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Ultem_Profile.qxd 6/3/03 2:54 PM Page 1
GE Plastics
®
ULTEM
GE Engineering
Thermoplastics
PEI Resin
PRODUCT GUIDE
Ultem_Profile.qxd 6/3/03 2:54 PM Page 2
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page 2 ULTEM ® PEI Resin Product Guide g GE Plastics
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.
ULTEM®, LEXAN®, CYCOLAC®, CYCOLOY ®, GELOY ®, NORYL®, VALOX®, VERTON®, STARFLAM®, SUPEC® and XENOY ® are registered
trademarks of General Electric Company, USA.
XYLEX™ is a trademark of General Electric Company, USA.
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Contents
Title Page 1 2.6 Telecom, Molded
Interconnect Devices (MIDs) . . . . . . . . . . . . . . 8
Disclaimer 2 2.7 Electrical and Lighting . . . . . . . . . . . . . . . . . . . 9
Contents 3 2.8 HVAC / Fluid Handling . . . . . . . . . . . . . . . . . . . 9
1 Introduction ........................... 4 3 Product Selection . . . . . . . . . . . . . . . . . . . . . 10
3.1 Product Description . . . . . . . . . . . . . . . . . . . . . . 10
2 Applications .......................... 5
3.1.1 ULTEM ® 1000 resin series Base Polymer . . . 10
2.1 Tableware / Catering . . . . . . . . . . . . . . . . . . . . 5 3.1.2 ULTEM ® 2000 resin series . . . . . . . . . . . . . . 10
P
2.2 Medical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.1.3 ULTEM ® 3000 resin series . . . . . . . . . . . . . . 10
S 2.3 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.1.4 ULTEM ® 4000 resin series . . . . . . . . . . . . . . 10
C
C 2.4 Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1.5 ULTEM ® CRS 5000 resin series . . . . . . . . . . 10
W
W 2.5 Automotive Lighting . . . . . . . . . . . . . . . . . . . . . 8 3.1.6 ULTEM ® 6000 resin series . . . . . . . . . . . . . . 10
g GE Plastics ULTEM ® PEI Resin Product Guide Contents page 3
3.1.7 ULTEM ® 7000 resin series . . . . . . . . . . . . . . 10 5 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.8 ULTEM ® 9000 resin series . . . . . . . . . . . . . . 10
3.1.9 ULTEM ® ATX resin series (polyetherimide /
6 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
polycarbonate-ester blend) . . . . . . . . . . . . . 10
6.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Selection Tree . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Heat - Impact – Flow Comparison . . . . . . . . . . 16
6.3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Heat - Modulus – Flow Comparison . . . . . . . . . 17
6.4 Molding Conditions . . . . . . . . . . . . . . . . . . . . . . 38
4 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Secondary Operations . . . . . . . . . . . . . . . . 44
4.1 Thermal Properties . . . . . . . . . . . . . . . . . . . . . . 18
7.1 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Flammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Mechanical Properties . . . . . . . . . . . . . . . . . . . 20
P 7.3 Mechanical Assembly . . . . . . . . . . . . . . . . . . . . 44
4.4 Electrical Properties . . . . . . . . . . . . . . . . . . . . . 23
S 7.4 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5 Environmental Resistance . . . . . . . . . . . . . . . . 27
C
7.5 Metallization . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
W
Addresses 47
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1 Introduction ULTEM ®
Polyetherimide Resins PEI PEI + PCE PEI + SI
ULTEM® Polyetherimide resin, PEI, is an Key properties of the ULTEM® 1000 resin base
amorphous high performance polymer which is polymer are:
characterized by excellent thermal properties, · High long-term heat resistance exhibiting a glass
good chemical resistance, inherent flame transition temperature (Tg) of 217°C, HDT/Ae of
retardancy and exceptional dimensional stability. 190°C and relative thermal index (RTI) of 170°C
· Inherent flame retardancy with low smoke
The base polymer ULTEM® 1000 resin has a evolution, meeting ABD, FAR and NBS
transparent amber brown color, is manufactured requirements
by polycondensation and has the following · Excellent dimensional stability (low creep
chemical structure: sensitivity and low, uniform coefficient of
thermal expansion)
O O · Exceptional strength and modulus at elevated
P C C temperatures
S
N
CH3
N · Good resistance to a broad range of chemicals
C O C O C such as automotive fluids, fully halogenated
O CH3 O n hydrocarbons, alcohols and aqueous solutions
C
W
page 4 1 Introduction ULTEM ® PEI Resin Product Guide g GE Plastics
·Stable dielectric constant and dissipation
factor over a wide range of temperatures
unreinforced – 1000 series
and frequencies
· Transparency to visible light, infrared light General purpose glass reinforced – 2000 series
and microwave radiation low warpage
· Compliancy with FDA, EU, national food
glass reinforced
contact regulations and USP Class VI Wear resistant – 4000 series
· Outstanding processibility on conventional unreinforced
molding equipment Carbon fiber filled – 7000 series carbon reinforced
unreinforced
Injection molding Chemical resistant – CRS 5000 series
glass reinforced
unreinforced
High heat – 6000 series glass reinforced
ULTEM ®
high heat
P PEI Resin
unreinforced
S Aircraft – 9000 series
glass reinforced
C
Polymer blend – ATX series
W
Injection molding
and Extrusion General purpose unreinforced – 1000 series
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Applications
Tableware / Catering
Medical
Aircraft
Automotive
Automotive Lighting
Telecom, Molded Interconnect
Devices (MIDs)
P
Electrical and Lighting
S
HVAC / Fluid Handling
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 2 Applications page 5
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 can be recycled 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.
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
P · Reheating in combi-steamer and
S
thermal contact heater
· Proven property retention through
C over 1000 cycles in industrial
washing machines with detergents
W
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·Excellent stain resistance even with stain-prone
products like tomato ketchup, carrots and
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 trays made from ULTEM®
resin can be easily handled by hands)
· ULTEM® ATX resin series for superior impact
behavior and intermediate thermal performance
· ULTEM® resin series for superior impact behavior
and similar heat performance to ULTEM® 1000 resin
2.2 Medical
P
ULTEM® resin provides value added performance
S for reusable medical devices like sterilization
trays, stopcocks, dentist devices and pipettes.
C
W
page 6 2 Applications ULTEM ® PEI Resin Product Guide g GE Plastics
The reasons why ULTEM® resin can be the right 2.3 Aircraft
choice for medical applications are:
· Full compliance with ISO10993, FDA and The inherently flame retardant ULTEM® resin
USP Class VI product family is widely used in the aircraft
· Ability to withstand various sterilization methods industry in applications like air and fuel valves,
like EtO gas, gamma radiation, autoclaving food tray containers, steering wheels, interior
and dry heat cladding parts and (semi-)structural components.
