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PRODUCT GUIDE
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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 GEPS 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 GEPS 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 GEPs 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 GEPs 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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h
Contents
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 217C, HDT/Ae of
retardancy and exceptional dimensional stability. 190C and relative thermal index (RTI) of 170C
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
unreinforced
Injection molding Chemical resistant CRS 5000 series
glass reinforced
unreinforced
2 h
Applications
Tableware / Catering
Medical
Aircraft
Automotive
Automotive Lighting
2.2 Medical
P
ULTEM resin provides value added performance
S for reusable medical devices like sterilization
trays, stopcocks, dentist devices and pipettes.
C
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
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
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
W
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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.
2.7 Electrical and Lighting In these segments ULTEM resin can provide:
Temperature resistance up to 200C,
From connectors to reflectors, ULTEM resin is
RTI of 170C and ball pressure test at 125C
the material of choice for todays 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 960C (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
W
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3 Product Selection
W
EPR series has four-times higher plating adhesion
and 30% better flow than standard ULTEM 2000
Unreinforced and glass reinforced grades
filled products
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
W
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h
3.2 Selection Tree
general purpose
wear resistant
chemical resistant
ULTEM
aircraft
P high impact
S
polymer blend
C
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)
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)
2212
20%
2212 (R, EPR)
milled-glass 2312
reinforced 30%
2312 (EPR)
low warpage
40% 2412 (EPR)
glass/mineral
reinforced
3451
P
W
see charts on pages 16 and 17
Ultem_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
ULTEM PEI resin general purpose | wear resistant | carbon fiber filled | chemical resistant
| higher heat | aircraft | high impact | polymer blend
C
CRS 5301 (Std.)
30%
W CRS 5311 (HF)
see charts on pages 16 and 17
Ultem_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
10% 6100
higher heat
6000 series
glass reinforced 20% 6200
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
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
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 16
200
1010 (F,R)
170
Heat HDT/Ae
160
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 |
180 9075
aircraft
170 9076
Heat HDT/Ae
aircraft
160
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 |
200 2210
2110 (R)
190 2312
appearance
30% milled glass fibers
180
170
Heat HDT/Ae
160
P
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 MPa
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4 Properties*
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
W
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150
100
ULTEM 1000 resin
Polyethersulfone
Polysulfone
High heat
polycarbonate
30 120
20 60
10 0
ULTEM 1000 Polyethersulfone Polysulfone High heat ULTEM 1000 resin Polyethersulfone Polysulfone
resin polycarbonate
4.3 Mechanical Properties ULTEM 1000 resin series a(60s) 100/100 < 50 pass
ULTEM Resin
100
50
0
-50 0 50 100 150 200
Temperature (C)
140
100
90 120
80
100
70
80
60
50 60
40
40
30
ULTEM 1000 resin
Polyethersulfone
Polysulfone
High heat
polycarbonate
W
Ultem_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 175C 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)
P 10 8
C 10 7
-120 -80 -40 0 40 80 120 160 200 240 280
W Temperature (C)
Polyethersulfone
Polysulfone
High heat
polycarbonate
temperature.
P
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 23
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
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)
3.20
23C
Dielectric constant
F I G U R E 4 -12 82C
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
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 25
0.007
82C
Dissipation factor
F I G U R E 4 -13 49C
0.006 23C
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)
0.018
ULTEM 1000 resin
Dissipation factor
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)
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 .
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
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 cleaners
Ultem_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.)
Chlorinated Solvents 3 )
1,1,2 Trichloroethylene 23 2 hrs. 0.25 sv.c. f.
2 hrs. 0.5 sv.c. f.
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
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 formaldehyde
Ultem_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.
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
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 30
23C
Tensile stress (MPa)
80
P
S 60
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)
Agency recognition
ULTEM resins have been tested and comply
with a number of agency regulations and
specifications.
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 32
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-producers responsibility.
F I G U R E 5 -1 7801
180 2400
Stress-strain curve
2300
(23C) 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
W
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.
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.
W
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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., 100F
to Flow* to Flow*
(38C)] and later exposed to higher than ambient
temperatures [i.e., 150F (66C)] 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
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
W
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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
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
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 36
FIGURE 6-4
Clamping force for ULTEM resins.
