Fortron PPS
for Thermoplastic
Composites
November 2012
1 © Ticona PPS-014R1 5/12 US EN
Contents
Introduction to Ticona
Fortron® PPS
– Chemistry
– Properties
– Applications
Fortron® PPS Composites
– Background
– Processing Options
– Properties
– Applications
Summary
2 © Ticona PPS-014R1 5/12 US EN
Broad Portfolio of Engineering and
High-Performance Polymers
Ticona Engineering Polymers
LCP – Vectra® /Zenite®
PPS – Fortron®
High-Performance
PCT – Thermx®
Polymers (HPP)
(TI1 > 150 °C) PEEK PET – Impet®
PI
FP PBT – Celanex®
PEI PBT Alloy – Vandar®
Price for performance
LCP
PES PAI
PPS TPC-ET – Riteflex®
PAR PPA
PCT POM – Hostaform®
Engineering PSU
PA46 LFRT – Celstran®, Factor ®
Polymers (ETP) PC Compel®
(TI1 > 90 °C) PET
CFR-TP – Celstran®
COC PBT
UHMW-PE
PA 6/66 UHMW-PE – GUR®
PPO POM
TPC-ET
LFRT
CFR-TP
Amorphous Partially crystalline
TI1 = Temperature Index
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Fortron® PPS
Summary – Structure and Properties
Semicrystalline
– Tg 85°C, TM 285°C
– Density 1.35 g/cm3
Inherently Flame Retardant:
– UL94-V0, LOI > 45
Chemical Resistance –
n Dimensional Stability
– Fuels, oils, solvents
– Water-glycol
Easy to Process
– Injection molding
Polyphenylenesulfide (PPS)
– Extrusion
Poly(thio – 1,4 - phenylene)
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Fortron® PPS
Semi-crystalline thermoplastic polymer, perfectly suited
for parts that have to withstand the high mechanical and
thermal requirements which require…
A high melting point range between 280° and 290°C
Inherently flame resistant
Excellent resistance to chemicals, oils and fluids
An ideal alternative to conventional materials such as
thermosetting polymers and metals
High hardness and stiffness and superb long-term creep
under load properties
Ease to injection mold, blow mold and machine
Weight reduction combined with high dimensional stability
5 © Ticona PPS-014R1 5/12 US EN
Fortron® PPS Has No Known Solvent
Below 200°C
Chemical resistance with minimal attack or
swelling even at elevated temperatures
– Resists: acids/bases pH 2 to 12
– Resists: strong bleaches
– Resists: auto fluids – coolants,
transmission & brake
– Resists: gas & alternate fuels
(methanol, ethanol)
– Resists: hydrolysis
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Fortron® PPS 0214C1 –
Matrix Material for Composites
Linear, unmodified PPS polymer
High molecular weight / high viscosity: 140 pa·s
– For extrusion and injection molding applications
Specified for aircraft applications
– In use at Airbus and Boeing
– VIAM qualification
– Federal state unitary enterprise “All Russian Scientific Research
Institute of Aviation Materials”
Tested in regards to flammability, smoke density
and smoke toxicity:
– ABD0031
– FAR/JAR 25.853
– New: DIN 5510 and ISO 5659
7 © Ticona PPS-014R1 5/12 US EN
Fortron® PPS 0214C1 – Smoke Density
Tested with 2 mm Plaques
Smoke density according to Airbus Standard ABD0031
– Non-flaming – Max. Value: 0, Average: 0
• DS max. @ 4 min: 0; ABD and FAR Passed
– Flaming – Max. Value: 32 (6 min.), Average: 23 (6 min)
• DS max. @ 4 min: 15; ABD and FAR Passed
Tox-Test (ABD0031):
ABD / FAR passed Value Max. Value in ppm
– Hydrogen Cyanide HCN: NF: 0 – F: 0 150
– Carbon Monoxide CO: NF: 0 – F: 10 1000
– Nitrous Gases NO-NO2: NF: 0 – F: 0 100
– Sulfur Dioxide/
Hy. Sulfide SO2 - H2S: NF: 0 – F: 10 100
– Hydrofluoric Acid HF: NF: 0 – F: 0 100
– Hydrochloric Acid HCl: NF: 0 – F: 0 150
8 © Ticona PPS-014R1 5/12 US EN
Fortron® PPS 0214C1 – Flammability
Tested With 2 mm Plaque
Vertical Burning Test 12 s ABD0031
– Total burn time: 12 s
– Flame extinguish time: 0 s
– No. of particles: 0
