DSM Engineering Plastics

Our mission is to
satisfy customers
with engineering resins
and specialty compounds
supported by leading-edge
technologies and
services resulting in
cost-effective solutions.
Produc tion Sites
Europe
Emmen Netherlands
Polymerization & Compounding
G eleen Netherlands
Polymerization
G enk Belgium
Compounding
Stade G ermany
Polymerization
North Americ a
Evansville I ndiana
Compounding
Augusta G eorgia
Polymerization
Stoney Creek O ntario Canada
Compounding
Asia Pac ific
Jiangsu China
Compounding
Pune I ndia
Compounding
Tokyo Japan
M/S Joint Venture & Toll Compounding
1
Contents
Introduc tion 2
Stanyl

PA46 overview 2
Stanyl

PA46 product scope 3

Automotive Applic ations 4
Engine 5
Transmission 6
Engine-management systems 7
Sensors 7
Alternators, starters and small
electric motors 10
Tubing 10
Charge air cooler end caps 11
Elec tric al and Elec tronic
Applic ations 13
Electrical industry 13
Electronics industry 13
Stanyl

High Flow

14
Challenges for the E/E industries 14
Connectors 15
Wire-wound components 17
Electric motors 18
Gear Wheels, Bearings,
and Bearing Cages 19
G ear wheels 19
Bearings and bearing cages 20
Charac teristic Properties
of Stanyl

PA46 21
G eneral 21
Crystallinity 22
Temperature performance 22
M echanical properties 24
Electrical properties, flammability,
and UL classifications 27
Chemical resistance 28
Designing with Nylons 29
Product design 29
Tooling design 30
Proc essing Nylon 32
M achinery 32
M aterial handling 33
Processing conditions 34
Secondary-treatment 36
DSM Produc t Portfolio 37
Contac t Information back cover
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DSM Engineering Plastic s is a
Business G roup in the performance
materials cluster of DSM , with sales in
2001 of $558 million ( Euro 603 million)
and approximately 1, 350 employees
worldwide. I t is one of the worlds lead-
ing players in the field of engineering
thermoplastics offering a broad portfolio
of high performing products.
DSM Engineering Plastics operates in all
major markets of the world including the
Americas, Asia, and Europe. Within
each region customers can count on our
innovative research, development, and
support facilities. O ur in-house
resources are backed by a corporate
research and development center that is
utilized in creating new solutions for
customer needs. The advanced level of
account management, in combination
with our effective global communication
network, secures the support customers
need wherever it is required.
With polymerization and compounding
facilities for a range of polyamides, poly-
esters, polycarbonates, and Ultra High
M olecular Weight PE and extrudable
adhesive resins, we serve our global
customer base and assure a constant,
reliable supply of products.
All our compounding facilities in the
world ( in the Netherlands, Belgium,
USA, Canada, China, and I ndia) are
being expanded continuously to keep
up with the growing demand.
As a result of a constant product innova-
tion and creation process, DSM
Engineering Plastics can offer a cohesive
portfolio of high performing engineering
plastics. Established trade names are:
Akulon

( nylons)
Akulon

Ultraflow

( a high flow nylon 6)

Arnite

( thermoplastic polyester)
Arnitel

( copolyester elastomers)
Stamylan

UH ( UHM WPE)
Stanyl

PA46 ( PA46)
Stanyl

PA46 High Flow

( high flow PA46)

Stapron

( PC-blends)
Xantar

( polycarbonate)
Xantar

C ( PC/ABS-blends)
Yparex

( extrudable adhesive resins)

Complemented in some regions by
products such as:
Electrafil

( conductive thermoplastics)
Fiberfil

( reinforced & filled thermoplastics)

Nylatron

( lubricated thermoplastics)
Plaslube

( lubricated thermoplastics)
These materials all have their specific
properties, yet they share the same high
quality thanks to state-of-the-art produc-
tion processes and quality systems like
Total Q uality M anagement, I SO 9001,
and Q S 9000.
I ts an approach to quality that can be
found throughout the DSM organization:
- in relations with industry partners,
working closely together in true
cooperation, ready to meet any tech-
nical challenge
- in technical service and after sales,
providing support to help customers
optimize their processes
- in logistics and delivery, shipping
products anywhere in the world
quickly and reliably.
From product concept, through pro-
cessing, to final application, DSM
Engineering Plastics brings the portfolio,
skills, and global presence to help its
industrial partners create world-class
products and solutions.
DSMis active worldwide in life science
products, performance materials, and
industrial chemicals. The group has annu-
al sales of close to $5.5 billion ( Euro 6
billion) and employs about 20, 000 people
at more than 200 sites worldwide. DSM
ranks among the global leaders in many
of its fields. The companys strategic aim
is to grow its sales ( partly through acqui-
sitions) to a level of approximately $9.2
billion ( EUR 10 billion) in 2005. By that
time at least 80% of sales should be gen-
erated by specialties, i.e. advanced
chemical and biotechnological products
for the life science industry and perfor-
mance materials.
2
Stanyl

PA46 overview
Stanyl

( polyamide 46) is the heat-

resistant nylon of DSM . Stanyl

is used
in demanding applications in the auto-
motive and electrical/electronics
industries, but it also meets many
other application requirements. I t is an
aliphatic polyamide formed by the
polycondensation of 1, 4-diaminobu-
tane and adipic acid ( see Figure 1) .
Although there are similarities
between the molecular structure of
Stanyl

and that of PA66, the higher

number of amide groups per given
length of chain and the more symmet-
rical chain structure of Stanyl

result in
a higher melting temperature 295C
( 560F) , a higher crystallinity, and
faster crystallization ( see Table 1) .
The crystallinity of Stanyl

is approxi-
mately 70% , compared with 50% for
PA66. This results in a high heat distor-
tion temperature of 170C ( 340F) for
unreinforced Stanyl

and 290C ( 555F)

for glass fiber reinforced Stanyl

. These
features give Stanyl

a technical edge
over other engineering plastics like
polyamide 6 and 66, polyesters, and
PPA's with regard to heat resistance,
mechanical properties at elevated tem-
peratures, wear and friction behavior
and, due to an advantage in cycle-
time, economical processing.
Stanyl

is produced and marketed

exclusively by DSM and is available
worldwide. Compounding is carried out
in the USA, Europe, Asia, and Japan.
The Stanyl

business has been I SO

9001 certified since 1991. Technical
support in design, molding, and materi-
al selection is provided by a dedicated
staff of specialists. This support is pro-
vided locally and on a global basis.
The excellent properties of Stanyl