800 7,000
Clamping Force, N
700 6,000
600
5,000
500 4-6 Tons per sq. in. 4,000
400 for unfilled resins
3,000
300
200 2,000
100 1,000
0 0
P
0 50 100 150 200 250 300
S Projected Area, Inches2
Barrel Selection and Screw Design The non-return valve should be of the sliding
Considerations check ring type. Flow-through clearances of at
Conventional materials of construction for least 80% of the cross-section of the flow area in
compatible screws and barrels are generally the metering zone of the screw are usually
acceptable for processing ULTEM resins. The necessary.
use of bimetallic barrels is suggested.
Drying Parameters
Depending on screw diameter, a compression ULTEM resin, like most thermoplastics, absorbs
ratio of about 2.2:1 with a length to diameter ratio atmospheric moisture which can cause degradation
of 20:1 is preferred. A short feed zone (5 flights) of the polymer during processing. Moisture
and a long compression zone (11 flights) with a content higher than 0.02% can be expected
gradual constant taper leading to a short metering to cause appearance issues, brittle parts and
zone (4 flights) is also suggested. The compression an increase in the melt flow of the material
should be accomplished over a gradual and ( F I G U R E 6 - 5 ). The suggested moisture level
constant taper since sharp transitions can result in can usually be reached by predrying ULTEM
excessive shear and material degradation. If resin at temperatures suggested in TA B L E 6 - 3 .
specific screw selection is not possible, general
P purpose screws with length to diameter ratios
S from 16:1 through 24:1 and compression ratios
from 1.5:1 to 3.0:1 have been used successfully.
C Vented barrels are not suggested for processing
ULTEM resins.
W
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TA B L E 6 - 3 FIGURE 6-5
ULTEM resin drying suggestions. Moisture absorption of ULTEM 1000 resin vs. relative
humidity at 24 hours.
ULTEM Resin Drying Temp. Drying Time*
Grades (F) (Hrs.) 0.7
Unreinforced 300 4 0.6
Weight Gain, %
Reinforced 300 6 0.5
Blended 275 6 0.4
*Times suggested are mean times and may be longer for some colors 0.3
and grades. Moisture content should be 0.2% or less.
0.2
0.1
0
0 10 20 30 40 50 60 75 80 90 100
Relative Humidity, %
Desiccant
Process
W
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TA B L E 6 - 4
Typical Processing Parameters
Typical Injection Molding
Molding Conditions 1000
1010 2300 4000
2100 2310 4001
2110 2312 8015
2200 2400 9075
2210 2410 9076
2212 3451 ATX200 ATX100
Processing Parameters Units (min.) (max.) (min.) (max.) (min.) (max.)
Melt Temperature F (C) 660 (348) 750 (398) 660 (348) 700 (371) 630 (332) 670 (354)
Nozzle F (C) 650 (343) 750 (398) 660 (348) 700 (371) 620 (326) 660 (348)
Front Zone F (C) 650 (343) 750 (398) 660 (348) 700 (371) 630 (332) 670 (354)
Middle Zone F (C) 640 (337) 750 (398) 650 (343) 690 (365) 610 (321) 650 (343)
Rear Zone F (C) 630 (332) 750 (398) 640 (337) 680 (360) 590 (310) 630 (332)
P
Mold Temperature F (C) 275 (135) 325 (163) 275 (135) 325 (163) 200 (93) 275 (135)
S Back Pressure psig (MPa) 50 (0.3) 100 (0.7) 50 (0.3) 100 (0.7) 50 (0.3) 100 (0.7)
Screw Speed rpm 40 70 40 70 40 70
C
C
Shot to Cylinder Size % 40 60 40 60 40 60
W
W Clamp Tonnage tons/in 2 3 5 3 5 3 5
Vent Depth inch 0.0010 0.0030 0.0010 0.0030 0.0010 0.0030
AR9100
AR9200
AR9300
CRS5001
CRS5011
CRS5111
CRS5211 7201
CRS5311 7801
Processing Parameters Units (min.) (max.) (min.) (max.)
Melt Temperature F (C) 690 (366) 730 (387) 720 (382) 800 (426)
Nozzle F (C) 680 (360) 720 (382) 710 (376) 790 (421)
Front Zone F (C) 690 (365) 730 (387) 720 (382) 800 (426)
Middle Zone F (C) 670 (354) 710 (376) 700 (371) 790 (421)
Rear Zone F (C) 650 (343) 690 (365) 680 (360) 760 (404)
Mold Temperature F (C) 275 (135) 325 (162) 275 (135) 325 (162)
P
Back Pressure psig (MPa) 50 (0.3) 100 (0.7) 50 (0.3) 100 (0.7)
S Screw Speed rpm 40 70 40 70
Shot to Cylinder Size % 40 60 40 60
C Clamp Tonnage tons/in 2 3 5 3 5
Vent Depth inch 0.0010 0.0030 0.0010 0.0030
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 40
C MINIMUM
0
W 0 1 2 3 4 5 6
Screw Diameter, in
125
reduce sinks and voids. For ULTEM resin blends,
use the slowest practical injection speed to help 15 100
minimize shear rate at gate areas.
