High Performance Materials Premium Supplier of Engineering …congresosudamericano.com.br/emailmkt/mala_congresso... · 2017-10-23 · 1 Title of presentation Speaker Place, date

1 Title of presentation ▪ Speaker ▪ Place, date … [ OPTIONAL ]

High Performance Materials Premium Supplier of Engineering Plastics Durethan ® high modulus EF and XF grades

Alexandre Keith TamuraIII Congreso Sudamericano de Composites, Poliuretano y Plásticos de Ingeniería, 19th October 2017

2 III Congreso Sudamericano de Composites, Poliuretano y Plásticos de Ingeniería, 19th October 2017

� Lanxess in general

� Introduction to HPM

� HiAnt Engineering Services

� Product Portfolio

� Durethan high modulus EF and XF grades

Agenda


Lanxess in general


LANXESS – a globally operating specialty chemicals c ompany

Specialty chemicals company

� Spin-off from Bayer in 2004

� Specialty chemicals portfolio: plastics, rubber, intermediates and specialty chemicals

Global success story

� 52 sites worldwide

� Approximately 16,200 employees in 29 countries

� Global sales of € 7.9 billion in 2015

Strategy of profitability and resilience

� Enhancing its leading position in mid-sized markets


Global presence

Asia/PacificGermany

Latin America

EMEA(without Germany)

North America

29

1726

11

Sales per region (2015, in %)

Employees per region(2015, in %)

Asia/Pacific Germany

Latin America

EMEA(without Germany)

North America

9

4518

8

20

17

Global production network

*

* Intend to stop production of EPDM rubber in Marl by the end of 2015

Sydney (AU)

Ningbo (CN)

Qingdao (CN)

Toyohashi (JP)

Cabo de Santo Agostinho (BR)

Sarnia (CA)

PortJérôme (FR)

Antwerp (BE)

Zwijndrecht (BE)

Dormagen (DE)

Leverkusen (DE)Hamm-Uentrop (DE)

Krefeld-Uerdingen (DE)

Wuxi (CN)

Nagda (IN)

La Wantzenau(FR)

Bitterfeld (DE)

Filago (IT)

Branston (UK)

Porto Feliz (BR)

Burgettstown (US)

Mannheim (DE)

Zárate (AR)

Greensboro (US)

Chardon (US)

Burzaco (AR)

Changzhou (CN)

Singapore (SG)

Gastonia (US) Lipezk (RU)

Triunfo (BR)

Liyang (CN)

Duque de Caxias (BR)

Bushy Park (US)

Baytown (US)

Geleen (NL) Brunsbuttel (DE)

Marl (DE)

Jhagadia (IN)

Rustenburg (ZA)

Merebank (ZA)Newcastle (ZA)

Nantong (CN)

Little Rock (US)

Merlo (AR)

Pittsburgh(US)

Brilon (DE)

Orange (US)

Epierre (FR)

Vilassar de Mar (ES)


Offering solutions for global megatrend challenges

Mobility Urbanization

Agriculture Water


� Material ProtectionProducts

� Inorganic Pigments

� Rhein Chemie Additives

� Leather

� Liquid Purification

Technologies

� Tire & Specialty Rubbers

� High Performance

Elastomers

� High Performance Materials

� Advanced Industrial Intermediates

� Saltigo

The “new” LANXESS

New segment structure as of Q2 2016

Performance Chemicals ARLANXEO*High Performance MaterialsAdvanced Intermediates

* Fully consolidated in the first three years


Introduction to HPM


� Customers: ~ 600

� Employees: ~ 1500

� Market position: Among global top 5

� Engineering plastics based on Polyamide (PA) and Polybutylene terephthalate (PBT), continuous fiber-reinforced thermoplastic composite sheets

� High-end development service package

Applications

Products & Brands

Facts

High Performance Materials (HPM) -Leading supplier of engineering plastics


� HPM offers a wide range of high-tech plastics to core industries (e.g. automotive, electronics, construction etc.)