lead to important advantages for the

customer such as cost reduction,
longer lifetime, and high reliability ( see
Figure 2) . Stanyl

bridges the gap

between conventional engineering
plastics such as PA6, PA66, and poly-
esters, and exotic materials such as
LCP, polysulphones, and PEEK .
Benefits for both molders and end
users include:
- resistance to high temperatures
- lower material costs due to excel-
lent mechanical properties allowing
thinner walls which lead to weight
reduction and lower part prices
- 30% productivity increase of
molding equipment
- greater design freedom due to
excellent mechanical properties
and good mold-flow behavior
- economical, safe, and convenient
processing due to the use of
80C ( 175F) water-heated molds
- no post-treatment due to
absence of flash
- no retooling necessary when
switching from PA6, PA66,
or polyesters.
Introduc tion
Figure 1 Differenc es in the struc tures of polyamides.
Table 1 Typic al properties based on struc ture.
M elting point C ( F) 225 ( 435) 265 ( 510) 295 ( 560)
Density kg/m
3
( lb/ft
3
) 1140 ( 71) 1140 ( 71) 1180 ( 74)
Crystallization rate:
- at 200C ( 390F) 0.2 6 >15
- at 230C ( 445F) 0 0.7 10
Properties PA 6 PA 66 Stanyl

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3
Stanyl

PA46 produc t sc ope

Stanyl

is offered in a wide variety of

grades including unfilled ( non-rein-
forced) , as well as grades containing
glass fiber, mineral, lubricants, and/or
flame retardants. A complete list can
be found in Table 2.
Produc t c os t analys is . DSM has
developed a computer software tool,
Product C ost Analysis ( PC A) , to cal-
culate the cost price of components,
taking into consideration factors
such as raw-material price, material
density, mold cost, and labor and
machine costs ( both strongly related
to cycle times) .
PCA will also calculate the optimum
number of cavities depending on the
number of parts to be produced. This
analysis, combined with design rec-
ommendations ( e.g. on optimum wall-
thickness, ribbing and gating) from
DSM 's technical and design services
department, has in many cases led to
a cost saving solution or an improved
price/performance ratio with Stanyl

.
Non-flame-retardant TW341 TW200F6 30
( HB or V-2) TW441 TW200F8 40
TW363 TW241F10 50
TW241F12 60
Flame retardant ( V-0) TE351 TE250F6 30
TE250F8 40
TE250F9 45
46HF5040 40
Wear & Friction TE373 TW271F6 30
TW275F6 30
Grades Non-reinforc ed GF-reinforc ed (%)
Table 2 The Stanyl

produc t portfolio.
Figure 2 Stanyl

's exc ellent properties at elevated temperatures 160C (F) lead to

important advantages for the c ustomer.
4
Heat-resistant plastics are increasingly
replacing traditional engineering plas-
tics in automotive applications. The
driving force behind this development
is the need to respond to three major
industry trends:
the growing use of new electronic
systems for improved safety,
comfort, and motor management
the demand for longer warranty
periods and operating lifetime
the increase in under-the-hood
temperatures caused by:
- lower coefficients of drag,
which result in less air flow
under-the-hood
- encapsulation of the engine
for acoustic-insulation and/or
aesthetic reasons
- introduction of turbo chargers
and catalytic converter systems,
which radiate considerable
amounts of heat
- size reduction of the engine
compartment due to more
compact design.
Stanyl

has proven to be an ideal

replacement for metal for economic
reasons. I t offers excellent creep
resistance, strength, stiffness ( see
Figure 3) , and fatigue resistance at
high temperatures, while at the same
time providing the well-known advan-
tages of plastics. These are easier
processing and limited finishing
requirements, freedom to develop
complicated designs and integrated
functions, weight and noise reduc-
tion, and corrosion resistance.
Stanyl

has been approved by all

major automotive manufacturers. I t
with-stands high loads and stresses,
high temperatures and exposure to
aggressive environments, and is there-
fore suited for under-the-hood applica-
tions. Stanyl

can be found in the fol-

lowing applications:
- engine ( chain tensioners, oil-filter
parts, engine covers)
- transmissions ( clutch rings,
shift forks, thrust washers,
bearing cages)
- motor-management
- air-system intercooler ( emmision
control systems, end caps,
turbo-charger parts)
- brake and electronic systems
( alternator parts, sensors and
switches, connectors)
- tubing
- sensors and connectors for
under-the-hood
- air-intake devices
- cable fasteners
- alternators and starter-motor parts
- valves and pump housings for
exhaust-gas control and sec-
ondary air-supply systems.
Automotive Applic ations
Figure 3 Stanyl

retains its stiffness at elevated temperatures.

Wheel Nuts
Plastic wheel nuts are exposed to harsh environments and potential
abuse. The outstanding toughness Stanyl

exhibits extends the life of
the wheel nuts and provides improved performance.
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5
Engine applications are generally
used in very demanding environments
where Stanyl

s high melting point,

toughness, and excellent wear prop-
erties provide outstanding perfor-
mance regardless of engine size or
configuration. With trends in weight,
cost, and noise reduction Stanyl

offers opportunities in O verhead Valve

( O HV) , O verhead Cam ( O HC) , and
hybrid engines for both metal replace-
ments and clean sheet thermoplastic
designs. M etal replacement with
Stanyl

has been especially success-

ful in part consolidation, NVH and
component wear, and durability
improvement. Successful and poten-
tial high performance engine applica-
tions include:
- valve lifter guides
- rocker arm fulcrums
- chain tensioners and guides
- threaded oil filter housings
- sensors
- timing and starter gears
- cam gears and sprockets
- gasket carriers.
With guarantees exceeding 100, 000
miles for engines between tune-ups
and roadside service at the car com-
panies expense, engine and power
train components must be lasting and
durable. Stanyl

s proven success
makes it an ideal candidate for engine
component improvement.
Engine
Stanyl

is highly suitable for applica-

tions that involve contact with hot
motor oil or transmission oil. Extensive
testing has shown that Stanyl

retains
a high degree of stiffness, good
impact resistance, excellent stability
and wear properties in such environ-
ments. Even in the more aggressive
environment of automatic transmission
oils the decrease in properties over
time is remarkably low.
Stanyl

displays a clear advantage
over PA66 with its superior mechanical
performance before and after aging at
150C ( 300F) for 1, 000 hours.
Under normal running conditions, the
temperature of motor oil varies
between 130C ( 265F) and 150C
( 300F) , while peak temperatures of
165C ( 330F) can occur. At these
temperatures the retention of proper-
ties of the plastics used is crucial.
A successful application of Stanyl

in
these conditions is the chain tension-
er. Chain tensioners from Stanyl

are
commercially used by various auto-
motive manufacturers all over the
world. The requirements for
materials used in chain ten-
sioners are high stiffness at
elevated temperatures,
excellent resistance to wear, and
good resistance to oils. Chain tension-
ers made of Stanyl

wear consider-
ably slower than those made of PA66.
M oreover, the high stiffness at elevat-
ed temperatures enables the replace-
ment of the frequently used system ( a
metal frame with a PA66 top layer) by
a full-plastic Stanyl

solution.
This results in a very cost-effective
system. I ts operating life is three to
seven times longer than that of a
PA66 system.
For high temperature automotive under-
the-hood c omponents like valve lifter
guides, Stanyl

is the material solution.

