VESTAKEEP PEEK PEEK Polyether Ether Ketone Powders

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1 VESTAKEEP PEEK PEEK Polyether Ether Ketone Powders

2 Evonik, the creative industrial grou from Germany, is one of the world leaders in secialty chemicals. As a technology leader for high-erformance olymers we are secialized in manufacturing customized roducts and systems. Our VESTAKEEP olyether ether ketone owder is art of our high temerature olymers roduct ortfolio.

3 Directory VESTAKEEP : High erformance in owder form Introduction... 6 Manufacture... 6 Alication... 6 Delivery... 6 Proerties Overview of VESTAKEEP owders Processing VESTAKEEP owder alications and correction of defects Toxicological evaluation of VESTAKEEP owders, as well as information on environmental comatibility and safety Contacts... 15

4 VESTAKEEP PEEK: High erformance in owder form Comounds and owders made of VESTAKEEP are esecially suitable for alications subject to extreme mechanical, thermal, and chemical requirements. Evonik markets its VESTAKEEP comounds and owders worldwide. A roven quality management system from develoment, through roduction, all the way to quality assurance ensures the high quality of roducts entering the market. Our system is certified to ISO 9001:2008 and ISO 14001:2009, and is constantly otimized. Over the years, numerous customers have tested this quality system and confirmed its sueriority. For R&D and roduction, we have also launched an environmental management system that is regularly certified to ISO 14001:2009. This brochure rovides an overview of the roerties and alications of VESTAKEEP owders, which are available in various article sizes and viscosities (molecular weights), deending on the rocessing method, as well as rocessing instructions. VESTAKEEP comounds are described in a searate brochure. VESTAKEEP comounds are articularly characterized by the following material roerties:. Very high heat deflection temerature. Low water absortion and therefore high dimensional stability. High hardness. Good strength. Excellent sliding friction behavior. Very minimal abrasion. Good electrical roerties. Excellent chemical resistance. Excellent hydrolytic stability 4

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6 1 Introduction Manufacture VESTAKEEP PEEK is olycondensed from the building blocks hydrochinone and 4,4 -difluorobenzohenone in a multi-stage rocess. Alication VESTAKEEP PEEK owders can be used for a wide range of alications, such as in electrical, electronic, and communications engineering, and in the automotive and food industries. They are also roven suitable for the manufacture of comosites. They can be rocessed with a number of methods, such as comression molding, electrostatic owder sraying, flame sraying, and scattering. They can also be used as a susension in aqueous as well as solvent-based systems. Delivery VESTAKEEP owders are delivered in boxes with moisture-roof PE liners. Powders (P): in 10 kg boxes, 25 boxes with a total weight of 250 kg on one allet. Fine owders (FP) and ultrafine owders (UFP): in 15 kg boxes, 25 boxes with a total weight of 375 kg on one allet. We will also deliver in bulk ackaging uon request. Under normal storage conditions, storage time is ractically unlimited rovided that the ackaging has not been damaged. Avoid storing at temeratures above 45 C. Like other artially crystalline olyaryl ether ketones, unmodified VESTAKEEP aears amber-colored in the melt and grayish in its solid crystalline state (natural colors). VESTAKEEP is translucent in its solid, amorhous state and has a characteristic amber color. 6

7 Overview of the most imortant roerties Proerties* Test method Unit VESTAKEEP owder Physical and thermal roerties and fire behavior Density 23 C ISO 1183 g/cm Melting range DSC, 2nd heating C arox. 340 Volume flow rate (MVR) 380 C/5 kg ISO 1133 cm 3 /10 min 70 Temerature of deflection under load Method A Method B 1.8 MPa 0.45 MPa ISO 75-1/2 C C Linear thermal exansion 23 C 55 C, longitudinal ISO K Oxygen index 3.2 mm ISO 4589 % 38 Flammability acc. UL mm IEC V-0 Glow wire test GWIT 2 mm GWFI 2 mm IEC /13 IEC /13 C C Mold shrinkage in flow direction in transverse direction ISO % % Mechanical roerties Tensile test Stress at yield Strain at yield Strain at break 50 mm/min ISO 527-1/-2 MPa % % Tensile modulus ISO 527-1/-2 MPa 3700 CHARPY imact strength 23 C -30 C ISO 179/1eU ISO 179/1eU kj/m 2 kj/m 2 N N CHARPY notched imact strength 23 C -30 C ISO 179/1eA ISO 179/1eA kj/m 2 kj/m 2 6 C 6 C *measured on a tension bar N = no break C = comlete break incl. hinge break H Chemical resistance Due to its chemical structure VESTAKEEP PEEK features an outstanding chemical resistance. Please direct more detailed inquiries to the indicated contact ersons. 7