� Global network guarantees market and customer proximity

� Global quality guaranteed by uniform production standards worldwide

� Security of supply by backwards integration into strategic raw materials

� Drive innovation to provide tailored activities and services

A reliable partner - worldwideHPM global compounding network Site for upstream integration

São Paulo, BR

Krefeld-Uerdingen, DE

Gastonia, US

Hamm-Uentrop, DEAntwerp, BE

Pittsburgh, US

Porto Feliz, BR Mumbai, IN

Jhagadia, IN

Hong Kong, CN

Wuxi, CNBrilon, DE

Product and application development center

Strong setup to serve markets worldwide

Dormagen, DE


Photo Porto Feliz site

IPG

RCH

HPM


Porto Feliz plant – Production Capability

� State of the art compounding plant

� Capacity : 20 kt

� Product range :

� Compounds of Polyamide 6, Polyamide 66 and Polybutyleneterephthalate

� Glass reinforced, un-reinforced, flame retardant and color grades

� Fully automated production facility state of the art laboratory equipment

� Warehouse with 1.000 storage positions

� Shift system 24 / 5


HPM Compounding Plant, Porto Feliz

� Plant overview � Warehouse

� Bagging machine � Waste water treatment


Process Description of the Core Process

Classifier+cooler

pelletizer

waterbath

Polymeradditives

Glass fiber / minerals

Gravimetric feeding

Trockner

Puffer

Interm.silos

FPsilos

Polyamid / PBT – Compounds (finished ptoduct)

Base resin + glass fiber +additives

box Finished productsilo


Our customers benefit from an efficient value chain combined with high-end engineering

* Caprolactam is the starting material for the polymerization of polyamide 6

Excellent product andapplication development

Top quality and high security of supply combined wi th technical expertise

Engineering know-howRaw materials

� Cyclohexane� Sulfur� Ammonia

� Glass fibers

� Caprolactam*� Polyamide� Polybutylene

terephthalate

HPM intermediates Engineering plastics/Advanced composites

Polyamide (PA)-basedengineering plastics

Polybutylene terephthalate(PBT)-based engineering plastics

Continuous fiber-reinforced thermoplastic composites

Engineering know-how for all stages of advanced component development – integral to added value compounds business


� Technology upgrade (performance)

� Fuel and CO2 reduction (“green”)

� Design freedom

� Increasing safety

� Cost savings (integration of elements)

� Reducing time to market

HPM solutions as enablerAutomotive industry focus

� Lightweight / ultra lightweight structures

� Under-the-hood and powertrain components

� New applications to enable e-mobility

Development partner for the automotive industry


� Ecological aspectsHalogen free, recycling, renewable

� MiniaturizationReduce space, higher electronic packaging density

� Safety & reliability E-mobility, new fire standards

HPM solutions as enablerE&E industry trends

� A wide range of FR grades (halogen and non-halogen)

� Extensive technical service, e.g. additional tests for UL Yellow Card, VDE certificate, mechanical values, electrical values and coordination of fire tests

� New concepts for LED lightings

Development partner for the E&E industry


Application DevelopmentProduct Development

� Material and recipe development and management

� OEM approval management

� Product listings and certifications

� Intellectual property management

� Development of new application fields

� Technology scouting, technical marketing

� Project management

� Technical communication

� Proximity to customers

Product and Application Development


Processing LabComputer Aided Engineering (CAE)

� Development and application of advanced CAE tools to predict component performance

� Processing simulation (injection molding process, forming simulation)

� Structural simulation, integrative simulation

� Design optimization, topology optimization

� Development of material/process combinations− Composite technology− Fluid injection technology− Foaming (e.g. MuCell)

� Compounding of development products and sample molding

� Processability screening

Customer Engineering Services


RDTC** WuxiMaterial Testing DOR

Performing tests for CAE *-relevant material data:

� Equipment: 6 special material testing machines (for creep, fatigue and tensile tests)

� Technology driven

Performing tests for standardized material data :

� 3 testing engineers, 18 testing technicians

� Equipment: 1 injection molding machine and 18 standard testing machines

� 380.000 injection molded test specimens per year

� 67.000 mechanical, physical and rheological tests per year

Material Testing

* Computer Aided Engineering

** Research and Development Testing Center


Hong Kong

Dormagen

Part Testing

Serving our customers with specialized tests according to customer needs and for simulation:

� Durability tests, creep and fatigue (pressure variation test (PVT), vibration test, ageing, etc.)