· Excellent chemical resistance against most of
the lipids, detergents and disinfectants
· ULTEM® 1000E transparent grade offers lower
residual stress and increased toughness
P
S
C
W Goodrich Hella Aerospace Lighting Systems made the new passenger service unit using ULTEM® resin.Ultem_Profile.qxd 6/3/03 2:54 PM Page 7
ULTEM® resin is chosen because it offers:
· The ULTEM® 9000 resin series for full ·Ability to manufacture ULTEM resin based
®
compliance with aircraft industry regulations for thermoplastic composites which allow increased
aircraft interiors including ABD 0031, FAR productivity in component manufacturing over
25.853, OSU 65/65 heat release tests and NBS traditional composite materials
smoke density tests · Ability to manufacture ULTEM® foam cores for
· The ULTEM® 1000, 2000, CRS 5000, 6000 and tough, light-weight sandwich panels
7000 resin 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 a material of choice for aircraft interiors
· Chemical resistance against most fuels and fluids
· Excellent processibility with a very good part
reproducibility
· ULTEM® CRS 5000 resin series for better
resistance against hydraulic aircraft fluids, such as
P
Skydrol, compared to ULTEM® 1000 resin
S
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 2 Applications page 7
2.4 Automotive ·Heat resistance up to 200°C, RTI of 170°C
ULTEM® resin in the automotive industry provides
·Chemical resistance against most automotive
fuels, fluids and oils
manufacturers with a high performance, cost-
effective alternative to metal: strong enough to
·Excellent dimensional stability (low creep
sensitivity and low, uniform coefficient of
replace steel in some applications and light thermal expansion)
enough to replace aluminum in others. · Superior torque strength and torque retention
For applications like transmission components,
· Excellent processibility with very tight
molding tolerances
throttle bodies, ignition components, sensors and
thermostat housings, ULTEM® resin can offer:
· Elimination of secondary operations
like machining and anodizing
P
S
C
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2.5 Automotive Lighting ·High heat resistance up to 200°C, RTI of 170°C
·Metallization without primer
The ULTEM® resin product family can be a
specifically good fit in a heat dominated area like
·Competitive system cost vs. traditional thermoset
materials
automotive lighting. ·Design and processing flexibility which allows
typical free form reflector design
Typical applications are headlight reflectors,
foglight reflectors, bezels and light bulb sockets
·Integration possibilities for mounting and
adjustment fixings
where ULTEM® resin can provide: ·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)
· Easier recyclability of ULTEM® resin versus the
“traditional” materials
P
· ULTEM® 1010M grade offers improved
processability in metallized lighting applications
S
C
W
page 8 2 Applications ULTEM ® PEI Resin Product Guide g GE Plastics
2.6 Telecom, Molded Interconnect
Devices (MIDs)
Its unique plating capabilities make ULTEM® ·Excellent dimensional stability (low creep
resin the material of choice for Telecom and sensitivity and low, uniform coefficient of
MID applications. ULTEM® resin allows the thermal expansion)
combination of electrical functions with the · Consistent processibility and therefore
advantages of injection molded three-dimensional reproducibility of parts
mechanical components in: electrical control · ULTEM® resin EPR grades offer enhanced flow
units, computer components, mobile phone and platability versus ULTEM® filled grades.
internal antennae, rf-duplexers or microfilters
and fiber optic connectors.
ULTEM® resin can offer:
· Unique plating capabilities with the chemical
bonding process
P · Significant productivity through integration
of components and ease of assembly through,
S among others, snap fits
· High heat resistance up to 200°C
C
· Stable dielectric constant and dissipation factor
W over a wide range of temperatures (subzero to
200°C) and frequencies (1 H z - 10 10 Hz)Ultem_Profile.qxd 6/3/03 2:54 PM Page 9
2.7 Electrical and Lighting In these segments ULTEM® resin can provide:
·Temperature resistance up to 200°C,
From connectors to reflectors, ULTEM resin is
® RTI of 170°C and ball pressure test at 125°C
the material of choice for today’s demanding ·Excellent dimensional stability (low creep
electrical and lighting applications. 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
·ULTEM® 6000 resin series for high heat
P connectors
S
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 2 Applications page 9
2.8 HVAC/Fluid Handling
In circumstances where heat and fluids are ·Weld line strength, needed because of high
combined in an application, ULTEM® resin temperatures and dynamic pressures
can offer an ideal balance of properties. ·Potable water approval up to 90°C (KTW approval)
·Excellent mechanical properties under
For applications like water-pump impellers, hot water conditions
expansion valves, hot water reservoirs and heat ·Good hydrolytic stability
exchange systems, ULTEM® resin is chosen ·Excellent dimensional stability (low creep
because it offers: sensitivity and low, uniform coefficient of
· Long-term heat resistance, RTI of 170°C thermal expansion)
P
S
C
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3 Product Selection
3.1 Product Description 3.1.3 ULTEM ® 3000 resin series
·Glass and mineral filled
3.1.1 ULTEM 1000 resin series Base Polymer
®
·High strength
·General purpose ·Improved dimensional stability versus ULTEM ®
·Unreinforced 2000 series
·Food contact compliant grades available
·USP Class VI compliant grades available 3.1.4 ULTEM ® 4000 resin series
·Low viscosity grades available ·Wear resistance
·Extrusion and injection molding grades ·Reduced coefficient of friction
3.1.2 ULTEM ® 2000 resin series
·Unreinforced and glass reinforced grades
·Glass reinforced 3.1.5 ULTEM ® CRS 5000 resin series
P ·Greater rigidity vs. ULTEM 1000 resin ®
·Superior chemical resistance over ULTEM ®
·Improved dimensional stability over ULTEM ®
1000 resin
S
1000 resin ·Better resistance against hydraulic aircraft fluids
C ·Low viscosity grades available compared to ULTEM 1000 resin
®
W
·EPR series has four-times higher plating adhesion
and 30% better flow than standard ULTEM 2000 ®
·Unreinforced and glass reinforced grades
filled products
page 10 3 Product Selection ULTEM ® PEI Resin Product Guide g GE Plastics
3.1.6 ULTEM ® 6000 resin series 3.1.9 ULTEM ® ATX resin series (polyetherimide/
·Highest heat resistance of all ULTEM ®
resin polycarbonate-ester blend)
grades ·Intermediate heat performance
·ULTEM ATX 100 resin offers higher impact
®
3.1.7 ULTEM ® 7000 resin series performance compared to ULTEM 1000 resin
®
·Carbon fiber-reinforced ·Very high flow compared to ULTEM 1000 resin
®
·Exceptional strength-to-weight ratio ·Metallizable without primer
·Highest modulus of all ULTEM resin grades ® ·Food contact compliant grades available
3.1.8 ULTEM ® 9000 resin series
·Fulfills aircraft industry regulations
(ABD, FAR, OSU and NBS)
·Delivered with individual lot certification
·Unreinforced and glass reinforced grades
·Extrusion and injection molding grades
P
S
C
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3.2 Selection Tree
general purpose
wear resistant
carbon fiber filled
chemical resistant
ULTEM ®
PEI resin higher heat
aircraft
P high impact
S
polymer blend
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 3 Product Selection page 11
Heat • Impact • Modulus
GRADE Flammability • Flow
Grade: All are injection molding grades unless
otherwise indicated.