– Ignited particles: 0
– Total burn length: 5 mm
Vertical Burning Test 60 s ABD0031
– Total burn time: 60 s
– Flame extinguish time: 0.6 s
– No. of particles: 2.4
– Ignited particles: 1.4
– Total burn length: 44 mm
9 © Ticona PPS-014R1 5/12 US EN
Internal UL Flammability Testing
Material Part Thickness Unaged Sample Aged Sample
Rating Rating
Unfilled Fortron PPS 3.0mm (0.12”) V-0* V-0*
Control 1/32” V-0 V-2
1/64” V-2 V-2
3.0mm (0.12”) V-0* V-0*
Unfilled PEEK 1.5mm (0.059”) V-0* V-0*
Control 1/32” No V-Rating V-2
1/64” No V-Rating No V-Rating
Thin PEEK samples failed to achieve a V-Rating
because of long burn times and cotton ignition
Thin PPS parts have V-0 equivalent burn times but
molten polymer drips can ignite the cotton = V-2 Rating
*Data as reported by Underwriters Laboratory
10 © Ticona PPS-014R1 5/12 US EN
Fortron® PPS Dimensional Stability
Extremely low moisture absorption – 0.02%
Minimal effect of temperature
CLTE – 19 x 10-6 /°C (6165A4)
Precision molding
Low shrinkage - 0.3% (6165A4)
Creep resistance
For Precision Parts Even at Elevated Temperatures
11 © Ticona PPS-014R1 5/12 US EN
Low PPS Water Absorption
Results in Dimensional Stability
0.16
1.25
0.14
0.12
0.1
(%)
0.08
0.06
0.04
0.02
0
PPS PEI PEEK
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Top Fortron® PPS Segments
Semicon Industrial EE & Sensors
Fibers
Composites
Automotive
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Fortron® PPS
Extrusion: Film, Fiber, Netting, etc.
Aircraft Composite High Tenacity Monofilament
Filter Netting
Stock Shapes CPI Filter
14 © Ticona PPS-014R1 5/12 US EN
Fortron PPS
®
for Thermoplastic
Composites
May 2012
15 © Ticona PPS-014R1 5/12 US EN
Why Thermoplastic PPS Composites
vs. Thermoset Composites?
Improved Properties Improved Processing
Tougher, good fatigue performance Eliminate bagging materials and labor
– 4x tougher than toughened epoxies – May also eliminate kitting and debulking
Damage tolerant steps and equipment
Insensitive to moisture Eliminate autoclave possible
– Cost, space and bottleneck issues
High-temperature performance
Rapid processing vs. thermosets
Very low flammability, smoke,
toxicity Can be reformed
Low residual stress in molded parts Simple, longer lasting tool
Excellent chemical resistance Fusion bonding eliminates fasteners
and adhesives
– Reduces cost and weight
Green processing
– Recyclable
– No VOCs in processing
– Less process scrap
– Fewer process energy requirements
16 © Ticona PPS-014R1 5/12 US EN
Thermoplastic Composite Matrix
Cost Advantage
The material cost for
100
a thermoplastic matrix
Processing
80
Material
might be equal or
even higher
System Cost in %
60
40
Lower cost for
20 handling, processing,
0
and assembly can
lead to a substantial
nal
ntio
C on v e advantage in total
ic
ast
T he rmo
pl cost
Even the High Cost Thermoplastic Polymers Offer Improved
Cost Savings vs. Epoxy Based Composites
17 © Ticona PPS-014R1 5/12 US EN
Example for Value Chain in
Aircraft Industries
Producer Thermo-
Plastic Film
of Forming- Assembling Aircraft
Pellets Producer
Composites Process
18 © Ticona PPS-014R1 5/12 US EN
Station 1: Film Production
Fortron PPS
Pellets
Starting Product: Film Production
PPS Pellets Station 1 – Lipp-Terler GmbH in
Temperature stability Gaflenz near Linz, Austria. The
High level of hardness and pellets are converted into films with
impact strength a thickness of 50 to 200 µm. The
film leaves the special plant in rolls
Excellent resistance to chemicals
of 100 kg in a flawless state, crystal
Broad temperature range clear and with the required
Inherent flame resistance characteristics with regard to
strength and dimensional stability.