8 2 Overview of VESTAKEEP owders VESTAKEEP owder grades VESTAKEEP owder High-viscosity Medium-viscosity Low-viscosity Average article size [µm] Particle distribution [µm] Scattering owder Comression molding; HCM Flame sraying Electrostatic sraying Susension Ultimate 5000 FP ca. 65 ca P 4000 FP ca. 60 ca P 2000 FP ca. 55 ca UFP20 ca UFP10* ca FS 1000 P ca ca * on request M2P/M4P grades are described in our medical brochure Key to roduct descrition P: Powder FP: Fine owder UFP: Ultrafine owder VESTAKEEP 2000 UFP 20 Trade name Viscosity Ultrafine owder Ø Particle size (µm) 8

9 Particle size distribution VESTAKEEP owders are offered in a variety of article size distributions. VESTAKEEP Symatec Helos [%] [µm] VESTAKEEP 4000 FP VESTAKEEP 2000 FP VESTAKEEP 2000 UFP20 VESTAKEEP 2000 UFP10* * on request VESTAKEEP article size distribution [%] [µm] VESTAKEEP 4000 P VESTAKEEP 2000 P 9

10 3 Processing 3.1. Coating rocesses Electrostatic sraying In the EPS (electrostatic owder sraying) rocess, the owder is electrostatically charged by an electrical field of high field strength on the sray nozzle. Deending on the sraying system, this involves either direct charging, which occurs in direct contact with the electrode, or ionization charging, in which the owder articles are charged through accretion of free air ions. In this case, the electrode, as the corona oint, generates the required air ions. The owder articles are transorted along the electrical field lines to the grounded workiece. Before cooling, the arts should be heated in an oven until the coating is evenly melted on them. The degree of crystallinity can be set through the cooling rocess. Water and sudden cooling result in amorhous and therefore transarent coatings. The crystallinity of amorhous layers can be increased by conditioning the coating. This is usually done at 200 C in a circulating air oven. The amount of time required deends on the mass of the coated arts. Concerning comonents with a large thermal mass, slow cooling rates can result in cracks in the coating. In these cases the suitable cooling rates should be determined emirically. Chilling in water can lead to thermal shock and should be avoided. Flame sraying Flame sraying, develoed at the beginning of the last century, is one of many tyes of thermal sraying rocesses. In this rocess, the combustion of a gas/ oxygen mixture generates the thermal energy to melt the owder and warm the surface of the substrate. A carrier gas normally comressed air serves as the medium for transorting the melted articles to the substrate surface. The advantages of this rocess include low investment costs and the otion of coating large arts on site, without an oven. VESTAKEEP 2000 FS is best suited for this alication because it has a sufficiently low melt viscosity. Disersion coating Aqueous disersions based on VESTAKEEP fine owder can be used to coat metal surfaces. These can be rocessed by diing or by sray gun. Disersions are articularly suitable for the manufacture of thin layers and for geometries that cannot be electrostatically coated because of the Faraday cage. No costly equiment is needed. Medium-viscosity VESTAKEEP owder is esecially suitable for disersion coating. Its low melt viscosity generates good flow roerties and roduces smoothflowing layers. On request we rovide detailed technical information about all coating rocesses. 10

