innovative peek fabrication technologies
TRANSCRIPT
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Innovative PEEK Fabrication Technologies for High Performance System Solutions
John WallingMarketing Manager – AmericasVictrex Polymer Solutions
GlobalSpec - Plastics & Plastics Fabrication October 6, 2010
Michael SandeenProduct and Technical Manager – Americas Victrex Polymer Solutions
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Agenda• Introduction: Victrex Polymer Solutions• PEEK polymer: properties, benefits, applications• PEEK processing methods• Innovative VICTREX® PEEK™ polymer fabrication technologies:
OvermoldingLaser weldingPipe liningLaser sintering Thermoplastic bagging for composites
• Summary
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Victrex Polymer Solutions• A division of Victrex plc• The leading global manufacturer of high performance polyaryletherketones,
including the versatile VICTREX® PEEK™ polymer• 30 years of polyketone experience • Victrex plc listed at London Stock Exchange (VCT)
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PEEK Polymer• A linear aromatic semi-crystalline thermoplastic• Granules, powder or ultrafine powder• Key benefits:
High temperature performanceMechanical strength and dimensional stabilityWear resistanceChemical resistanceHydrolysis resistanceElectrical performancePurityRecyclable
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PEEK Processing MethodsPEEK is available in numerous forms:• Injection molded parts• Compression molded parts • Extruded shapes• Films• Composites• Powder Coatings• Filaments• Fabrics
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Innovative VICTREX PEEK Polymer Fabrication Technologies
• Overmolding
• Laser welding
• Pipe lining
• Laser sintering
• Thermoplastic Bagging for Composites
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Mold Cavity #1
OvermoldingWhat is it? Secondary injection process to apply elastomers directly onto VICTREX PEEK part surfaceChallenges:• Need hermetic seal and even compression profile across width mechanical interlock not acceptable• Requires strong durable bond at interface to avoid delamination
Cross-SectionDesired
Mold Cavity #2
Cross-SectionUnacceptable
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Overmolding – Case Study• Company: Amphenol PCD• Application: Aircraft wire harness and tubing clamps
• Material #1 (substrate): VICTREX® PEEK™30% glass-fiber• Material #2 (elastomer): Silicone, fluorosilicone, rubber
Silicone elastomer for standard electrical wire Softer durometer rubber
for more delicate wiring
• Amphenol developed proprietary process to condition surface of VICTREX PEEK polymer substrate prior to injecting elastomer
• Clamp strength and cushion adhesion tested with long term immersion in jet fuel, hydraulic fluid
• Boeing will replace majority of aluminum and steel clamps with overmolded PEEK clamps on the new 787
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Laser WeldingWhat is it? Secondary thermal joining process utilizing new industrial laser technologyChallenges:• VICTREX PEEK polymer assemblies must survive extreme environments• Most adhesives limited by long term exposure to temperature, moisture or chemicals• Bonding of thin VICTREX PEEK-based films demands tight process control and rapid
heating cyclePOWER
MOTIONContour Welding
MASK
LINE LASERMask Welding
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Laser Welding – Case Study• Company: Leister Technologies LLC• Application: Surface mount switch prototype
• Material #1: APTIV™ PEEK-based film (natural)• Material #2: VICTREX PEEK polymer (black)
• APTIV film replaces Kapton® polyimide as flex circuit substrate which can be laser welded directly onto the body of an injection molded surface mount switch
• Laser welding replaces the adhesive prone to failure in this sub-assembly
• Laser weld can meet humidity and thermal cycling requirements for consumer electronics
Photo courtesy of Leister Technologies demonstrates successful mask welding of two layers of APTIV film. Black lettering and perimeter outline show the tight tolerance precision of the laser weld joint. The black color is actually from the bottom layer of film.