Chain Tensioners
Stanyl

is used in automotive platforms around the globe

by major chain drive manufacturers to replace multi-component
metal arms in chain tensioning systems for high performance
engine applications.
6
Transmission
Stanyl

's properties remain at an

acceptable level in applications where
aggressive oils and high temperatures
limit the use of conventional poly-
amides. Stanyl

can therefore replace

exotic material such as PEEK .
An example is the use of Stanyl

in
the self-adjusting clutch ring. The
self-adjusting clutch allows pedal
efforts to remain constant as the
clutch disk wears. I ts spring-loaded
thermoplastic ring features serrations
which are wedged forward to main-
tain the proper gap between the
pressure plate and cover fulcrums.
This results in a consistent feel for
the driver throughout the vehicles
life. The self-adjusting feature fully
eliminates traditional threaded cable
mechanisms for manual clutches,
thus reducing maintenance and
associated costs. Dimensional toler-
ances for the serrations are extreme-
ly narrow, and Stanyl

s low post-
mold shrinkage makes it the ideal
material for a clutch ring.
Stanyl

can be used in other transmis-

sion components such as thrust wash-
ers, gear-shift forks, housings and
speedometer gear wheels. Fatigue,
limiting PV, wear and torque resis-
tance are critical in these applica-
tions. The thrust washer, for example,
has to absorb the high compression
loads that arise in the differential dur-
ing acceleration.
Stanyl

and PA66 were tested for

speedometer gear wheels under
severe conditions as described
above. O nly Stanyl

was able to offer
the desired performance, due to its
superior mechanical properties com-
pared with PA66 and PPA.
Stanyl

is also used in a two-mass fly-

wheel containing flexible elements
consisting of springs mounted
between two plastic seats. This fly-
wheel is used in luxury cars to damp-
en vibrations and thereby enhance
comfort. Neither PPS ( with 40% glass
fiber) nor PA66 meets the require-
ments specified for the flywheel
regarding creep resistance.
The temperature at the friction surface
can rise to 290C ( 555F) . Stanyl

has
clearly demonstrated its suitability for
this demanding application.
Figure 4 Stanyl

offers the highest stiffness at elevated temperatures.

Balanc e Shaft Cover and Chain Guide
This injection-molded single piece combined two components in an
effort to consolidate parts, integrate functions, and reduce part
weight. Stanyl

provided structural integrity for the balance shaft

cover and wear and abrasion resistance for the chain guide. Both
functional areas use temperatures of up to 155C ( 310F) .
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7
Engine-management
systems
The heat-resistance properties of
Stanyl

have led to the commercializa-

tion of a number of devices for emis-
sion-control systems. These include
secondary air supply ( SAS) systems.
Continuous-use temperatures can
reach 160C ( 320F) , while peak tem-
peratures can touch 200C ( 390F) .
I n other automotive management sys-
tems such as ABS, TCS ( traction con-
trol system) , and direct ignition, differ-
ent kinds of housings, sensors, con-
nectors, and switches are applied. For
reasons of creep, fatigue, and vibra-
tion resistance, Stanyl

is often select-
ed in these cases.
PA66 often fails to fulfill the high-tem-
perature requirements, whereas PPS
has insufficient impact resistance and
is more difficult to process.
Stanyl

is also used in recyclable oil

filter housings that must withstand
high temperatures from the engine
and road abuse such as rocks,
bumps, and weather. Stanyl

delivers
this typical under-the-hood environ-
ment performance with heat resis-
tance, toughness, and high impact
properties. Stanyl

s excellent heat
and creep resistance properties help
to maintain torque retention and pre-
vent oil leaks in the housing.
Sensors
Todays vehicles obtain their maxi-
mum performance by using complex
microprocessor technology to perform
thousands of calculations per second
based on input from sensors located
through out the vehicle. To obtain cru-
cial input data sensors are mounted in
some very harsh environments. To
access data in a variety of locations
different mounting techniques are nec-
essary. Techniques include snap in
mounting for less demanding applica-
tions, bolt on sensors for more
demanding applications, and thread-
ed mounted applications for the most
demanding. M any powertrain sensors
are installed by threading them directly
into engine blocks, oil pans, transmis-
sion housings, or intake manifolds.
Installation without breakage.
In the past, the only way to produce a
sensor that could thread into a power-
train housing was to make it from metal.
Thats no longer the case. Demanding
threaded powertrain sensors can now
be made out of engineering thermo-
plastics, specifically Stanyl

.
Stanyl

provides toughness for rec yc lable

oil filter housings.
Stanyl

PA46 provides strength at high

temperatures for wheel speed sensors.
Sensors
Stanyl

sensors and connectors, used in areas where high-

temperature resistance is required, replace multi-part,
machined metal components in high performance sensors.
8
When you think about threading a plas-
tic sensor application into a metal sub-
strate you might assume that the part
wont be able to meet the tightening
demands in an application such as an
oil pan. Stanyl

s balanced combina-
tion of high tensile strength, high shear
modulus and toughness allow it to
meet the torque requirements during
installation. I nherent to thread design in
any material is the production of stress
concentration at the root of the thread.
When tightening a threaded part in
place this area is where cracking and
failure usually occur. Stanyl

s combi-
nation of properties lend the necessary
strength qualities to the part to resist
cracking and allow threaded sensors to
be installed without breaking.
Ensuring mounting integrity.
O nce the part is installed it must be
able to perform, and continue to per-
form, over the life of the vehicle. A
threaded sensor must stay tight to
prevent leakage and ensure correct
sensor position. M aintaining sufficient
clamping force is what keeps a
threaded part tight. When threading
a part into a substrate there is very
little torque produced because the
only resistance to the rotation of the
part is the friction between the
threads. The part has no stress or
strain in it. As the flange makes con-
tact with the substrate the rotation of
the part continues to draw the part
down while the flange resists being
pulled down. Strain and induced
stress start to occur at the smallest
cross-sectional area of the part and
increases with every degree of rota-
tion. The stress and retention of that
stress force is what retains the
clamping force.
Stress relaxation, which takes place in
all materials, is accelerated by heat.
Resistance to this, especially at high
temperature, is what permits threaded
sensors to be made with Stanyl