(R): Standard mold release, non-transparent,
non-food contact
(M): Optimized standard mold release for
metallized reflectors
(F): Food contact
(E): Mold release, transparent
(P): Powder
(EPR) Enhanced plating, release containing
(Std.) Standard
(HF): High flow
(S): Special filtered
(X): Improved low ionic capabilities
Heat: HDT/Ae in °C (ISO 75)
P Impact: Izod Notched at 23°C in kJ/m 2 (ISO 180/1A)
S Impact*: Izod Unnotched at 23°C in kJ/m 2 (ISO 180/1U)
Modulus: Flexural in MPa (ISO 178)
C Flammability: Recognized at mm thickness (UL94)
W 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 testedUltem_Profile.qxd 6/3/03 2:54 PM Page 12
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
also
standard
Extrusion
1000 (Std.,R,F,M,E,EF,P)
1010 (Std.,S,X)
easy flow
unreinforced 1010 (R,F,M)
1000 series
1100 (Std.,R,F,E,EF)
high pigment
loading
1110 (Std.,R,F)
10% 2100 (Std.,R)
20% 2200 (Std.,R)
P
standard
S 30% 2300 (Std.,R)
C
40% 2400
W
glass reinforced
2110 (Std.,R)
10%
2000 series 2110 (EPR)
page 12 general purpose
2210 (Std.,R)
20%
2210 (EPR)
easy flow
2310 (Std.,R)
30%
2310 (EPR)
40% 2410 (Std.,R,EPR)
2212
20%
2212 (R, EPR)
milled-glass 2312
reinforced 30%
2312 (EPR)
low warpage
40% 2412 (EPR)
glass/mineral
reinforced
3451
P
S
C
W
see charts on pages 16 and 17Ultem_Profile.qxd 6/3/03 2:54 PM Page 13
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
unreinforced 4001
wear resistant
4000 series 25% Glass
15% PTFE
4000
glass reinforced
20% Glass
8% PTFE
4211
20% 7201 (Std.,R)
carbon fiber filled carbon
7000 series reinforced
25% 7801 (Std.,R)
P
S
C
W see charts on pages 16 and 17
g GE Plastics ULTEM ® PEI Resin Product Guide 3 Product Selection page 13
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
standard CRS 5001
unreinforced
high flow CRS 5011
10% CRS 5111
chemical resistant
CRS 5000 series
15% CRS 5711 (HF)
CRS 5201 (Std.,R)
glass reinforced
20%
P CRS 5211 (R,HF)
S
C
CRS 5301 (Std.)
30%
W CRS 5311 (HF)
see charts on pages 16 and 17Ultem_Profile.qxd 6/3/03 2:54 PM Page 14
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
standard 6000
unreinforced
high flow 6010
10% 6100
higher heat
6000 series
glass reinforced 20% 6200
12% silica 6202
P high heat 6601
S
C
W see charts on pages 16 and 17
page 14 3 Product Selection ULTEM ® PEI Resin Product Guide g GE Plastics
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
extrusion 8015
unreinforced
9075
injection
molding
9076
aircraft
9000 series
10% AR9100
20% AR9200
glass reinforced
P
30% AR9300
S
C high flow AR9110
W
see charts on pages 16 and 17Ultem_Profile.qxd 6/3/03 2:54 PM Page 15
ULTEM ® PEI resin › general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
ATX100 (R,F)
opaque
polymer blend ATX200 (R,F)
ATX series
transparent 1285
high impact DU242 (opaque)
P
S
C
W see charts on pages 16 and 17
g GE Plastics ULTEM ® PEI Resin Product Guide 3 Product Selection page 15
P
S
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 16
3.3 Heat-Impact – Flow Comparison
ULTEM ® resin unreinforced
general purpose
°C –
standard
–
high flow
210
high pigment loading
–
200
1010 (F,R)
–
190 1000 (F,R)
–
180 1110 (F)
–
170
Heat HDT/Ae
–
160
P –
S
150 Flow Melt Volume Rate cm 3/10 min
–
5 13.3 21.6 30
C –
| 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 |
W Izod Notched Impact kJ/m 2
page 16 3 Product Selection ULTEM ® PEI Resin Product Guide g GE Plastics
ULTEM ® resin unreinforced
non general purpose
°C –
6000
higher heat wear resistant
–
chemical resistant
210
CRS 5011 higher heat
–
CRS 5001 aircraft
200 ATX 200 (F) high impact
– 4001 polymer blend
wear
190
–
180 9075
aircraft
–
170 9076
Heat HDT/Ae
aircraft
–
160
P –
S
150 Flow Melt Volume Rate cm 3/10 min
ATX 100 (F)
–
5 13.3 21.6 30
C –
| 0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 |
W Izod Notched Impact kJ/m 2Ultem_Profile.qxd 6/3/03 2:54 PM Page 17
3.4 Heat-Modulus – Flow Comparison
normal glass fibers ULTEM ® resin reinforced
10% 20% 30% 40% general purpose
°C –
standard
– 2300 (R) 2400 (R)
2100 (R) 2200 (R) high flow
210
milled glass
– 2310 (R) 2410 (R)
200 2210
2110 (R)
–
190 2312
appearance
–
30% milled glass fibers
180
–
170
Heat HDT/Ae
–
160
P –
S 150 Flow Melt Volume Rate cm 3/10 min
–
C 5 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 |
W
Flexural Modulus MPa
g GE Plastics ULTEM ® PEI Resin Product Guide 3 Product Selection page 17
normal glass fibers carbon fibers ULTEM ® resin reinforced
20% 25% 30% 25% non general purpose
°C –
CRS 5311 wear resistant
–
7801 chemical resistant
210
AR 9300 carbon fiber filled
– aircraft
4000 aircraft
CRS 5201 (R)
200 wear
–
190
–
180
–
170
Heat HDT/Ae
–
160
P –
S
150 Flow Melt Volume Rate cm 3/10 min
–
C 5 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 |
W
Flexural Modulus MPaUltem_Profile.qxd 6/3/03 2:54 PM Page 18
4 Properties*
4.1 Thermal Properties Heat deflection temperature and
continuous use ratings
In recognition of its inherent thermal stability,
An outstanding property of ULTEM® resin is UL has granted the ULTEM® 1000 resin base
its ability to withstand long-term exposure to polymer a relative thermal index (RTI) of 170°C,
elevated temperatures. This high heat perform- according to UL746B. The polymer’s high glass
ance, combined with excellent flammability transition temperature (Tg) of 217°C coupled
ratings and Underwriters’ Laboratory, UL, with its high heat deflection temperature
recognition, qualifies ULTEM® resin for (HDT/Ae 1.80 MPa) of 190°C contributes to
demanding high temperature applications. its excellent retention of physical properties at
elevated temperatures.