11 Fiber comosites To roduce fiber comosites, unidirectional fiber layouts or fabrics made of glass, carbon or aramid fibers are given VESTAKEEP as a matrix. The comosites are coated using owder coating rocesses or disersion coatings, as described above. For the roduction of comosites, we recommend the low-viscosity VESTAKEEP owders of the 1000 and 2000 lines. The article size is geared to rocesses for which FP and UFP owders are referred. Pretreatment No matter the coating rocess: The better the retreatment, the better the adhesion. This is why the arts to be coated must be reared by sandblasting and degreasing in suitable solvents rior to coating. This ste removes imurities and reares the surface of the metal for otimal adhesion. Corundum or marcasite should be used as the blasting agent. Sherical blasting agents like glass earls are not suitable because they do not roughen the surface. Blasted grease- and oil-free metal arts corrode very quickly, and should therefore be rocessed as soon as ossible after blasting. A rimer for imroving adhesion is not required. Zinc and iron hoshatizing should also be avoided. These conversion layers begin to disintegrate above 200 C and generate a searating layer, which imairs adhesion Comression molding Comression molding roduces molded arts by subjecting them to ressure in a mold. The roerties of comressionmolded arts are different from those of injection-molded arts. Normally, ressed arts have a higher level of crystallinity, and are therefore more rigid and solid but also harder and more brittle. The form ress cycle includes. Thickening the olymer in a mold. Heating the system over the melt temerature. A holding hase for further thickening. A cooling hase P and FP owder grades are normally used in comression molding. If granulates were used, the air inclusion would be too large, and with finer owders the molds are difficult to fill. Here, bridging can also cause air ockets, which results in orous comonents. By adding PTFE, grahite, nanoscale titanium oxide or silicon oxide, glass or carbon fibers, for examle, certain roerties such as surface hardness, frictional coefficient and abrasion resistance can be selectively imroved. To revent bubble formation through moisture, the owder should be dried for 3 hours at 150 C or overnight at 120 C, either in the drying cabinet or in the mold rior to rocessing. For easier demolding, small amounts (2 3%) of PTFE can be added to the owder. Before the mold is heated, the owder is thickened to allow air to escae. Processing arameters such as ressure, temerature, holding time, etc. deend on the quantity of owder, the surface area and geometry of the form, and must be determined case by case. To revent stresses in the mold, cooling should be slow and controlled and not exceed 40 K/hour. Beginning at aroximately C, the ressed article can be demolded. More details at 911

12 VESTAKEEP owder alications and correction of defects Process Problem Cause Solution Flame sraying The adhesion failed, even though the surface of the substrate was roughened rior to sandblasting. This is caused by the extreme difference in the coefficient of thermal exansion between the substrate and layer materials. Preheat substrate Cracks form during cooling Recrystallization and thermal shrinking cause extreme tensions in the layers, which then result in crack formation. The longer the lastic is held above the glass transition temerature, the better tensions in the lastic are dissiated and the greater the degree of crystallization. Preheat substrate Temer Pores Air inclusions caused by too many layers on to of each other Reduce number of owder layers Comression molding Pores Bubbles in the ressed article Moisture Air inclusions Predry at least for 3 h at 150 C Increase ressure before melting, increase holding time Increase temerature Flashing Ga too large between male and female molds Temerature too high Pressure too high Ga should be < 0.15 mm Lower temerature Lower ressure Demolding difficult or imossible Surface of male and female molds too rough No mold-release agent used Wrong mold-release agent used (not heat resistant) Electroolishing Use mold-release agent (heat-resistance > 400 C) Add 2 3 % PTFE to the owder Crack formation Tensions caused by shrinkage and recrystallization Temer Reduce cooling rate Demold below 150 C Mold incomletely filled Melt viscosity too high Pressure too low Increase temerature Increase ressure ES coating Chiing Foundation unclean (not degreased and/ or not sandblasted) 1. Degrease AND 2. Sandblast Agglomeration Moisture in owder due to imroer storage Powder must be stored dry and at room temerature Sintering on deflector cone and nozzles because ressure of feed air too high Reduce conveying air Low owder deosition Workieces insufficiently grounded Clean or relace suort Field intensity too low Change tension and interval Poor fluidization Humid comressed air or clogged fluid late, fluid ies Test comressed air for imurities, relace fluid late or fluid ies Vibrating the owder container is recommended for difficult owders, equiment can be easily retrofitted with a vibration table. If clums aear in the fluidized owder, the owder was dam as a result of either storage or humid comressed air. Use new owder and check the storage conditions of the owder Fluid air ressure set too low Too much fluidizing can also significantly reduce owder outut Check the ressure setting of the fluidizing air 12