. The
consistency at which the material per-
forms over elevating temperatures and
time is key to Stanyl

s performance.
Stanyl

maintains consistency from

80C ( 176F) and conditioned through
140C ( 284F) . Engineers designing
with Stanyl

will appreciate the unifor-
mity of this material property and can
be assured that the clamping force will
be maintained through the varying
environmental conditions of a power-
train component. This means that once
it is installed the sensor will stay tight
to prevent leakage and ensure sensor
performance over the life of the part.
Sta n nyl

PA46 performs even in

harsh automotive fluids. Stanyl

products are well known for their

resistance to a wide range of chemi-
cals. Sensors are continually placed
in harsh automotive environments and
are only exposed to automotive fluids,
but many times they are immersed in
these fluids at elevated temperatures
of 160C ( 320F) .
Stanyl

retains its properties after heat

aging even while immersed in fluids
such as ATF, engine oil, and fuel.
Chemical resistance is key for materi-
als used in the engine and powertrain.
Even after 1000 hours at 160C Stanyl

retains about 60% of its flexural modu-

lus. After 1000 hours at 150C ( 302F)
in ATF, another harsh chemical envi-
ronment, Stanyl

retains more than
60% of its stiffness properties and
almost 100% of its toughness.
Threaded Sensor
Stanyl

was chosen for this innovative sensor that threads into the oil pan
and measures inputs such as oil level and temperature. A 50% glass
fiber reinforced grade of Stanyl

( TW241F10) was selected for its high
stiffness and resistance to stress relaxation and creep at both room tem-
perature and elevated service temperatures. Parts must withstand con-
stant oil exposure and must maintain dimensional stability to avoid leak-
age around the threads.
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9
Today Stanyl

is being used in thread-
ed sensor applications in engine oil
and transmission fluid with years of
proven performance without failure.
Easy and c ost effec tive. Working
with Stanyl

is easy, cost effective,
and reduces sensor costs. Stanyl

allows greater design freedom and

part integration opportunities due to
its mechanical and good mold flow
properties. Stanyl

s excellent flow
characteristics minimize damage to
internal sensor elements and parts
and it minimizes movement of the
encapsulated items during molding.
When you use Stanyl

to design metal
replacements for sensors you are pre-
sented with opportunities to integrate
parts. For example, you can combine
the connector, the body and the
machined threaded part all out of one
material. This can elimimate pur-
chased parts, provide greater internal
control of the process and parts, and
insure the quality of the final product.
I t can reduce the assembly process of
the sensor and produce a cost sav-
ings. Replacing metal parts and
designing the sensor in Stanyl

can
yield cost savings up to 30% over
conventional sensor design for your
overall sensor costs.
Bac ked by 100 years of materi-
als experienc e and engineering
support. DSM Engineering Plastics
automotive technical support team is
available to help you realize your
design objectives. O ur knowledge-
able and experienced applications
engineers expand the boundaries
where versatile materials like Stanyl

can be utilized. With 100 years in the

materials business, DSM has the
research and application experience to
help you realize the value from your
product ideas.
Unmatc hed material perfor-
manc e for threaded sensor
pac kaging. A proven performer in
threaded sensors, Stanyl

combines
high strength and toughness to guar-
antee installation without breakage. I ts
high temperature resistance to stress
relaxation ensures mounting integrity
while its excellent chemical resistance
provides protection from harsh auto-
motive fluids. No other engineering
plastic offers this combination of
material performance. Together with
the experience of our design and
engineering team there are no limits to
the value captured by converting from
metal to Stanyl

.
Transmission Speed Sensor
The transmission speed sensor inputs data to the ECM which determines
optimum RPM shift levels and enables maximum engine efficiency. Stanyl

provides resistance to stress relaxation and creep to prevent loosening of

the threads and chemical resistance to aggressive fluids at elevated tem-
peratures. I n addition, it offers good toughness over a wide temperature
range, retains stiffness at peak temperature, and maintains excellent fatigue
resistance for durability. Utilizing Stanyl

in the sensor provided a cost

reduction through injection molding and part consolidation as well as weight
reduction through metal replacement and design flexibility.
10
Alternators, starters and
small elec tric motors
Stanyl

applications are also found in
alternators, starters, and electric
motors. O ne very interesting applica-
tion is the diode carrier in the alterna-
tor. The diode converts the alternat-
ing current generated in the alterna-
tor into a direct current.
Diode carriers typically consist of a
metal plate and polyether sulfone
( PES) inserts, over-molded with PA66.
These PES inserts are necessary
because the local temperature is
200C ( 390F) , at which the creep
resistance of PA66 is insufficient.
Thanks to the use of Stanyl

it is possi-
ble to integrate the PES and PA66
parts into one part. The result is a drop
in the final price of the component.
The use of Stanyl

in starter gears
offers several advantages over the
use of steel such as lower weight and
corrosion resistance. Stanyl

also
lends toughness and superior ther-
mal performance to starter gears.
Temperature requirements have also
led to brush holders being manufac-
tured in Stanyl

instead of PA66.
Tubing
Stanyl

TW363, an impact modified
grade, can be extruded into thin,
automotive vacuum tubing that can
be used for actuation purposes
under the hood. Such tubing made
from Stanyl

has been extensively
tested by automotive companies for
4, 500 hours on light trucks and mini-
vans operating in desert climates and
were found to be superior to the tub-
ing previously in use.
Stanyl

is used in under-the-hood
applications because of its excellent
long-term mechanical properties at
high temperatures in aggressive auto-
motive environments. At the same
time Stanyl

offers an economic
advantage due to wall thickness
reduction, longer lifetime expectancy
of the parts, and easy and fast pro-
cessing. Stanyl

also allows increased

design freedom and part integration,
leading to reduced handling costs.
Convoluted Tubing
The switch to Stanyl

PA46 from PA6 for convolut-

ed tubing provides savings to the manufacturer
since Stanyl

extrudes 20-30% faster than PA6.