P
S * Typical values only.
In all cases extensive testing of the application under
the end-use working conditions is strongly recommended. The
C
actual performance and interpreting of the results of
W end-use testing are the end-producer’s responsibility.
page 18 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
■ FIGURE 4-1 shows the ability of ULTEM® resin to
maintain this high heat deflection temperature
with increased stress, an important consideration
to the design engineer.
225
Heat deflection temperature (°C)
■ F I G U R E 4 -1
Heat deflection temperature
of ULTEM ® 1000 resin vs. 200
applied stress
175
150
125
P 0 1 2 3 4 5 6 7 8 9 10
Applied stress (MPa)
S
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 19
■ F I G U R E 4 - 2 compares the high heat deflection
temperature of ULTEM® 1000 resin with those
of other high performance engineering
thermoplastics.
Heat deflection temperature (°C) 250
■ F I G U R E 4 -2
Heat Deflection Temperature
(HDT/Ae 1.80 MPa)
200
150
100
ULTEM ® 1000 resin
ULTEM ® 2100 resin
(10% GF)
ULTEM ® 2400 resin
(40% GF)
Polyethersulfone
Polysulfone
High heat
polycarbonate
ULTEM ® ATX100 resin
ULTEM ® ATX200 resin
P
S
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 19
Coefficient of thermal expansion ■ TA B L E 4 - 1
Another important design consideration is the
thermal expansion of a material, particularly in Coefficient of linear thermal expansion
applications where plastic parts are mated with Material Flow direction Cross flow direction
metal parts or have metal inserts. ■ TA B L E 4 -1 lists (10 -5 /°C) (10 -5 /°C)
the coefficient of thermal expansion for the family ULTEM ® 1000 resin 5 5
of ULTEM® resin grades and demonstrates the
capability of matching the values of several metals. ULTEM ® 2100 resin 2.6 6
ULTEM ® 2200 resin 2.5 6
4.2 Flammability
ULTEM ® 2300 resin 2 6
Flame resistance
ULTEM ® 2312 resin 2.3 2.7
ULTEM® resin exhibits exceptionally good flame
resistance without the use of additives. For ULTEM ® 2400 resin 1.5 4.5
example, ULTEM® 1000 resin has been rated V0 Polysulfone 5.6
at 0.41 mm under UL94, and 5VA at 1.6 mm.
Polysulfone 10% GF 3.6
In addition, as seen in ■ F I G U R E 4 - 3 , it has a
limited oxygen index of 47, the highest of any High Heat Polycarbonate 7.5
P
commonly used engineering thermoplastic. Brass 1.6-1.8
S
Combustion characteristics Zinc 2.7
C A key factor in determining the relative safety Aluminum 2.2
W of a polymeric material is its smoke generation
Steel 1.2-1.5
under actual fire conditions. Measured againstUltem_Profile.qxd 6/3/03 2:54 PM Page 20
■ FIGURE 4-3 ■ FIGURE 4-4
Oxygen index Smoke evolution by NBS test Dmax 20 min
50 240
Oxygen index (%)
Smoke density (Dmax)
40 180
30 120
20 60
10 0
ULTEM ® 1000 Polyethersulfone Polysulfone High heat ULTEM ® 1000 resin Polyethersulfone Polysulfone
resin polycarbonate
P other engineering thermoplastics, ULTEM® resin
exhibits extremely low levels of smoke generation as
S demonstrated by the NBS smoke evolution test
results shown in ■ F I G U R E 4 - 4 . Furthermore, the
C
products of combustion of ULTEM® resin have been
W shown to be no more toxic than those of wood.
page 20 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
Aircraft industry regulations ■ TA B L E 4 - 2
ULTEM® resin is widely used in aircraft applications
because of its compliance with aircraft industry Aircraft regulation compliance according to
regulations. ■ TA B L E 4 - 2 lists the performance of ABD 0031, FAR 25.853, OSU
the different ULTEM® resin series according to Resin Grade FAR OSU Smoke Toxicity
these regulations. 25.853 Ds 4min
4.3 Mechanical Properties ULTEM ® 1000 resin series a(60s) 100/100 < 50 pass
ULTEM ® 2000 resin series a(60s) 100/100 < 50 pass
Strength
At room temperature, ULTEM® resin exhibits ULTEM ® CRS 5000
strength well beyond that of most engineering resin series a(60s) 100/100 < 50 pass
thermoplastics, with a tensile stress at yield of ULTEM ® 6000 resin series a(60s) 100/100 < 50 pass
105 MPa (ISO R527)and a flexural strength at
ULTEM ® 7000 resin series a(60s) 100/100 < 50 pass
yield of 160 MPa (ISO 178).
ULTEM ® 9000 resin series a(60s) 65/65 < 50 pass
Even more impressive is the retention of strength
P at elevated temperatures. At 190°C, a temperature
ABD 0031 contains requirements for smoke, toxicity and FAR 25.853.
well beyond the useful range of most other FAR 25.853 classifies materials for flammability.
S engineering thermoplastics, ULTEM® resin retains OSU (Ohio State University) calorimeter requirements for larger parts.
approximately 50 MPa tensile stress (ISO R527),
C
as illustrated in ■ F I G U R E 4 - 5 .