Cooling Time, s
to use a fast injection speed, a minimum holding
time to achieve gate freeze-off and a short cooling
time. ULTEM resin can frequently provide a 30
significant reduction in cycle time over other
thermoplastics and thermosets. The most 15
important factor influencing cycle time is part
thickness, as depicted in F I G U R E 6 - 9 .
0
0 0.05 0.10 0.15 0.20 0.25 0.30
Wall Thickness, Inch
P
W
Ultem_Profile.qxd 6/3/03 2:54 PM Page 42
Flow Length, mm
30 0.090 Inch (2.3mm) 0.090 Inch (2.3mm)
Flow Length, mm
25
600 600
20 20
400 400
15
10
200 10
200
0 0 5
0 600 650 700 750 800 850 900
Melt Temperature, F 0 0
P 0 5 10 15 20 25
3
Injection Pressure, 10 psi
S
30
Flow Length, mm
0 0 0 0
0 600 650 700 750 800 850 900 400 500 600 700 800 900
P
Melt Temperature, F Melt Temperature, F
S
W
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Regrind
Reground sprues, runners and non-degraded
parts may be added to the virgin pellets up to a
level of 25%. Grinder screen sizes should be at
least 5/16 to 3/8 inch (7.9 mm). If a smaller size is
used, too many fines could be generated, creating
molding problems such as streaking and burning.
It is important to keep the ground parts clean and
to avoid contamination from other materials.
Drying time should be increased since regrind will
not be the same size as virgin pellets, and
therefore water diffusion may be different.
W
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7 Secondary Operations
Recommended adhesive types for ULTEM resin Inserts, installation by heat or ultrasonics are the
are: preferred techniques. Press and expansion inserts
Epoxy adhesives give radial stresses. Overmolding and external
Polyurethanes adhesives threaded inserts are also possible.
Silicones adhesives Screws by thread forming or thread cutting.
Care should be taken with cyanoacrylates Thread forming screws with low flank angle
and acrylic systems which are aggressive for reduced radial stresses are preferred.
for ULTEM resin. Exposure to these solvents Hole (0.85 times screw diameter) and screw
might lead to stress cracking should be circular (not trilobular/square).
Boss diameter should be 2.5 times screw outer
7.3 Mechanical Assembly diameter.
Mechanical assembly techniques are widely used
All types of rivets can be used; be aware of
high stresses with some pop rivets.
with ULTEM resin parts. For unreinforced
ULTEM resin grades, the classical rules for
Staking is possible, with ultrasonic staking
being more practical than heat staking.
amorphous engineering thermoplastics apply. For
highly reinforced ULTEM resin grades, the use
Snap fit assembly
P of special thread cutting screws is advised because
of the low elongation at break. The different
S mechanical assembly techniques that can be used
C can be summarized as follows:
W
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7.4 Painting
A wide variety of colors and textures can be Coatings can also help to minimize color
applied to ULTEM resin using commercially degradation.
available organic paints and conventional Conductive coatings offer shielding against
application processes. Painting is an economical radio frequency interference (RFI) or
means of enhancing aesthetics and providing electromagnetic interference (EMI).
color conformity. A variety of conventional and waterborne paints
can be successfully applied to ULTEM resin.
General recommendations for painting Generic types are: Acrylic, Alkyd, Epoxy, Polyester,
ULTEM resin are: Polyimide, Polyurethane
If the ULTEM resin application is working under
Pre-treatment high temperature conditions, the selected paint
Hand washing the part with cleaning agents must offer equal high temperature performance.
based on alcohol or aliphatic hydrocarbons
or: Paint solvents
Power washing the part with cleaning agents It is important that solvent formulations are
based on detergents dissolved in water, acidic considered when selecting a paint for use with
P by nature, neutral or alkaline ULTEM resin. It can be extremely difficult to
achieve an ideal match between solvent and
S Paint selection substrate.