19 © Ticona PPS-014R1 5/12 US EN
Station 2: Composite Production
Fortron PPS Film
e. g. Carbon Fiber
Starting Product:
Basic Matrix of
PPS / Carbon Fiber Fabric
Laminate Production
Station 2 – Ten Cate Advanced Composites
BV, Nijverdal, Netherlands. The carbon fiber
fabric and PPS film are bonded together in
a press, under high pressure and high
temperature, into high-strength,
dimensionally stable and resistant
composites in the desired layer thickness.
20 © Ticona PPS-014R1 5/12 US EN
Station 3: Thermoforming
Positive Form
Composite Plate
Starting Product:
Composite plates
in the required size
Negative Form
Shaping
Station 3 – Fokker Special Products,
Hoogeveen, Netherlands.
The composite plates are pre-heated
and subsequently shaped into the
desired form under pressure and
high temperature.
21 © Ticona PPS-014R1 5/12 US EN
Station 4: Assembly
Front Wing Portion
Starting Product:
Front wing portion
(Weight of the parts is
20 percent less than
aluminum)
Assembly
Station 4 – Airbus
The completed construction
element is mounted at the
intended location.
22 © Ticona PPS-014R1 5/12 US EN
Technology Breakthrough: Fixed Wing
Leading Edge Airbus
Welded structure
Low weight and low
cost monolithic design
23 © Ticona PPS-014R1 5/12 US EN
Fortron® PPS
Success in the Aviation Industry
Safe, efficient,
environmentally friendly
Modern design
Licensed for aircraft
construction
New applications from
Fortron® PPS
24 © Ticona PPS-014R1 5/12 US EN
Reduced Process Energy Example
for TP vs TS Composites
Thermosets Thermoplastics
Assemble part in tool Assemble part in tool
Match Mold Process Cycle Stamp /Thermoform Cycle
(1+ hours) (minutes)
Cool, removal Subsequent part can be
stamped immediately
Energy Required Per Part can be less than a factor of 10
for TP vs TS with Match Metal Molding of Simple Parts
Additional Savings:
No Need for Prepreg Freezers
Reduced Facility HVAC Costs
25 © Ticona PPS-014R1 5/12 US EN
Reduced VOC’s and Toxic Products
Thermosets Thermoplastics
Prepregs usually Contain Prepregs Do Not Contain
Solvents (VOC’s) for Solvents
Tackiness No Cure By-Products
Cure By-Products can be No Halogenation
Complex Organic Necessary for Most High
Compounds Performance
Halogenated Additives Are Thermoplastics
Typically Used to Reduce – Excellent FST
Flammability Performance
– But Toxicity is
Increased
26 © Ticona PPS-014R1 5/12 US EN
T300 3K Carbon Fabric/Fortron® PPS
Composite Property Data*
160
140
-55°C
23°C
120
80°C
100
80
60
40
20
0
Tensile Compressive Flexural In Plane Shear Open Hole Open Hole Compression
Strength Strength Strength Tensile Compressive After Impact
Values are in ksi
Warp direction data
Average values - Tested per Mil-R-17
Steady and Stable Across Use Temperature
* TenCate CETEX Data
27 © Ticona PPS-014R1 5/12 US EN
T300 3K Carbon Fabric/
Fortron® PPS Composite Property Data*
10
9 -55°C
8 23°C
7 80°C
6
5
4
3
2
1
0
Tensile Modulus, Compressive Flexural Modulus, In Plane Shear
msi Modulus, msi msi Modulus, msi
Values are in msi
Warp direction data
Average values - Tested per Mil-R-17
Steady and Stable Across Use Temperature
* TenCate CETEX Data
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Working Together
in the Aviation Industry
29 © Ticona PPS-014R1 5/12 US EN
Technology Validation – Carbon/PPS:
Fokker 50 Undercarriage Door
Final step in a dedicated 10-year program
Press-formed ribs and spars
Welded assembly
Qualified carbon / PPS material
Certified by the
Airworthiness Authorities
Flown on a KLM aircraft for
3.5 years