WUltem_Profile.qxd 6/3/03 2:54 PM Page 21
ULTEM ® Resin
Tensile stress (MPa)
■ FIGURE 4-5 250 2400
2300
Tensile stress as a
2200
function of temperature 200 2100
1000
CRS5001
150
100
50
0
-50 0 50 100 150 200
Temperature (°C)
■ F I G U R E 4 - 6 demonstrates the higher tensile
stress of ULTEM® 1000 resin compared to other
high performance engineering materials. The out-
P standing inherent strength of ULTEM® resin is
further enhanced through reinforcement with
S glass fibers, as shown in ■ F I G U R E 4 - 7 which
compares ULTEM® 2200 resin (20% glass
C
reinforced grade) with other glass reinforced
W engineering thermoplastics.
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 21
■ FIGURE 4-6 ■ FIGURE 4-7
Tensile stress (23°C) at yield (50mm/min) Tensile stress (23°C) at break (5mm/min)
110
Tensile stress (MPa)
Tensile stress (MPa)
140
100
90 120
80
100
70
80
60
50 60
40
40
30
ULTEM ® 1000 resin
Polyethersulfone
Polysulfone
High heat
polycarbonate
ULTEM ® ATX100 resin
ULTEM ® ATX200 resin
ULTEM ® 2200 Polyethersulfone Polysulfone
resin 20% GF 20% GF 20% GF
P
S
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 22
Modulus
Another outstanding mechanical property of rigidity approaching that of many glass reinforced
ULTEM® PEI resin is its high modulus. The 3300 resins. In addition, the flexural modulus of
MPa flexural modulus (ISO 178) of ULTEM® 1000 ULTEM® resin remains exceptionally high at
resin is one of the highest room temperature elevated temperatures, as shown in ■ F I G U R E 4 - 8 .
moduli of any high performance engineering For example, at 175°C the modulus of ULTEM®
plastic. In load bearing applications where 1000 resin is higher than that of most engineering
deflection is a primary consideration, plastic at room temperature.
unreinforced ULTEM® resin provides structural
10 11
PPS
Flexural modulus (Pa)
■ FIGURE 4-8 40% GF
ULTEM ® resin
Flexural modulus of ULTEM ®
2400
resin at different glass ratios 10 10
1000
as a function of temperature vs.
PPS 40%GF
10 9
P 10 8
S
C 10 7
-120 -80 -40 0 40 80 120 160 200 240 280
W Temperature (°C)
page 22 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
Thus, ULTEM® resin offers designers the ■ FIGURE 4-9
opportunity to achieve desired stiffness with Flexural modulus (23°C) 2 mm/min
none of the sacrifices associated with glass
3400
Flexural Modulus (MPa)
reinforced materials, such as increased
machine and tool wear and decreased flow. 3200
■ F I G U R E 4 - 9 compares the flexural modulus
of the ULTEM® 1000 resin base polymer with that 3000
of other high performance engineering 2800
thermoplastics.
2600
Where greater stiffness is required, the glass
reinforced ULTEM® 2000 resin series or the 2400
carbon fiber reinforced ULTEM® 7000 resin series 2200
provide additional performance with flexural
moduli as high as 13500 MPa (ISO 178) at room 2000
ULTEM ® 1000 resin
Polyethersulfone
Polysulfone
High heat
polycarbonate
ULTEM ® ATX100 resin
ULTEM ® ATX200 resin
temperature.
P
S
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 23
Ductility Fatigue endurance
In addition to its unique combination of high Fatigue is an important design consideration for
strength and modulus, ULTEM® resin exhibits parts subjected to cyclical loading or vibration.
outstanding ductility. Its tensile elongation In such applications, an uniaxial fatigue diagram
at yield affords the freedom to incorporate (see ■ F I G U R E 4 -10 ) could be used to predict
snap fit designs for ease of assembly. Even product life. These curves can be used to
with the addition of 10% glass reinforcement, determine the fatigue endurance limit, or
ULTEM® 2100 resin retains ductility over a the maximum cycle stress that a material can
temperature range from subzero to 200°C. withstand without failure.
Impact strength Creep behavior
ULTEM® 1000 resin exhibits excellent practical When considering the mechanical properties
impact resistance. Since ULTEM® resins display of any thermoplastic material, designers must
notch sensitivity, adherence to standard design recognize the effects of temperature, stress level
principles is recommended. Stress concentrators and load duration on material performance.
such as sharp corners should be minimized ULTEM® resin displays excellent creep resistance
to provide the maximum impact strength in even at temperatures and stress levels which would
molded parts. ULTEM® ATX100 resin has been preclude the use of many other thermoplastics.
P developed specifically for applications where
high impact performance is required. The Izod
S notched impact strength of this series goes up
C
to 15 kJ/m2.
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 23
160 ULTEM ® resin
Stress (MPa)
■ F I G U R E 4 -10 2400
140
2300
Uniaxial fatigue test
120 2200
of ULTEM ® resin at 2100
different glass ratios 100 1000
80
60
40
20
0
10 2 10 3 10 4 10 5 10 6 10 7
Cycles to failure
4.4 Electrical Properties
P ULTEM® resins exhibit excellent electrical
properties which remain stable over a wide range
S of environmental conditions. This stability,
C
together with outstanding thermal and
mechanical properties, make ULTEM® resins
W ideal candidates for highly demanding electrical
and electronic applications.Ultem_Profile.qxd 6/3/03 2:54 PM Page 24
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. ■ F I G U R E S 4 -11 and 4 -12
demonstrate the stability of ULTEM® 1000 resin
over varying temperatures and frequencies.
3.20
10 3 Hz
Dielectric constant
■ F I G U R E 4 -11 10 6 Hz
Relative permittivity 3.15
of ULTEM ® 1000 resin vs.
temperature at 50% RH
3.10
3.05
P
3.00
S
2.95
C 0 50 100 150 200
W Temperature (°C)
page 24 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
3.20
23°C
Dielectric constant
■ F I G U R E 4 -12 82°C
Relative permittivity 3.15
of ULTEM ® 1000 resin vs.
frequency at 50% RH
3.10
3.05
3.00
2.95
1 10 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10
Frequency (Hz)
Dissipation factor
As shown in ■ F I G U R E 4 -13 , ULTEM® 1000
P resin exhibits an exceptionally low dissipation
factor over a wide range of frequencies,
S
particularly in the kilohertz (10 3 Hz) and
C gigahertz (10 9 Hz) ranges. In addition, this
low dissipation factor remains
WUltem_Profile.qxd 6/3/03 2:54 PM Page 25
0.007
82°C
Dissipation factor
■ F I G U R E 4 -13 49°C
0.006 23°C
Dissipation factor
of ULTEM ® 1000 0.005
resin vs. frequency
at 50% RH 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 10 10
Frequency (Hz)
constant over the resin’s entire useful
temperature range. This behavior is of prime
importance in applications such as computer
P circuitry and microwave components where
the resin provides a minimum loss of electrical
S
energy in the form of heat.