C
Paint selection is determined by the desired
decorative effect, specific functional needs
W and the application technique to be employed.
7.5 Metallization
Metallization of plastics is normally undertaken The best method is to keep the moldings clean
for decorative or functional reasons. Properties and to metallize the parts as soon as possible after
usually associated with metals such as molding, or store them in clean containers.
reflectiveness, abrasion resistance, electrical
conductivity and decorative surfaces can be Metallization methods
added through metallization. Vacuum metallization through Physical Vapor
Deposition. Physical Vapor Deposition is the
General recommendations for the metallization of depositing of an evaporated metal, mostly
ULTEM resin are: aluminum, on a substrate. To achieve
evaporation, the pure metal is heated in a
Pre-treatment deep vacuum.
Typically unreinforced ULTEM resin does not
need a basecoat or lacquer primer layer before
Vacuum metallization through sputtering (Plasma
Enhanced Chemical Vapor Deposition, PE-CVD).
metallization because of the good surface quality Sputtering or PE-CVD also take place in a
of ULTEM resin after molding. However, a vacuum. With high voltage equipment, a field
P surface activation pre-treatment is required in is created between the samples grounded carrier
S
most cases. Cleaning with cloth or solvents is not and a negative electrode: the metal target that
recommended because of sensitivity to scratches has the function of a metal or an alloy donor.
C that can be seen after metallization.
W
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Plating Electroplating
This can be done either by electroless plating After the application of a conductive metal layer
without the addition of current to the galvanic on the plastic, a further electrolytic deposition
process and/or followed by electroplating where of selected metals on top of this layer can be done.
current is used to effect an electrolytic deposition Most frequently used metals are either chrome,
of metals coming from a dissolved metal salt. nickel or gold in varying thicknesses.
Electroless plating
Dichroic coating
A non-conductive plastic is coated with a ULTEM resin is very suitable for use with dichroic
continuous metallic film by etching the plastic. coatings which reflect visible light but allow the
This creates micro cavities which make transmission of infra-red rays. By applying
interlocking possible. Chemical bond plating is multiple coating layers with different refraction
a special etching technique which is particularly indices, light with specific wavelengths can be
suitable for use with ULTEM resin. In this filtered. The dichroic coating process also takes
technique, a permanganate etch opens the place in a vacuum vessel, and is used in high heat
ULTEM resin molecule imide ring, and allows generating lamps such as small halogen lamps
copper to enter the molecule. A very high level of and dentist lamp reflectors.
adhesion can be established with this technology.
This technique is often used for EMI shielding
P
and for Molded Interconnect Devices, MIDs. For
S EMI shielding an electroless copper layer of 1-2
m is applied with a finish of 0.5 m of electroless
C nickel. For a MID application where the molded
part becomes a circuit board, an additional
W
copper layer is applied by electroplating.
After treatment
Due to the reactive nature of aluminum to
humidity, and the ultra-thin layer thickness,
aluminum must be protected against
environmental influences.
Note
General information on Secondary Operations
like welding, mechanical assembly, bonding
P painting and metallization of engineering
S thermoplastics can be found in the following
GE Plastics brochures:
C Assembly guide
Design guide
W
Painting guide
Metallization guide
Ultem_Profile.qxd 6/3/03 2:54 PM Page 47
Addresses
More information relative to this ULTEM PEI Resin Product Guide can be found on:
www.geplastics.com/resins/materials/ultem.html
AMERICAS
Italy Denmark
General Electric Plastics Italia S.p.A. GE Polymerland ApS United States
Viale Brianza, 181 Groningen 25 GE Plastics
I-20092 Cinisello Balsamo (Milano) DK-1270 Copenhagen Denmark One Plastics Avenue
Italy Telephone: (45) 33-979570 Pittsfield, MA 01201 USA
Telephone: (39) 02-618341 Telefax: (45) 33-324910 Telephone: (413) 448-7110
Telefax: (39) 02-61834211 Cable: GEPLASTICS
Finland
Russia GE Polymerland Finland O.Y. California
General Electric International A/O Virnatie 5 GE Polymerland, Inc.
Kosmodamianskaia Nab, 6th floor SF-01300 Vantaa 4160 Hacienda Dr.
Building 1 Finland Pleasanton, CA 94588
115054 Moscow Russia Telephone: (358) 9-47618800 Telephone: (510) 414-8992
Telephone: (7) 095-9357278 Telefax: (358) 9-47618820 Telefax: (925) 463-7282
Telefax: (7) 095-9357231
Turkey GE Polymerland, Inc.