Stanyl

also provides a high melting point of

295C ( 562F) , retention of properties, abrasion
resistance, and low stiffness.
Stanyl

c an be us e d to ove rmold me tal

and re duc e the numbe r of parts ne e d-
e d for a finis he d c ompone nt like this
alte rnator.
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Charge air c ooler end c aps
The demand for economical high out-
put from small engines has driven the
motor vehicle O EM s to use tur-
bochargers for boosting horsepower.
Added components translate to
added weight which counters other
efforts to increase fuel economy.
Turbocharger and engine cooling sup-
pliers have been challenged to mini-
mize the added weight in these sys-
tems without sacrificing system perfor-
mance. Replacing metal with engi-
neering plastics in system compo-
nents has led to a focus on charge air
coolers as well as air ducts.
Proven success of engineering plas-
tics in radiator end tanks made
charge air cooler end tanks an obvi-
ous area to explore. Unlike radia-
tors, charge air coolers are typically
air-to-air heat exchangers. C harge
air reaches temperatures of 200C
( 392F) so cast aluminum has tradi-
tionally been the metal of choice due
to its high temperature performance,
stiffness and strength and its rela-
tively low weight. Any charge air
cooler end tank made from engineer-
ing plastic would need to have simi-
lar performance, be much lighter
and, offer lower costs. With the
demands of 200C ( 392F) charge air
temperatures, high internal pres-
sures, vibration fatigue and shock, a
true high temperature engineering
plastic was needed.
Stanyl

high performance polyamide is

a proven performer in charge air cool-
er end caps. I nternationally, all the
major charge air-cooling system sup-
pliers use it for their most demanding
charge air cooler end caps. Stanyl

has superior elevated temperature

creep resistance when compared to
other high temperature engineering
plastics. That means sealing integrity
at elevated temperatures is very
robust. I t also has the best stiffness to
weight ratio [ above 120C ( 248F) ] ,
which means you need less material to
make a high performance component.
Stanyl

offers design and manufactur-
ing possibilities that cost more with
other high temperature engineering
plastics both in material, processing,
and weight. I f youre looking to reduce
weight and lower cost by replacing
metal in charge air cooler end caps,
Stanyl

is the best material choice.

Sealing integrity at elevated
temperatures. Stanyl

exhibits
superior elevated temperature stress
relaxation resistance when compared
to other high temperature engineering
plastics. During assembly the crimp-
ing operation of the metal tube header
to the end cap imparts a substantial
stress on the plastic material. Stanyl

offers a significant increase in stress

relaxation resistance over other high
temperature polymers. This resistance
to relaxation is important in order to
maintain an adequate seal load,
ensuring an airtight assembly. Thanks
to its high level of crystallinity, Stanyl

offers the best combination of creep

resistance, stress relaxation resis-
tance, and specific gravity of all the
high temperature polymers, especially
at temperatures above 120C ( 248F) .
Charge Air Cooler End Caps
C harge ai r coolers are used to cool down the turbocharged ai r i n order to
obtai n the maxi mum power out of di esel engi nes. The charge ai r cooler
and the plasti c end caps have to wi thstand temperatures up to 185 C
( 365 F) wi th pressures up to 1. 15 bar. Stanyl

TW200F6, well sui ted for

thi s hi gh demandi ng appli cati on, demonstrates an excellent fati gue resi s-
tance and an E-modulus of 4700 M Pa at 185 C ( 365 F) .
12
Turbo c harging systems
bec ome lighter in weight and
ec onomic ally attrac tive. Stanyl

with 30% glass fiber reinforcement is

8.5 14.5% lighter than PPS with 40%
glass and PPA with 45% glass.
Because of its lower specific gravity, a
Stanyl

end cap is significantly lighter

than either of these other two materi-
als. Stanyl

with 40% glass fiber rein-

forcement is 4 - 67% stiffer at 185C
( 365F) than either of these two other
materials ( its specific gravity is still
lower than either of these) . Due to the
exceptional strength of Stanyl

an end
cap that is thinner ( and lighter) than
end caps made from either of the two
other materials is possible. Yet, stiff-
ness remains unchanged!
Using Stanyl

will allow a designer or

engineer to develop a part that is thin-
ner and lighter than if they were to use
either of the two other materials. I n
addition, due to its rapid rate of crys-
tallization, Stanyl

will cycle up to 20%
faster than the other materials.
Because of that, on an annualized
basis, using Stanyl

can reduce your
per-part molding cost by 20% .
Not only will Stanyl

process faster,
but because of this speed you will
realize significant savings in
machine operating expenses.
Furthermore, using Stanyl

will give
you up to 20% extra capacity with
your existing equipment!
O nly Stanyl

can offer you the combi-
nation of weight and cost savings
along with superior high temperature
performance and faster processing.
Stanyl

allows for the production of
turbocharging systems that are
lighter weight and less expensive!
Stanyl

is the answer for the perfor-
mance and cost challenges posed
when replacing metal in charge air
cooler end caps. Ensuring sealing
integrity with its resistance to stress
relaxation at high temperature is just
the beginning. Couple that with excel-
lent stiffness well above 120C ( 248F)
with a low density and designers can
make a robust, light weight end cap
with less material and lower cost than
with any other high temperature engi-
neering plastic.
Charge Air Cooler End Caps
Stanyl

allows you to make lightweight, cost-effective charge air coolers that

are capable of withstanding high pressures, stresses, and heat loads.
Stanyl

is 10-20% lighte r than othe r

mate rials while maintaining an
e quivale nt s tiffne s s .
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Elec tric al industry
The temperatures encountered at the
inner parts of electrical applications
are sometimes rather high. This is a
result of the trend towards miniatur-
ization or the increase in operating
currents. C onsequently there is an
increasing demand for materials with:
- higher continuous-use
temperatures
- higher stiffness
- less creep at elevated
temperatures.
I n applications like electric-motor parts,
internal parts of circuit breakers, wire-
wound components, and switches,
Stanyl

offers cost-effective solutions

and can easily compete with materials
such as PPS, PEI , PES, PPA, and LCP
in terms of price/performance ratio. As
a result of its outstanding intrinsic prop-
erties Stanyl

has been successfully

applied in the following applications
and end markets:
- connectors
- circuit breakers
- wire-wound components
- SM D components
- switches
- electric-motor parts
- computers and peripherals
- telecommunications
- electrical and domestic
appliances
- consumer electronics.
Elec tronic s industry
The continuing trend towards miniatur-
ization of printed-circuit boards leads
to even smaller surface-mount devices
( SM D) with even smaller wall thick-
nesses. These electronic components
are more susceptible to the high peak
temperatures involved in modern
reflow-soldering techniques.
For these SM D applications materials
with a high heat distortion tempera-
ture must be used. Stanyl

combines
a heat distortion temperature ( HDT)
of 290C ( 555F) with an excellent
toughness and outstanding flow
behavior. Therefore it yields economi-
cal solutions and meets the latest
design requirements for all kinds of
end markets.
Elec tric al and Elec tronic Applic ations
Figure 5 Stanyl

out-performs well-known polymers suc h as LCP and PPS.