� Static mechanical tests (burst pressure, leakage, tension, compression and torsion test)

� Crash tests (backfire, stone impact and drop test)

� Welding (IR, vibration and ultrasonic)

� Analytical failure analysis

� Part Testing

� Service-hub for EMEA & AMS

� 3 testing technicians

� Service-hub for APAC & INDIA

� 1 testing engineer

� 1 testing technician


Expertise for all stages of advanced component deve lopment

HPM stands for high-end materials and in-depth engi neering know -how at its best

� Material development:Tailored material solutions

� Concept development:Leading in lightweight technology developments

� Computer Aided Engineering:Top-notch simulation methods

� Part testing: State-of-the-art testing facilities

� Processing:Development of material process combinations for new applications


HiAnt ®: Enabling innovative solutions with comprehensive customer support during all development stages

Feasibility study Detaileddevelopment Testing ProductionTooling

Material Development

Concept Development

ProcessingProcessing

Part Testing

Computer Aided Engineering


Expertise in different industries and customer cooperations translate into new applications

Cost and performance optimized solutions ready for series production

Lightweight solutions to enable mobility trends –innovative, flexible, fast

High-performance materials and high-end engineering know-how at its best

Smart solutions for a sustainable future of mobilit y –energized by LANXESS

�

�

�

�


HPM’s hero brand Durethan ® – outstanding features with great potential for innovation

Characteristics

Main brand

Benefits

� Enabling components of particular high technical demands − Withstanding substantial mechanical stresses, yet, excellent

reliability in continuous use� Ideal material for lightweight design

− Reducing the vehicle’s weight and fuel consumption

� Engineering thermoplastic polymers based on polyamide 6 and 66

� Excellent mechanical strength and stiffness with good electrical insulating properties

� Impressive resistance to heat, chemical and abrasion

� Exceptionally easy-flowing polyamide 6 with glass fiber contents up to 60% (Durethan® EasyFlow/XtremeFlow)


High Performance MaterialsDurethan Portfolio – Main Category Groups

� The Durethan portfolio contains:

− Durethan B (PA6, CPA based)

− Durethan A (PA66 based)

� Besides standard products (e.g. Durethan BKV30H2.0), HPM offers a portfolio of advanced and performance products suited to fulfill special customer requirements.

� Additionally, HPM serves customers with products customized for special processing technologies, such as :

− MuCell, e.g. BKV35CXH2.0

− GIT, e.g. AKV30GITH2.0

� For advanced injection moulding processing, HPM offers easy flow (EF) and extreme flow (XF) grades.

Feature Selected Product Example

Blow Molding Durethan BC550Z DUSXBL

Electrical conductivity Durethan BCF30XH2.0

Extreme Crash Performance / Toughness Durethan BKV240H2.0XCP

Extreme Temperature Stability Durethan BKV35XTS1

Extreme Welding performance Durethan BKV30XWPLT

Flame Retardancy Durethan BG30FN05

High Stiffness Durethan BKV60XF

Hydrolysis Resistance Durethan DPAKV50HRH2.0

Improved Light/Weather Resistance Durethan BKV30GW1

Improved Surface Quality Durethan BKV30GH2.0

Thermal conductivity Durethan BTC65H3.0EF


HPM’s hero brand Pocan ® – recognized for its innovative and outstanding features

� Engineering thermoplastic polymers based on polybutylene terephthalate (PBT) and blends

� Excellent resistance to heat and chemicals

� Powerful flame-retardant (FR) modifications

� Outstanding slip properties and high abrasion resistance

� Low susceptibility to stress cracking and low moisture absorption

Characteristics

Main brand

Benefits

� Injection molding grades and extrusion grades� Combination of dimensional stability, mechanical properties and FR-

package delivers optimal performance for E/E applications, certifications and listings at hand

� Functional integration (e.g. clips, fasteners and mounts) facilitates subsequent component installation, cut production costs


High Performance MaterialsPocan Portfolio – Main Category Groups

� The Pocan portfolio contains:

− Pocan (PBT)

− Pocan Blends (PBT+PET, PBT+PC, PBT+ASA…)

� Besides standard products (e.g. Pocan B3235), HPM offers a portfolio of advanced and performance products suited to fulfill special customer requirements.