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VICTREX PEEK Pipes and Linings• VICTREX® PEEK™ polymer has been selected for a wide range of development
programs requiring continuous lengths of extruded pipe/tubes• To support these programs Victrex invested in a specialist VICTREX PEEK Pipe
extrusion facility capable of producing high quality products for the industry• Pipe products are available in unfilled VICTREX PEEK polymer grades • Liner is minimally roller reduced (RR) and allowed to re-expand without external
heat source • Continuity of liner extrusions maintained via specialty coupling
with thermoformed end cap• VICTREX PEEK lining with standard carbon steel enables system similar
in performance to Corrosion Resistant Alloy pipe
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Pipe Lining – Case Study
• Collective well fluid temperature 140F• Producing 198 BBL oil/day 80% water cut • Incumbent service life 3 months• VICTREX PEEK lined tubing• Installed 21 joints in worst deviated section• No visible abrasion wear on PEEK lined section • VICTREX PEEK lined pipe extended service life by minimum 3x • Tubing only pulled due failure of secondary non-lined tubing section failures • VICTREX PEEK lined tubing remained fully operational
Bixby Wellhead #10: typical non-aggressive rod-pump application
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High Temperature Laser Sintering - HTLS• Low rate serial part production• Additive Manufacturing – Parts built with successive 0.005” layers
– Components manufactured directly from 3D CAD data– Costly tooling eliminated
• Accelerated product development & testing– Durable engineered parts with known material properties– Functioning VICTREX PEEK polymer prototypes
• “Free Complexity” – Design freedom not possible through traditional processes– Internal features, negative draft, part count reduction through consolidation
• EOSINT P800 System– Utilizes proprietary PEEK HP3 powder– 660mm (x) x 360mm (y) x 540mm (z) effective volume footprint
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HTLS – Case StudyCompany: Royal Engineered CompositesApplication: Aircraft ductingMaterial: HP3 PEEK powder
• Laser sintered VICTREX PEEK polymer replaces machined aluminum components, reducing weight and meeting other engineering requirements including FAR 25.853 compliant (vertical burn)
• One piece, complex design free of welds or joints• Development time less than 2 weeks including
multiple design iterations and no tooling costs
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Bagging for Composites
What is it? Vacuum bags enable high temperature and pressure forming of composites Applications: Aircraft structures: wing skins, floor beams, doors, etc. Challenges:• Traditional bagging approach with thermoset resins requires many layers; very labor intensive• Thermoset bags typically only survive a few curing cycles before failing leading to low yields• Industry shift to thermoplastic composites for productivity and performance…how to bag?
Various materials and designs, all require custom built multi-layer bagging system
Large panel surface areas with limited reuse cycles can create significant scrap
Vacuum port
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Bagging for Composites
mouldmould
vacuum portdam composite bleeder release plyrelease ply
pressure plate
breather vacuum bag
Thermoset approach• Complex multi-layer construction• Time consuming layup• Expensive tooling• Limited reuse, excessive waste
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sealthermoplastic APTIV® PEEK film
vacuum portmouldcomposite
Bagging for Composites
Thermoplastic approach• Single-layer bag• Bag melts into composite• Protective surface• Eliminates labor and waste
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Internal bagging for manufacture of hollow components• APTIV film bag/bladder expands, melts and consolidates into composite• Pressurized solely by heating (no autoclave required)• External surface defined by tooling• Protective resin-rich inner surface
P P P
mould
Aptiv film bagcomposite
heat heatheat
Bagging for Composites
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Successful preliminary trials have lead to development funding
inductive heating coil(~Ø90mm)
heating time ≈
1 minute
bagged composite
upper surface
consolidatedcomposite
lower surface
25µm Aptiv bagging film
Collaborators
Bagging for Composites – Case Study
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Summary
• VICTREX PEEK polymer is recognized as one of the highest performing melt processable thermoplastics
• Fabrication versatility enables VICTREX PEEK polymer to be shaped into many product forms and complex shapes
• VICTREX PEEK polymer system performance further enhanced through novel secondary operations
• Victrex Polymer Solutions’ innovative application engineering facilitates synergy of multiple processes to deliver enhanced value
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Questions? Contact information:[email protected] or +1 (484) 342 6001
COME VISIT OUR VIRTUAL BOOTH…
VICTREX® is a registered trademark of Victrex Manufacturing Limited in the US, European Community and elsewhere. PEEK™, APTIV™, PEEK-ESD™, T-Series™, HT™, ST™ and WG101™ are trademarks of Victrex plc. VICOTE® is a registered trademark of Victrex plc in the US, European Community and elsewhere.
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