Connec tors
Stanyl

is ideally suited for such applications as disc drive connectors.

14
Stanyl

High Flow

Stanyl

High Flow

46HF5040, a rein-
forced, flame retardant PA46, is a
new generation of DSM ' s Stanyl

PA46. Stanyl

High Flow

combines
the high strength and toughness lev-
els of the standard Stanyl

PA46
flame-retardant materials with excel-
lent flow characteristics virtually the
same as Liquid C rystal Polymers
( LC P) , a material often used for
I nformation and C ommunication
Technology ( I C T) equipment ( see
Figure 6) . The Stanyl

High Flow

V-0
grade can replace LC P, resulting in a
cost savings of up to 50% .
Stanyl

High Flow

46HF5040 has an
Underwriters Laboratories ( UL) 94 V-0
rating at 0.8 mm for all colors and a
UL approval for 50-100% regrind use
( UL yellow card file number for Stanyl

4/6 is E119177) . Stanyl

PA46 inher-
ently offers high toughness, even in
dry-as-molded condition. The weld-
line strength of the new grade is three
times higher than that of LCP, enabling
connector manufacturers to post-insert
pins directly after injection molding
without the risk of cracking, thereby
reducing reject level.
Components made of Stanyl

High
Flow

maintain their dimensional

integrity during reflow soldering up to
280C ( 535F) due to the extreme high
stiffness level of the material at these
temperatures. This is especially impor-
tant for the new lead-free soldering
techniques. While LCP is often speci-
fied for such components, the cost of
LCP is significantly higher than that of
Stanyl

. This costly "overdesign" can

now be eliminated because Stanyl

's
new High Flow series, specifically
Stanyl

46HF5040, meets the end
users' performance requirement and
can reduce part costs up to 50% .
Stanyl

can withstand the higher reflow
temperature profiles being driven by
the higher melt temperatures of lead
free solders.
Challenges for the E/E
industries
Stanyl

is ideally suited for various
components in the electrical and elec-
tronics industries. I ts main feature is
its resistance against soldering heat in
items such as surface-mount connec-
tors, switches, and bobbins.
Surfac e-mount tec hnology.
Stanyl

's high heat distortion tempera-

ture of 290C ( 555F) means that com-
ponents maintain their dimensional
integrity during soldering. A clear
example is a surface-mount jack made
of Stanyl

, which will retain its dimen-

sional integrity at a soldering tempera-
ture of 280C ( 535F) , at which other
high-performance plastics deform.
Figure 6 With respec t to strength, Stanyl

High Flow

is best in c lass.
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15
Connec tors
Stanyl

meets the requirements for

various connector designs such as
modular jacks, shrouded headers,
power connectors, fine-pitch connec-
tors, breakaway connectors, sub-
miniature D-connectors, memory-card
connectors, SI M M sockets, edge-card
connectors, ZI F-PG A connectors,
[ DI M M ( SDRAM ) , RDRAM , DDR] , and
telephone-handset connectors. All of
these connectors can be made of
flame-retardant Stanyl

grades.
Connectors used in the automotive
industry are discussed on page 7.
Proc essing. With Stanyl

an overall
cycle-time reduction of up to 30% can
be achieved compared to polyamides
and polyesters, resulting in a clear eco-
nomic advantage. I t has been demon-
strated that the cycle time of an edge-
card connector, originally made from
PPS, can be reduced by 50% , without
any flash being produced and with
dimensional specifications being met.
The shrinkage of Stanyl

is close to that
of commonly used polyesters and
polyamides. Thus existing tools can be
used without any adjustments.
The on-going miniaturization of con-
nectors means that wall sections are
becoming thinner and more complex.
The excellent flow properties of Stanyl

enable sections as small as 0.1 mm

( 0.004 in) to be filled without any prob-
lem ( see Figure 7) .
Stanyl

is specified in surface-mount
fine-pitch connectors with pitches of
0.5 mm ( 0.02 in) . These are used in
products such as printers, video cam-
eras, and lap-top computers.
Even the best-flowing grades of Stanyl

show no flash, in contrast with many

other high flow polymers, such as PPS.
Figure 7 Stanyl

's exc ellent flow properties c ompared with other glass fiber
reinforc ed, flame-retardant materials.
Stanyl

shows no flash, PPS does.

(Identic al memory-c ard c onnec tors
molded with the same tool.)
Stanyl
PPS
16
Post-insertion. Stanyl

exhibits
excellent toughness even in dry-as-
molded condition, enabling connector
manufacturers to post-insert directly
after molding without the risk of
cracking ( see Figure 8) . After condi-
tioning, Stanyl

is superior to other
thermoplastics.
Pin retention. I n Figure 9 the pin
retention of Stanyl

is compared to that
of PPS, before and after soldering.
Stanyl

shows a 50% higher retention

force than PPS after an infrared solder-
ing cycle at 260C ( 500F) .
End-wall break-out strength.
Shrouded headers are versatile head-
ers found in up-market disk drives and
switchboards. As shown in Figure 10,
the end-wall break-out strength of
Stanyl is higher than that of PPS, PBT,
PCT, PPA and PA6T. This enables
designers to reduce the wall thickness
within existing specifications. M ore-
over, the excellent flow characteristics
of Stanyl

enable designers to com-
bine the shrouded header with the
power connector and to integrate
other functions ( all-in-one connectors) .
For notebook computers these combi-
connectors are miniaturized to a 2.0
mm ( 0.08 in) pitch, 50-position
input/output connector.
Snap-fits, latc hes, and pegs.
Stanyl