� HPM offers a state of the art FR-PBT portfolio including halogenfree solutions with excellent UL-listings.

� For advanced injection moulding processing, HPM offers extreme flow (XF) grades.

Feature Selected Product Example

General Purpose FR and Non-FR Pocan BF4232 and B3235

Reduced warpage FR and Non-FR Pocan DPCF2200 and A3131

Higher heat resistant Pocan T7141

Higher toughness FR and Non-FR Pocan B4222Z and TS3221

Thin wall application FR and Non-FR Pocan KU2-7503/1 and B1205XF

Halogen free FR Pocan BFN4231

Improved surface quality Pocan T7391

Improved UV-resistance Pocan T7331POS151

Food contact Pocan B1501

Light reflection Pocan B7375

Laser direct structuring Pocan DPT7140LDS


HPM’s hero brand Tepex ® – continuous fiber reinforced thermoplastic composite sheets

� Tepex® are custom-made plastic composite sheets consisting of continuous-fiber-reinforced compound materials with a thermoplastic polymer matrix

� Excellent mechanic properties due to their reinforcement with glas-, carbon or aramid fibers

� The plastic/plastic hybrid technology combines Tepex® with Durethan® injection molding

Characteristics

Main brand

Benefits

� Suitable for volume production

� Guarantees resource efficient processing

� Easy to recycle

� Great potential for lightweight design

Durethan ® high modulus EF and XF grades


short cycle times

simpler molds / less gates

reduction of material quantity

Durethan ® EF and XF PortfolioAdvantages of EF and XF grades

Processing advantages

Better flowability enables:

� lower processing temperatures

� longer flow path

� reduced wall thickness

� better surface quality

� lower warpage

� injection molding machines with

lower clamp force

� less tool and machine wear

Cost advantages

short cycle times

simpler molds / less gates

reduction of material quantity

smaller machine size or multiple tools

possible with same machine size

less maintenance required




0

50

100

150

200

250

DurethanBKV30

GF30

DurethanBKV30EF

GF30

DurethanBKV30H2.0XF

GF30

DurethanBKV60EFDUS060

GF60

DurethanBKV60XF

GF60

[%]

Flowability(from flow spiral, 8x2 mm²)

Strength Stiffness

Polyamide compounds with increased flowability

� Longer flow path

� Reduced cycle time

� Less energy consumption

� Reduced costs

Highly reinforced polyamide compounds

� Lower viscosity enables higher GF reinforcement

� High stiffness (modulus)

� High strength

Ideal for light weight applications

Durethan ® EF and XF PortfolioAdvantages of EF and XF grades

Increased Flowability High modulus materials + increased flowability (only XF)

Progression of key properties


Durethan ® BKV60XF – Flowability in comparison with BKV60EF and BKV30 – Flow spiral

Flowability under near real-life conditions?

Durethan ®

BKV60EF285 mm

Durethan ®

BKV60XF349 mm

Durethan ®

BKV30H2.0295 mm

Flow spiral: 8 x 2 mm²Melt temperature: 290 °CMoisture content of granules: 0,06 - 0,07%

Melt viscosity at 280 °C

-4% +18%

visc

osity

shear rate

� Durethan® BKV 60 XF exhibits a significant advantage in flowability in flow spiral test.