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 25
■ F I G U R E S 4 -14 and 4 -15 demonstrate the superior
performance of ULTEM® PEI resin 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
ULTEM ® 1000 resin
Dissipation factor
■ F I G U R E 4 -14 0.016 Polyethersulfone
Dissipation factor Polysulfone
0.014
vs. frequency
at 23°C, 50% RH 0.012
0.010
0.008
0.006
P 0.004
S 0.002
0
C 1 10 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10
W Frequency (Hz)Ultem_Profile.qxd 6/3/03 2:54 PM Page 26
0.010
Polysulfone
Dissipation factor
■ F I G U R E 4 -15 ULTEM ® 1000 resin
Dissipation factor 0.008
vs. temperature
at 2.45 x 10 9 Hz
0.006
0.004
0.002
0
0 50 100 150 200 250
Temperature (°C)
P
S
C
W
page 26 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
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 resin is
shown in ■ F I G U R E 4 -16 .
ULTEM ® 1000 resin
Dielectric strength (kV/mm)
■ F I G U R E 4 -16 250
Dielectric strength
of ULTEM ® 1000 resin 200
as a function of
thickness 150
100
P
50
S
0
C 0.01 0.1 1 10
W
Thickness (mm)Ultem_Profile.qxd 6/3/03 2:54 PM Page 27
4.5 Environmental Resistance In an effort to further enhance the inherent
chemical resistance of ULTEM® resin, a
Chemical resistance chemical resistant ULTEM® CRS 5000 resin
Unlike other amorphous resins, ULTEM® series has been developed. These amorphous
polyetherimide resin demonstrates unusually materials combine the chemical resistance
good resistance to a wide range of chemicals. characteristics often associated with crystalline
■ TA B L E 4 - 3 lists the performance of ULTEM® and specialty materials with the excellent
1000 and CRS 5000 resin series in a variety of processing characteristics typical of ULTEM®
common environments at several stress levels. resins.
In applications requiring prolonged immersion,
finished part performance should always be Cleaning and degreasing
evaluated on the actual part under actual Cleaning or degreasing of ULTEM® resin finished
service conditions. parts can be performed using methyl or isopropyl
alcohol, soap solutions, heptane, hexane or
ULTEM® resin displays excellent property naphtha. The parts should not be cleaned with
retention and resistance to environmental stress partially halogenated hydrocarbons or with
cracking when exposed to most commercial ketones such as MEK or strong bases, such as
automotive and aircraft fluids, fully halogenated sodium hydroxide.
P hydrocarbons, alcohols and weak aqueous
solutions. Exposure to partially halogenated
S hydrocarbons and strong alkaline environments
should be avoided.
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 27
■ TA B L E 4 - 3
Chemical compatibility of ULTEM ® 1000 resin and ULTEM ® CRS 5001 resins
Media Temp (°C) Immersion (days) Strain (%) ULTEM ® ULTEM ®
CRS 5001 resin 1000 resin
Alcohols 1 )
Methanol 23 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
60 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
Aqueous Detergents 2 )
& Cleaners
Domestic Detergent 23 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
60 21 0.25 n.a. n.a.
Key to performance
21 0.5 n.a. n.a.
n.a. no attack
Bleach (10%) 23 21 0.25 n.a. n.a. f. failure / ruptured
P
c. crazing
21 0.5 n.a. n.a.
sv.c. severe crazing
S 60 21 0.25 n.a. n.a. s.c. slight crazing
21 0.5 n.a. n.a. – not tested
C
1
) Other examples of alcohols include ethyl, propyl and some glycols
2
W ) Other examples of aqueous detergents include hypochlorite bleaches and phosphate cleanersUltem_Profile.qxd 6/3/03 2:54 PM Page 28
■ TA B L E 4 - 3 ( continued)
Media Temp (°C) Immersion (days) Strain (%) ULTEM ® ULTEM ®
CRS 5001 resin 1000 resin
Water
Steam 100 21 0.25 n.a. n.a.
21 0.5 n.a. f. (216 hrs.)
Distilled Water 23 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
Chlorinated Solvents 3 )
1,1,2 Trichloroethylene 23 2 hrs. 0.25 sv.c. f.
2 hrs. 0.5 sv.c. f.
1,1,1 Trichloroethylene 23 21 0.25 n.a. n.a.
Chloroform 21 0.5 n.a. f. (24 hrs.)
Esters
Dibutylphtalate 23 21 0.25 n.a. n.a.
21 0.5 c. f. (24 hrs.)
85 21 0.25 n.a. f.
24 hrs. 0.5 c. f.
Key to performance
P Aromatic Hydrocarbons 4 ) n.a. no attack
Toluene 23 21 0.25 n.a. f. (48 hrs.) f. failure / ruptured
S c. crazing
48 hrs. 0.5 c. f. (2 hrs.)
sv.c. severe crazing
C 85 0.25 c. (48 hrs.) f.
s.c. slight crazing
0.5 c. (48 hrs.) f. – not tested
W 3
) Other examples of chlorinated solvents include methylene chloride and ethylene chloride
4
) Other examples of aromatic hydrocarbons include benzene, xylene and gasoline
page 28 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
Media Temp (°C) Immersion (days) Strain (%) ULTEM ® ULTEM ®
CRS 5001 resin 1000 resin
Ketones and Aldehydes 5 )
Methyl Ethyl Ketone 23 21 0.25 n.a. f. (2 hrs.)
(MEK) 0.5 c. (48 hrs.) f. (2 hrs.)
75 0.25 s.c. (48 hrs.) f.
0.5 c. (48 hrs.) f.
Aircraft Fluids
Skydrol 500B 23 21 0.25 n.a. n.a.
Hydraulic Fluid 21 0.5 n.a. f. (72 hrs.)
85 21 0.25 n.a. f.
0.5 c. (24 hrs.) f.
Automotive Fluids
Gasoline 73 21 0.25 n.a. n.a.
ASTM Fuel C 21 0.5 n.a. n.a.
60 21 0.25 n.a. n.a.
21 0.5 n.a. f.
P
Diesel Fuel 23 5 0.25 – n.a.
Key to performance
S 0.5 – n.a.
n.a. no attack
Brake Fluid 23 21 0.25 n.a. n.a. f. failure / ruptured
C c. crazing
21 0.5 n.a. n.a.
sv.c. severe crazing
W 85 21 0.25 n.a. f. (168 hrs.)
s.c. slight crazing
0.5 f. f. – not tested
5
) Other examples of ketones and aldehydes include acetone, acetealdehyde and formaldehydeUltem_Profile.qxd 6/3/03 2:54 PM Page 29
■ TA B L E 4 - 3 ( continued)
Media Temp (°C) Immersion (days) Strain (%) ULTEM ® ULTEM ®
CRS 5001 resin 1000 resin
Automotive Fluids
Transmission Fluid 23 5 0.25 – n.a.