's toughness allows designers

great freedom in the design of snap-
fits, latches, and pegs. I n the case of
high-current connectors, safe con-
struction is needed to prevent acci-
dental separation of mating connec-
tors. Stanyl

is chosen because it
combines high stiffness with high
toughness, especially in thin sections.
This ensures excellent behavior during
repeated mating cycles.
Figure 9 30% glass fiber reinforc ed, flame-retardant Stanyl

offers a far better pin

retention before and after soldering than 40% glass fiber reinforc ed PPS.
Stanyl

and the miniaturization in the

disk-drive industry.
Figure 8 Positioning of glass fiber reinforc ed, flame-retardant thermoplastic s.
Stanyl

for SIMM soc kets up to 150 mm

(6.0 in) in length.
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17
Moisture absorption. Like all
polyamides, Stanyl

absorbs moisture
from the environment. However,
Stanyl

offers grades with the required

dimensional stability even when sub-
jected to tropical environments. These
grades meet even the stringent speci-
fications required for SI M M sockets up
to an overall length of 150 mm ( 5.9 in) .
See Page 25 for more information on
moisture absorption.
Wire-wound c omponents
M any different wire-wound compo-
nents are used in transformers, filters,
relays and electric motors. They are
either of the standard pin-through-
hole or the surface-mount type.
Stanyl

is chosen for these applica-
tions for various reasons pertaining to
the production process.
Winding. The high stiffness and
high toughness of Stanyl

improve
the quality of the bobbin and dimin-
ish the reject level after winding.
When thermosets or PPS are used
the reject level can be high due to the
brittleness of these materials. Due to
its superior creep performance,
Stanyl

is better than other polyamides

and PPA's when it comes to with-
standing heat-treatment procedures
( such as encapsulation) on wire-
wound components. For example,
Stanyl

shows a superior creep perfor-
mance at 140C ( 285F) under a load
of 20 M Pa ( 2, 900 psi) .
Dip soldering. After winding, the
wire is soldered to the connecting
pin. This is done by passing the pin
through a solder bath. The solder
bath operates at temperatures
between 193C ( 380F) and 260C
( 500F) . Although the plastic itself is
not in direct contact with the heat
source, heat conducted via the pins
may soften the plastic and allow the
pins to move. Stanyl

performs better
in this respect than the widely used
PA66 or PC . PPS is too brittle and
shows too much flash.
Processing, post-treatment, and
environmental issues such as recy-
cling make the use of thermosets
increasingly unattractive.
Eliminating wrapping film and
potting. Before encapsulation, poly-
ester film may be wrapped around the
coil. Stanyl

has enabled designers to

leave out this extra production step by
replacing the film by hinges which are
integrated with the bobbin, with sec-
tions of less than 0.3 mm ( 0.01 in) .
The excellent flow of Stanyl

enables
processors to over-mold the complete
bobbin. This eliminates the expensive
potting procedure.
Stanyl

, a c ost-effec tive solution for

wire-wound c omponents.
Figure 10 With Stanyl

wall thic knesses c an be reduc ed due to better end-wall

break-out strength.
18
Elec tric motors
When a motor is miniaturized while its
power supply remains the same or
increases, its internal temperature
may rise significantly depending on
the design. O verloading or blocked
rotors can lead to temperatures rapid-
ly exceeding 250C ( 40F) . Safety
margins may be required for ade-
quate functioning.
The UL 1446 classification of Stanyl

guarantees that it will withstand the

heat generated during both normal
operation and overload conditions of
an electric motor ( see Table 3) .
Stanyl

can be found in various parts
of an electric motor, including end
laminates, brush holders, gears, and
end brackets.
End laminates. The winding
process exerts a considerable stress
on the end laminate. Brittle materials
such as thermosets, polyesters, and
PPS need a highly controlled winding
process to prevent cracking.
Production costs are consequently
high. The high toughness of Stanyl
offers improved reliability and lower
production costs. After winding, the
load on the end laminate can be per-
manent, requiring high creep resis-
tance at elevated temperatures. I n
blocked-rotor situations peak temper-
atures of more than 250C ( 480F)
may occur. When combined with a
load, these may result in deformation
of the plastic, leading to malfunction-
ing of the motor. The high HDT of
Stanyl

[ 290C ( 550F) ] prevents the
occurrence of such deformations.
Brush holders. Due to the use of
brushes, significant power loss
occurs at high currents. This, in com-
bination with internal friction between
brushes and commutator, can result
in temperatures exceeding 220C
( 425F) . O nly a limited number of
materials can with-stand these condi-
tions. I nitially thermosets were used,
but high production costs led to the
search for alternative thermoplastic
materials. PPS was found to be too
brittle. Stanyl

offers an ideal combi-

nation of high stiffness at elevated
temperatures and toughness, giving
greater reliability at lower cost.
End Laminates
Stanyl

is used in vacuum cleaners, lawn mowers, and
washing-machine motors for end laminates.
Table 3 UL 1446 Insulation System Rec ognition for Stanyl

PA46.
B 130C ( 265F) TE350, TE250F6, TE250F8, TE250F9, TW250F6
C 155C ( 310F) TE200F6, TE250F6, TE250F8, TE250F9
TW200F6, TW250F6, TW300, TW341
H 180C ( 355F) TE200F6, TE250F6, TE250F8,
TE250F9, TW200F6, TW250F6
For high temperature E/E c omponents,
Stanyl

is the solution for motor end

laminates.
UL 1446 c lasses Stanyl

Grades
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Gear wheels
The properties of Stanyl

make it ide-
ally suited for gear wheel applications
where severe demands are made on:
- toughness
- fatigue resistance
- wear resistance
- tooth strength.
The advantages of Stanyl

become
more prominent as the temperature
of the gear wheels operating environ-
ment increases.
M oreover, Stanyl

's stiffness at elevat-

ed temperatures, its excellent fatigue
behavior and high impact strength
enable gear wheel manufacturers to
use Stanyl

instead of metal ( see
Figure 11) . This leads to smoother
running of the motor combined with
noise reduction. I n most cases
replacement of metal will also reduce
the total cost price of the assembled
gear. Complex shapes can easily be
made in Stanyl

and production costs

will thus be reduced.
I njection molded gears are used in
applications ranging from motion
translation in copiers and printers to
transmitting torque in the horsepower
range. The ability to be used unlubri-
cated, the reduction or elimination of
running noise, and the high productivi-
ty/low cost potentials of plastics gear-
ing are some of the reasons for the
high growth seen in this area. DSM
produces a broad portfolio of thermo-
plastic resins and compounds that can
provide the correct balance of these
critical properties, meeting the most
demanding performance criteria in a
cost-effective form.
Gear Wheels, Bearings, and Bearing Cages
Figure 11 Exc ellent performanc e of Stanyl

in starter reduc tion gear wheel.

Starter Gear
The use of Stanyl

in this starter gear offered several advantages over the

use of steel such as lower weight and corrosion resistance. I n addition,
Stanyl

provided superior toughness and thermal performance.
Stanyl

is used in a variety of gear designs.