� Mold cavity: 400 x 250 x 1,5 mm³� Film gate� Equal melt and mold temperature as well as

pressure ratios

Durethan ® BKV 60 XF –Flowability dependent on moisture content

Test setup

224

239,7

250,5

264

283,9281,5

310,5319 322

329,5

342,5

200

220

240

260

280

300

320

340

360

0 0,05 0,1 0,15 0,2F

low

leng

th [m

m]

Moisture content [%]MT: 280°CWT: 80°C

BKV30H2.0(PA6 GF30)

BKV60EF(PA6 GF60)

BKV60XF(PA6 GF60)

~ 3

30 m

m

BKV60EF vs. BKV60XF

BKV60EF

BKV60XF


Tensile test – strain at break f(T)Tensile test – Modulus f(T)

Durethan ® BKV60XF –Temperature dependency of mechanical properties

Temperature [°C]

0

2500

5000

7500

10000

12500

15000

17500

20000

22500

[MP

a]

BKV60 EF

BKV60 XF

Temperature [°C]

0

1

2

3

4

5

6

7

[%]

BKV60 EF

BKV60 XF


Durethan ® BKV60XF –PA6 GF60 with very good surface quality

Injection speed / Surface qualityBKV 30 H2.0(PA6 GF30)

BKV 60 EF(PA6 GF60)

BKV 60 XF(PA6 GF60)

Injection speed

10 mm/s

30 mm/s

50 mm/s

70 mm/s

90 mm/s

� Trend: increased injection speed usually enhances the surface quality

� Achievable surface quality decreases with increasing thermal conductivity / solidification rate

� BKV60XF exhibits very good surface quality due to excellent flowability and delayed crystallization

Influence factors


Durethan ® BKV60XF –Excellent long-term temperature resistance

0

50

100

150

200

250

0 500 1000 1500 2000 2500 3000 3500

Tens

ile s

tres

s at

bre

ak [

MP

a]

Storage duration [h]

Tensile test (DIN EN ISO 527)after heat aging

BKV 60 XF,heat aging at 160 °C

BKV 60 XF,heat aging at 180 °C


Durethan ® BKV60XF –Mold proving full plastic front end

DPBKV60H2.0EF

� High stiffness and strength

� Good flowability

Durethan ® BKV60XF

� Melt temperature 30 °C lower

� Additionally, filling pressure was decreased by 30 %

� Significantly enhanced

surface quality

Standard material Advantages XFPart

Full plastic frontend


The new XF-Generation with e Xtrem good Flowability –Durethan ® BG60XXF

� PA 6 (GF+GB)60

� Excellent flowability (similar to BKV60XF)

� Low warpage, (further) improved surface quality

� Tablet back cover, arm rest, exhaust lamellas

0,25 0,2

0,650,8

0

0,2

0,4

0,6

0,8

1

BG60XXF BKV60XFS

hrin

kage

[%]

Gesamtschwind. längs Gesamtschwind. quer

Plate 150*105*3 mm³, 280/80 °C

0,32

0,21

0,34

0,5

0,37

0,25

0,34

0,54

0

0,2

0,4

0,6

BG60XXF BKV60XF

Shr

inka

ge [

%]

Molding shrinkage parallel Molding shrinkage transverseTotal shrinkage parallel Total shrinkage transverse

Plate 60*60*2 mm³, 280/80 °C

Durethan ® BG60XXF

Total shrinkage parallel Total shrinkage transverse

Durethan ® TP202-035 900116 (new “AKV60XF”) –New PA66 Xtreme Flow high modulus grade

� PA66 GF60

� TP202-035 (“AKV60XF”)

� Xtreme flowing

� High modulus (20 GPa), strength (235 MPa) & HDT

� Permanent use temperature up to 180 °C

� For structural as well as UTH applications material with good mechanical properties as well as good flowability are required

� AKV60XF exhibits similar mechanical properties in static tests as BKV60XF

Product description

� Structural parts

� UTH

Motivation

Flow curve at 290 °C

Possible applications

10

100

1000

10 100 1000 10000visc

osity

[Pas

]

shear rate [1/s]

AKV30H2.0

AKV50H2.0

TP202-035


Comparison of Durethan ® high modulus

EF and XF grades *

* using guide values


Comparision PA66 GF50 and PA6 GF50

AKV50H2.0 (PA66 GF50)

BKV50H2.0(PA6 GF50)

BKV50H2.0EF(PA6 GF50)