0.5 – n.a.
120 7 0.25 – n.a.
0.5 – n.a.
Antifreeze (75%) 23 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
150 21 0.25 n.a. f.
0.5 f. (72 hrs.) f.
Mineral Oil 23 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
140 21 0.25 n.a. f. (168 hrs.)
21 0.5 n.a. f. (168 hrs.)
Key to performance
Acids 6 ) n.a. no attack
Sulphuric Acid (37%) 23 21 0.25 n.a. n.a. f. failure / ruptured
Inorganic 21 0.5 n.a. n.a. c. crazing
P sv.c. severe crazing
90 21 0.25 n.a. n.a.
s.c. slight crazing
S 21 0.5 n.a. n.a. – not tested
6
) Other examples of acids include hydrochloric, phosphoric and glacial acetic
C
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 29
Media Temp (°C) Immersion (days) Strain (%) ULTEM ® ULTEM ®
CRS 5001 resin 1000 resin
Acids 6 )
Acetic Acid (20%) 23 21 0.25 n.a. n.a.
Organic 21 0.5 n.a. n.a.
90 21 0.25 n.a. n.a.
21 0.5 n.a. n.a.
Strong Bases 7 )
Sodium 23 21 0.25 n.a. n.a.
Hydroxide (30%) 21 0.5 n.a. n.a.
90 0.25 f. f.
0.5 f. f.
Key to performance
Weak Bases 8 ) n.a. no attack
Ammonium 23 21 0.25 n.a. n.a. f. failure / ruptured
Hydroxide (10%) 21 0.5 n.a. n.a. c. crazing
sv.c. severe crazing
90 0.25 f. f.
s.c. slight crazing
0.5 f. f. – not tested
P 6
) Other examples of acids include hydrochloric, phosphoric and glacial acetic
7
) Other examples of strong bases include other metal hydroxides and some amines
S 8
) Other examples of weak bases include dilute forms of metal hydroxides and some amines
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 30
Aqueous solutions Chemical (concentration) % Retention % Weight Gain
ULTEM® resin is resistant to mineral acids, of Tensile Stress
mineral salt solutions and dilute bases Deionized water 94 1.25
(pH less than 9) as shown in ■ TA B L E 4 - 4 .
Zinc chloride (10%) 96 1.13
This property, together with high
temperature performance and Potassium carbonate (30%) 97 0.85
transparency, qualifies the resin for Tin chloride (10%) 97 1.05
applications such as laboratory ware
Citric acid (40%) 96 1.06
and automotive heat transfer systems.
Hydrochloric acid (20%) 99 0.61
Phosphoric acid (20%) 97 0.99
Sulphuric acid (20%) 97 0.89
Chromic acid (15%) 94 0.73
Formic acid (10%) 94 1.29
Nitric acid (20%) 96 1.07
Acetic acid (20%) 95 1.15
P ■ TA B L E 4 - 4 Potassium hydroxide (10%) 97 1.55
S Chemical Resistance of ULTEM ® Ammonium hydroxide (10%) 68 1.79
1000 resin to Aqueous Solutions
C Sodium hydroxide (10%) 97 1.00
at 23°C, no stress applied
(100 day immersion) Cyclohexylamine (1%) 97 1.10
W
page 30 4 Properties ULTEM ® PEI Resin Product Guide g GE Plastics
Hydrolytic stability Ultraviolet exposure
■ F I G U R E 4 - 17 depicts the excellent tensile stress ULTEM® resin is resistant to UV radiation without
retention of ULTEM® 1000 resin after 10,000 hours the addition of stabilizers. Properties like tensile
of immersion in water at 100°C. In addition, tests stress, modulus and Izod notched impact show a
show that ULTEM® resin’s physical properties negligible change after long-term exposure to UV.
remain virtually unchanged after repeated cycling However, care should be taken, since color changes
from steam pressure to drying in vacuum at room and loss of Izod unnotched impact performance
temperature. Therefore ULTEM® resin is a very might occur after long-term exposure.
good material for repeated autoclavability.
23°C
Tensile stress (MPa)
■ FIGURE 4-17 100°C
Effect of water exposure 120
on tensile stress of ULTEM ®
1000 resin 100
80
P
S 60
C
W 0 2000 4000 6000 8000 10000
1 month 1 year
Time (hours)Ultem_Profile.qxd 6/3/03 2:54 PM Page 31
Radiation resistance
Parts molded in ULTEM® resin demonstrate
excellent resistance to gamma radiation, as
shown in ■ F I G U R E 4 - 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
Tensile stress (MPa)
Tensile strain (%)
■ F I G U R E 4 -18
111 80 % Strain ultimate
Effect of gamma radiation % Strain of yield
104 70
exposure on tensile
properties of ULTEM ® 97 60
1000 resin 90 50
83 40
76 30
69 20
10
P
S 0 100 200 300 400 500 600
Radiation exposure level (106 rads)
C (1 Megarad/hour of Co60 Exposure rate)
W
g GE Plastics ULTEM ® PEI Resin Product Guide 4 Properties page 31
Agency recognition
ULTEM® resins have been tested and comply
with a number of agency regulations and
specifications.
ULTEM® resins’ heat stability and flammability
characteristics make them excellent choices
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
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Design *
5
To extract the maximum performance from Molded-in stress in parts can be minimized by:
ULTEM® resin, the designer should strive to take ·Avoiding thin walls and sharp corners
full advantage of the excellent physical properties ·Avoiding large and sharp transitions in wall
of the material as well as the design freedom thickness
offered by the injection molding process. ·Ensuring balanced and uniform part filling
·Properly designing ribs and coring to increase
The designer should minimize molded-in stress stiffness without increasing wall thickness
in applications made from ULTEM® resin because
the higher the stress level in a finished part, the ULTEM® resin can be ideally suited to the design
more susceptible it is to chemical attack. of long-term high temperature and mechanically
stressed applications as confirmed by the uniaxial
fatigue diagram in ■ F I G U R E 4 - 1 0 on page 23 of
this brochure.
P
S
* In all cases extensive testing of the application
C under the working conditions is strongly recommended.