13 Process Problem Cause Solution ES coating Powder adhesion If the air ressure is too high, it will blow the owder out of the corners and cavities. Reduce air ressure Too little enetration into the corners and recesses because tension is too high or the wrong nozzle is used Reduce tension and use suitable nozzles Foundation unclean, oils, etc. Suervise retreatment Powder cloud too big, distance between gun and workiece too great Minimize interval, use the correct nozzle, work with more dosage air Cratering Craters aear when gas escaes from the workiece, the owder is contaminated, or imurities are not comletely removed e.g. oil in comressed air, silicon sray Use new owder, clean sray guns and lines, degrease and sandblast substrate, install oil searator Pulsation Powder hose is too long Shorten owder hose or increase diameter Powder with oor fluidity Using a owder container with fluidizing air and vibration can be helful. Irregular owder outut Interfaces or radii too small when owder hose is run The radii must be at least mm. Mutual reulsion Mutual reulsion occurs when the owder layer is too thick. Reduce the flow Mutual reulsion is also affected by temerature and atmosheric humidity. Climatization of the coating zone may be required in the case of very difficult owder. Yellowing Temerature for owder baking too high or bake time too long Lower temerature Black sots Contamination Contamination with foreign owder can be revented through careful cleaning of the lant. Also, different owders should not be mixed. Layers too thick or too thin Adjust owder outut. Regular maintenance Blow out guns and check for sintered areas. Check the settings of the owder sray guns. Blow out injectors and hoses. Check grounding control. Check to ensure the comressed air is clean, dry and oil-free. Check owder hoses for sintered areas and marks 13

14 4 Toxicological evaluation of VESTAKEEP owders, as well as information on environmental comatibility and safety VESTAKEEP owders are water-insoluble, solid olymers. Because of their high molecular weight (>30,000 g/mol), they are not absorbed through the skin, or through the resiratory or gastrointestinal tracts. VESTAKEEP owders are, therefore, largely inert hysiologically and do not cause systemic toxicity. As in the case of other inert dusts, exosure to VESTAKEEP dusts could ossibly result in mechanical irritation in the uer resiratory assages and the mucous membranes of the eye. Product dust can remove the skin s natural moisture, and this dryness can cause atchy irritation. Sensitization of the skin is not exected. Stes must always be taken to ensure adequate ventilation and exhaust when rocessing thermolastics. Based on our best current understanding, VESTAKEEP owders do not have any adverse effects on man, animals, lants, or microorganisms. For labeling in accordance with alicable legislation, as well as the water hazard classification, lease consult the most recent safety data sheet. VESTAKEEP owders can be disosed of in accordance with local regulations. The EU safety data sheet for VESTAKEEP contains more information. For environmental and economic reasons, recycling of the roduct is referred. Please direct more detailed inquiries on roduct safety to the indicated contact ersons. 14

15 Contacts Americas Peter Colburn hone mobile Asia Ricardo Willemann hone mobile Euroe Frank Lindner hone mobile Technical coordination Uwe Kannengießer hone mobile direct contacts further contacts

16 This information and all technical and other advice are based on Evonik s resent knowledge and exerience. However, Evonik assumes no liability for such information or advice, including the extent to which such information or advice may relate to third arty intellectual roerty rights. Evonik reserves the right to make any changes to information or advice at any time, without rior or subsequent notice. EVONIK DISCLAIMS ALL REPRESENTATIONS AND WARRANTIES, WHETHER EXPRESS OR IMPLIED, AND SHALL HAVE NO LIABILITY FOR, MERCHANTABILITY OF THE PRODUCT OR ITS FITNESS FOR A PARTICULAR PURPOSE (EVEN IF EVONIK IS AWARE OF SUCH PURPOSE), OR OTHERWISE. EVONIK SHALL NOT BE RESPON- SIBLE FOR CONSEQUENTIAL, INDIRECT OR INCIDENTAL DAMAGES (INCLUDING LOSS OF PROFITS) OF ANY KIND. It is the customer s sole resonsibility to arrange for insection and testing of all roducts by qualified exerts. Reference to trade names used by other comanies is neither a recommendation nor an endorsement of the corresonding roduct, and does not imly that similar roducts could not be used. = registered trademark Evonik Industries AG High Performance Polymers Marl Germany hone /e