Spain GE Plastics Turkey 7700 Irvine Center Drive
General Electric Plastics Ibrica S.A. Dudullu Organize Sanayi Bolgesi Suite #450
Avenida Diagonal, 652-656 2.Cadde No 173 Irvine, CA 92618
Edificio D. Planta 3 81250 Umraniye Telephone: (714) 328-5188
08034 Barcelona Spain Istanbul Turkey Telefax: (949) 754-1639
Telephone: (34) 93-2521600 Telephone: (90) 216-3651565 (pbx)
P Telefax: (34) 93-2802619 Telephone: (90) 216-3654959 (pbx) Illinois
Telefax: (90) 216-3650115 GE Polymerland, Inc.
S Sweden 2200 Cabot Drive
GE Polymerland Sweden A.B. Suite 102
C Solna Strandvg 98, Box 324 Lisle, IL 60532
17175 Stockholm Sweden Telephone: (630) 248-0706
W Telephone: (46) 0-855950180 Telephone: (630) 505-2500
Telefax: (46) 0-855950185 Telefax: (630) 505-2528
Ultem_Profile.qxd 6/3/03 2:54 PM Page 48
LNP Engineering Plastics (Asia) Pte. Ltd. GE Plastics Haryana GE Plastics Japan, Ltd.
Room 1008, Tower 1, The Gateway, 8th Floor Gateway Towers Tokyo Office
25 Cannon Road DLF City Phase III NH 8 Nihombashi Hamacho Park Bldg.
Tsimshatsui, Kowloon Gurgaon 122002 2-35-4, Nihombashi-Hamacho
Telephone: (85) 2-26290812 Haryana, India Chuo-ku, Tokyo 103, Japan
Telefax: (85) 2-26290800 Telephone: (91) 124-5018001 Telephone: (81) 3-56956800
Telefax: (91) 124-5018021/8022 Telefax: (81) 3-56954859
India
GE Plastics India Limited GE Plastics Mumbai GE Plastics Japan Moka
Plastics Avenue Solitaire Corporate Park Building 7 2-2 Kinugaoka, Moka-Shi
P.O. Jawahar Nagar 8th Floor, Unit 1, New Link Road Tochigi-Ken 321-4392, Japan
Baroda 391320 Mumbai 400093, India Telephone: (81) 285-802111
Gujarat, India Telephone: (91) 22-56972390 Telefax: (81) 285-802156
Telephone: (91) 265-2232147/2232177 Telefax: (91) 22-56972383
Telefax: (91) 265-2232144 LNP Engineering Plastics, Japan
Indonesia Nihombashi, Hamacho Park Building,
GE Plastics India Limited GE Plastics Indonesia 2-35-4, Nihombashi-Hamacho,
Millers Boulevard KH Mas Mansyur Kav. 126 Chuo-Ku
70/2, Millers Road Jakarta 10220, Indonesia Tokyo 103-0007, Japan
Bangalore 560052 Telephone: (62) 21-5744980 Telephone: (813) 5695-4606
Karnataka, India Telefax: (62) 21-5747101 Telefax: (813) 5695-4859
Telephone: (91) 80-2263144/3145
Telefax: (91) 80-2254247 Japan GEM Polymers Ltd. Osaka Factory
GE Plastics Japan, Ltd. 5, Takasago, 1-Chome, Takaishi-City
P
1015 Aza Sumiyakizawa Osaka 5920001, Japan
Hodozawa, Gotemba-shi Telephone: (81) 722-680457
S Shizuoka 412, Japan Telefax: (81) 722-680458
Telephone: (81) 550-892323
C
Notes
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Ultem_Profile_BC.qxd 6/27/03 4:24 PM Page 1
CYCOLAC Resin
CYCOLOY Resin
GELOY Resin
LEXAN Resin
NORYL Resin
ULTEM Resin
W
W XENOY Resin
To Find Out More
Call our toll-free numbers:
XYLEX Resin
USA: 800-845-0600
Europe: 00-800-1234-4000
China Mainland: 800-820-4377
Japan: 81-285-80-2370
Korea: 82-080-850-6000
Hong Kong: 800-900-956
Taiwan: 0080-86-1002
Singapore: 800-860-0002
E-mail us at:
GELIT@gepex.ge.com
Visit:
www.geplastics.com/resins/materials/ultem.html