The actual performance and interpreting of the results
W of end-use testing are the end-producer’s responsibility.
page 32 5 Design ULTEM ® PEI Resin Product Guide g GE Plastics
The most important material property to be
able to design for stiffness and strength is the Note
stress-strain curve of the material. General information on designing with
engineering thermoplastics can be found
In ■ F I G U R E 5 - 1 , the curves of unreinforced in the GE Plastics “Design Guide.”
ULTEM® 1000 base polymer and reinforced
ULTEM® 2100, 2200, 2300, 2400 and 7801 resins
are depicted.
210 ULTEM ® resin
Stress (MPa)
■ F I G U R E 5 -1 7801
180 2400
Stress-strain curve
2300
(23°C) 150 2200
2100
120 1000
90
P
60
S
30
C
0
0 0.8 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2
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Strain (%)Ultem_Profile.qxd 6/3/03 2:54 PM Page 33
6 Processing
6.1 Materials
An amorphous thermoplastic polyetherimide,
ULTEM® resin combines high performance with
good processing characteristics. It offers a
combination of high heat resistance with high
strength, modulus and broad chemical resistance.
ULTEM® resins are inherently flame resistant with
low smoke emission. Some grades have a UL 94
V-0 rating* at a thickness of 0.25 mm. Other
grades display a high dielectric constant and a
high dissipation factor over a wide range of
P temperatures and frequencies.
S ULTEM® resin is a high performance amorphous
C engineering thermoplastic. ■ TA B L E 6 - 1 shows
the basic ULTEM® resin families.
W
g GE Plastics ULTEM ® PEI Resin Product Guide 6 Processing page 33
■ TA B L E 6 - 1
The basic ULTEM ® resin families include the following:
Property Characteristics Typical Designations
Unreinforced Resin grades offering outstanding mechanical, thermal and environmental 1000 series
resistance properties.
Glass Reinforced Resin grades offering increased strength and stiffness. Low warpage grades are 2000 series
(10% to 30% GF) also available.
Wear Resistant Resin grades with low coefficients of friction designed for gears, bearings and other 4000 series
sliding surface contact applications.
Chemical Resistance Resins that offer resistance to strong acids and bases, aromatics and ketones. 5000 series
Also heat resistance.
Higher Heat Resins designed specifically for high heat aircraft interior applications requiring 6000 series
thermal dimensional stability.
High Strength Resin grades offering outstanding stiffness and strength. 7000 series
Hydrolytic Stability Heat blended resin grades offering impact strength, stain resistance. Suitable for food ATX series
P service and automotive application environments.
S
C
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■
6.2 Mold Design TA B L E 6 - 2 shows typical shrinkage for various
grades of ULTEM® resin at 0.125" wall thicknesses.
Shrinkage By referring to these figures designers can predict
ULTEM® resins, being amorphous, exhibit a more accurate shrink rate for a specific part
relatively predictable, repeatable shrink rates. geometry. End-use environmental testing of
ULTEM® 1000 resin shrinks isotropically; shrinkage finished parts, however, should be used to provide
becomes anisotropic when the resin is reinforced. the most reliable data.
Part design, gate location and processing
conditions will all influence shrinkage. ■ TA B L E 6 - 2
·A decrease in mold temperature can be expected Nominal shrink rate, in/in @ 0.125"
to produce a corresponding decrease in mold wall thickness.
shrinkage. It should be noted that if a part is
ULTEM ® Resin Grade Parallel to Perpendicular
molded at low mold temperatures [i.e., 100°F
to Flow* to Flow*
(38°C)] and later exposed to higher than ambient
temperatures [i.e., 150°F (66°C)] some additional 1000 0.007 0.007
post-mold shrinkage may occur. 2100 0.005 0.006
· An increase in injection pressure will produce
2200 0.003 0.005
a decrease in mold shrinkage. A part that is
P not completely packed will typically experience 2300 0.002 0.004
excessively high mold shrinkage.
S · Lowering the melt temperatures will produce
2400
4000
0.001
0.003
0.003
0.005
a slight decrease in mold shrinkage.
C ■ F I G U R E S 6 - 1 through 6 - 3 show the effect of
4001 0.006 0.007
W various factors on the shrink rate of ULTEM®
resin. *Median values
page 34 6 Processing ULTEM ® PEI Resin Product Guide g GE Plastics
■ FIGURE 6-1 ■ FIGURE 6-2
Effect of injection pressure on shrinkage of Effect of injection rate on shrinkage of
ULTEM ® 1000 resin.* ULTEM ® 1000 resin.*
Injection Pressure, MPa Injection Rate, cm3/s
0 50 100 150 0 10 20 30 40
1.0 1.0
Shrinkage, %
Shrinkage, %
0.8 0.8
0.6 0.6
0.4 0.4
0 5 10 15 20 25 0 1 2 3
3
Injection Pressure, 10 psi 3
Injection Rate, In /3
P
S
C
WUltem_Profile.qxd 6/3/03 2:54 PM Page 35
■ FIGURE 6-3
Effect of wall thickness on shrinkage of
ULTEM ® 1000 resin.*
Wall Thickness, mm
0 1 2 3 4 5 6 7
1.0
Shrinkage, %
0.8
0.6
0.4
0 0.04 0.08 0.12 0.16 0.20 0.24 0.28
Wall Thickness, inch
P * These curves represent shrinkage that can be expected when
processing engineering thermoplastic resins at the standard
S conditions recommended in this guide. Varying processing
conditions can affect shrinkage. Prototype tests in part geometry
C will provide the most reliable data.
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g GE Plastics ULTEM ® PEI Resin Product Guide 6 Processing page 35
6.3 Equipment high end of the temperature range, reduced
residence time is usually required to reduce the
Machine Selection possibility of material heat degradation. Therefore,
ULTEM® resins can be molded in most standard for higher temperature molding requirements, it
injection molding machines. Reciprocating screw is suggested that the minimum shot size be greater
machines are suggested. than 60% of the machine capacity.
When determining the size of equipment to be Once the total projected area of the complete shot
used for molding a particular ULTEM® resin part, (all cavity and runner areas subjected to injection
total shot weight and total projected area are the pressure) has been determined, 4 to 6 tons of
two basic factors to be considered. clamp force should be provided for each square
inch of projected area to reduce flashing of the
Optimum results are generally obtained when the part. Glass reinforced resins may require slightly
total shot weight (all cavities plus runners and higher clamp force (estimate one ton per square
sprues) is equal to 30 to 80% of the machine inch more). Wall thickness, flow length and
capacity. Very small shots in a large barrel molding conditions will determine the actual
machine may create unnecessarily long resin tonnage required (■ F I G U R E 6 - 4 ).
P residence times. If it is necessary to mold at the
S
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