30 © Ticona PPS-014R1 5/12 US EN
Technology Breakthrough: Fixed Wing
Leading Edge Airbus A340-500/600
Welded structure
Low weight and low
cost monolithic design
Strong partnering with
Airbus UK and TenCate
Technology is now
state of the art
– current application Airbus A380
31
Metal Substitution with
Linear PPS Composite Resulted
in 20–50% Lighter Components
KB WP: 18m, 2.5 tons Main Ribs (L&R)
Multi-technology concept
Keel Beam Application – Panels and spars
Thermoset Prepreg lay-up
– TP ribs and angles
– Aluminum and titanium brackets
32 © Ticona PPS-014R1 5/12 US EN
A330/340 Family: Common Aileron
A318
A319
A320
A321
A330-200
A330-300
A340-300
A340-500 240 Parts per Airframe
A340-600
A380-800
33 © Ticona PPS-014R1 5/12 US EN
Airbus A340 500/600 Aileron
Thermoplastic Composite Parts
Edge Ribs
Main Ribs
Edge Rib
Leading Edge
Ribs, Angles & Panels
34 © Ticona PPS-014R1 5/12 US EN
Airbus A340 500/600
Thermoplastic Composite Components
Part Description: Panel of the Pylon Forward
Second Structure – 22 per
Aircraft
Dimensions: L = 700 – 1400 mm
W = 200 – 400 mm
Thickness 2.8 mm
Double-Curvature Shape
Material: PPS / Carbon Fiber
Bronze Mesh Top-layer for
EMI Shielding
35 © Ticona PPS-014R1 5/12 US EN
Leading Edge Airbus A380
8 assemblies / wing
Wing length: 26 meters
16 segments, 52-meter length
400 kg total weight
36 © Ticona PPS-014R1 5/12 US EN
Weight Reduction – The Vision
Fortron® PPS in Aircraft Interior
46% Lighter Seat Parts Due to
Metal Substitution
Aluminum 280 g
Fortron 150 g
Product innovations for Composites
37 © Ticona PPS-014R1 5/12 US EN
Weight Reduction – The Vision
Linear PPS for Aircraft Interiors
Fortron® PPS is the prime
candidate for several aircraft
interior efforts
Applications include seat frames,
brackets, beams, ducts
Lower cost vs. PEI and PEKK
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240 CETEX® Parts in Ailerons
Common Aileron for
A330-340 Family
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Summary
Fortron® PPS is a demonstrated, producible, low-cost,
high-performance thermoplastic for composite
applications
– Aircraft interior and exterior applications
– Down hole applications
– Corrosion resistant environments
– High-temperature usage
– The low-cost, green alternative
Industrial thermoplastics composites manufacturing is a
demonstrated production process
– Proven success in aerospace
Ticona technical personnel will work with you to meet
your composites needs
40 © Ticona PPS-014R1 5/12 US EN
Fortron PPS ®
for Thermoplastic Composites
Bruno Balico dos Santos
For more information on Ticona Application and Development Engineer
Performance Driven Solutions.™ Office: +55 11 3147 3372
www.ticona.com/composites Mobile: +55 11 98573-0763
Email:
[email protected]41 © Ticona PPS-014R1 5/12 US EN
Information is current as of November 2012 and is subject to change without
notice.
The information contained in this publication should not be construed as a promise
or guarantee of specific properties of our products.
Any determination of the suitability of a particular material and part design for any
use contemplated by the user is the sole responsibility of the user. We strongly
recommend that users seek and adhere to the manufacturer’s current instructions
for handling each material they use.
Any existing intellectual property rights must be observed.
© 2012 Ticona. Except as otherwise noted, trademarks are owned by Ticona or its
affiliates. Fortron is a registered trademark of Fortron Industries LLC.
42 © Ticona PPS-014R1 5/12 US EN
