) 270 6789 Fax (86) (1) 512 7345 Hong Kong GE Plastics Hong Kong Ltd. Room 1088 - Tower 1 The Gateway, Tshimshatsui Kowloon, Hong Kong Tel. (852) 2629 0827 Fax (852) 2629 0800 Japan GE Plastics Japan Ltd. Nihombashi Hamacho Park Building 2-35-4, Nihombashi-Hamacho Chuo-ku, Tokyo 103, Japan Tel. (81) 3 5695 4888 Fax (81) 3 5695 4859 Korea GE Plastics Korea Co. Ltd. 231-8 Nonhyun-Dong Kangnam-Ku Seoul 135-010, Republic of Korea Tel. (82) 2 510 6250/1 Fax (82) 2 510 66 66/7 Singapore GE Plastics Singapore Pte Ltd. c/o 23 Benoi Road, Singapore 2262 Tel. 65 846 3290 Fax 65 861 3063 Taiwan GE Plastics Taiwan 9/F 37 Min Chuan East Road Sec 3 Taipei 10462 Taiwan, Rep. of China Tel. (886) 2 509 2124/6 Fax (886) 2 509 1625 Thailand GE Plastics Thailand 21st Floor Thaniya Plaza Building 52 Silom Road Bangkok 10500, Thailand Tel. (66) (2) 231 2323 Fax (66) (2) 231 2322

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Ultem ® profile Addresses page 41

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DISCLAIMER: THE MATERIALS AND PRODUCTS OF THE BUSINESSES MAKING UP THE GE PLASTICS UNIT OF GENERAL ELECTRIC COMPANY*, USA, ITS SUBSIDIARIES AND AFFILIATES ("GEP"), ARE SOLD SUBJECT TO GEP'S STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GEP MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (I) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (II) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING GEP MATERIALS, PRODUCTS, RECOMMENDATIONS OR ADVICE. EXCEPT AS PROVIDED IN GEP'S STANDARD CONDITIONS OF SALE, GEP AND ITS REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of GEP's materials, products, recommendations, or advice for its own particular use. Each user must identify and perform all tests and analyses necessary to assure that its finished parts incorporating GEP materials or products will be safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive any provision of GEP's Standard Conditions of Sale or this Disclaimer, unless any such modification is specifically agreed to in a writing signed by GEP. No statement contained herein concerning a possible or suggested use of any material, product or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of General Electric Company or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material, product or design in the infringement of any patent or other intellectual property right. * Company not connected with the English company of a similar name. Lexan®, Noryl®, Noryl EF®, Noryl GTX®, Noryl® Xtra, Valox®, Ultem®, Xenoy®, Cycolac®, Cycoloy®, Enduran®, Cytra®, Gelon® and Geloy® are Registered Trademarks of General Electric Co., USA.

Ultem profile Eng/10/2001 AD

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Ultem profile (English)

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