Tensile modulus[MPa]

d.a.m. 16100 16300 16200

cond. 10200 9800 9800Tensile stress[MPa]

d.a.m. 230 220 215

cond. 160 140 140Tensile strain[%]

d.a.m. 2,6 3 2,7

cond. 4 5 3,5Izod impact strength[kJ/m²]

d.a.m. 90 90 85

cond. 90 90 80Notched Izod impact strength [kJ/m²]

d.a.m. 15 20 17

cond. 20 25 20

Moisture uptake 23 °C, 50% r.h, [%] 1,4 1,5 1,5

HDT-A (1,80 MPa) [°C] 247 210 210

020406080

100120140

Tensilemodulus,

d.a.m.Tensile

modulus, cond.

Tensile stress,d.a.m.

Tensile stress,cond.

Tensile strain,d.a.m.

Tensile strain,cond.

Izod impactstrength, d.a.m.


Notched Izodimpact

strength, d.a.m.

Notched Izodimpact

strength, d.a.m.

Moistureuptake

HDT-A

AKV50H2.0(PA66 GF50)

BKV50H2.0(PA6 GF50)


[%]


Comparision PA66 GF60 and PA6 GF60

AKV60XF(PA66 GF60)

BKV60XF (PA6 GF60)


Tensile modulus[MPa]

d.a.m. 20000 20200 20000

cond. 13300 13000 12000Tensile stress[MPa]

d.a.m. 235 215 225

cond. 145 140 145Tensile strain[%]

d.a.m. 1,5 2,3 2,4

cond. 2,7 2,8 3,5Izod impact strength[kJ/m²]

d.a.m. 70 80 80

cond. 60 75 80Notched Izod impact strength [kJ/m²]

d.a.m. 14 15 16

cond. 12 18 20

Moisture uptake 23 °C, 50% r.h, [%] 1,2 1,3 1,3

HDT-A (1,80 MPa) [°C] 250 208 213

020406080

100120140160

Tensilemodulus, d.a.m.

Tensilemodulus, cond.

Tensile stress,d.a.m.

Tensile stress,cond.

Tensile strain,d.a.m.

Tensile strain,cond.



Notched Izodimpact strength,

d.a.m.

Notched Izodimpact strength,

d.a.m.

Moisture uptake

HDT-A

AKV60XF(PA66 GF60)

BKV60XF(PA6 GF60)


[%]



with carbon fiber


Durethan ® BCF30H3.0EF (CF30) vs. DPBKV60H2.0EF (GF60) Comparison of stiffness and strength

[MPa][MPa]

BCF30H3.0EF shows higher stiffness than DPBKV60H2.0EF

BCF30H3.0EF shows slightly lower strength than DPBKV60H2.0EF

20500 20000

2300020500

0

5000

10000

15000

20000

25000

Tensile modulus Flexural modulus

DPBKV60H2.0EF BCF30H3.0EF

230

370

230

350

0

50

100

150

200

250

300

350

400

Stress at break Flexural strength



Durethan ® BCF30H3.0EF (CF30) vs. DPBKV60H2.0EF (GF60) Weight specific stiffness and strength

[MPa*dm 3/kg][MPa*dm 3/kg]

Significantly lower densitiy of BCF30H3.0EF (1,262 vs. 1,7 kg/dm 3) results in better weight specific performance.

12059 11765

18225

16244

0

5000

10000

15000

20000

Tensile modulus Flexural modulus

DPBKV60H2.EF BCF30H3.0EF

135

218

182

277

0

50

100

150

200

250

300

Stress at break Flexural strength


48 Title of presentation ▪ Speaker ▪ Place, date … [ OPTIONAL ]

ALLGEMEINER HINWEIS: Die gezeigten Beispiele können unter Schutzrechte Dritter fallen.

GENERAL REMARK:The shown examples may depend on intellectual properties of third parties.

Documents

High Performance Materials Premium Supplier of Engineering …congresosudamericano.com.br/emailmkt/mala_congresso... · 2017-10-23 · 1 Title of presentation Speaker Place, date