20
Bearings and bearing c ages
Thermoplastic materials have
replaced metal in a number of parts
in bearing systems. Stanyl

offers a
property profile which provides
designers and engineers with the
opportunity to improve the perfor-
mance or reduce the cost of bearings
and bearing cages:
- high stiffness and creep resis-
tance at elevated temperatures
- excellent toughness even in
dry-as-molded condition
- superior resistance to chemicals,
including lubricant oils such as
ATF, TAF, and EP oils
- outstanding fatigue resistance
- high limiting pressure velocity ( PV)
and wear resistance.
As Stanyl

retains its superior stiff-
ness at elevated temperatures as
well as in aggressive environments
such as lubricant oils, designers can
use the parts:
- at higher pressure velocity ( PV)
limits
- at higher operating temperatures.
M oreover, Stanyl extends the operating
life of the bearing. At temperatures
where the diameter of the PA66 bear-
ing cage begins to decrease rapidly,
the Stanyl

bearing cage remains
dimensionally stable ( see Figure 12) .
Figure 12 Stanyl

retains its superior stiffness at elevated temperatures, even in

aggressive environments.
Stanyl

provides a c ost savings for

bearing c ages.
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General
Stanyl

PA46 properties. The

excellent properties found in Stanyl

lead to important advantages for the

customer including cost reduction,
longer lifetime, and high reliability.
Stanyl

bridges the gap between con-
ventional engineering plastics such as
PA6, PA66 and polyesters, and exotic
materials such as LCP, polysulfones
and PEEK .
- excellent short-term and long-term
heat resistance
- high stiffness at elevated
temperatures
- high creep resistance, especially
at elevated temperatures
- outstanding toughness
- excellent fatigue behavior
- good resistance to chemicals
- excellent flow
- lower material costs due to
excellent mechanical properties
allowing thinner walls which lead
to weight reduction and lower
part prices
- 30% productivity increase of
molding equipment
- greater design freedom due to
excellent mechanical properties
and good mold-flow behavior
- economical, safe, and convenient
processing due to the use of 80C
( 176F) water-heated molds
- no post-treatment due to
absence of flash
- no retooling necessary when
switching from PA6, PA66
or polyesters.
Stanyl

c omponents. O ffering a
heat deflection temperature of 285C
( 545F) and a continuous use temper-
ature of 166C ( 330F) , Stanyl

is an
excellent engineering material for high
heat components in the automotive,
mechanical, and electrical/electronics
industries. Stanyl

is the material of
choice for components that must
maintain structural integrity under high
short-term temperatures ( as in I R and
wave soldering) or wherever snap-fit
design or other critical assembly con-
siderations are paramount.
High heat. Stanyl

's performance
compared with the most important
engineering plastics is illustrated in
Figures 18 and 19. With respect to
temperature resistance, unreinforced
Stanyl

is positioned above the well-

known engineering plastics such as
polyamide 6 or 6/6 and polyesters,
and just below high performance
materials such as polysulphones,
polyetherimides, and polyketones.
I f we compare 30% glass fiber rein-
forced materials, the heat distortion
temperature of Stanyl

even comes
very close to that of PEEK ( see
Figure 19) .
Charac teristic Properties Of Stanyl

PA46
Figure 18 High-heat properties of unreinforc ed engineering plastic s.
Figure 19 High-heat properties of 30% glass fiber reinforc ed engineering plastic s.
22
Crystallinity
The high crystallization rate of Stanyl

results in the formation of many small

spherulites. This explains the superior
toughness of Stanyl

compared with
other engineering plastics. I n addition,
the high crystallization rate of Stanyl

enables faster cooling and thus a

short cycle time.
G lass fiber reinforced Stanyl

shows
an unmatched elongation at break
( see Figure 21) .
Temperature performanc e
The temperature performance of every
engineering plastic can be divided
into:
- a peak-temperature resistance or
a short-term temperature resis-
tance, expressed by the Heat
Distortion Temperature ( HDT)
- a resistance to long-term exposure
at elevated temperatures under
zero-load conditions, expressed
by the Continuous- Use
Temperature ( CUT) .
Heat Distortion Temperature.
The HDT is a measure of the tempera-
ture resistance under a given load. I t
is defined as the temperature at which
a test bar shows a pre-defined
strain; this is related to the stiffness
level at elevated temperatures. The
HDT of Stanyl

is much higher than

that of other engineering plastics:
170C ( 335F) for unreinforced Stanyl

and 290C ( 555F) for 30% glass fiber

reinforced Stanyl
.
Figure 20 Impac t and temperature resistanc e of unreinforc ed engineering plastic s.
Figure 21 Tensile and temperature behavior of 30% glass fiber reinforc ed
engineering plastic s.
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130C ( 265F) 20, 000 h 12, 000 h
145C ( 290F) 10, 000 h 6, 000 h
160C ( 320F) 5, 000 h 3, 000 h
175C ( 345F) 2, 500 h 1, 500 h
Continuous-Use Temperature.
The CUT is defined as the temperature
at which a given mechanical property
( e.g. tensile strength) of the material is
reduced to 50% of its original value
within a pre-defined period of time
( usually 5, 000 or 10, 000 hours) .
From Figure 22 it can be concluded
that the CUT of glass fiber reinforced
Stanyl

at 5, 000 hours is 170C ( 335F) .

The different CUTs for different aging
times are summarized in Figure 22 for
a number of Stanyl

grades.
The drop in tensile strength is 50% at
these conditions. The CUTs of Stanyl

and PPA are similar. However, the

absolute value of the tensile strength
of Stanyl

at 170C ( 335F) is signifi-
cantly higher than that of PPA. This
advantage remains after aging as
demonstrated in Figure 23.
I n Table 5 the half-lives ( based on ten-
sile strength) of two 30% glass fiber
reinforced materials, PA66 and Stanyl

,
are shown at different thicknesses and
temperatures. I t is evident that 30%
glass fiber reinforced Stanyl

offers a
superior performance. The tensile half-
life is about 60 to 70% longer than that
of the comparable PA66 grade.
Table 5 Half-life based on tensile strength.
Figure 22 Continuous-use temperatures of some Stanyl grades.
Figure 23 Tensile strength after heat aging.
30% Glass fiber reinforc ed
Temperature Stanyl

PA66
Test spec imen 2 mm (0.070 in) thic k
Test spec imen 4 mm (0.157 in) thic k
140C ( 285F) 20, 000 h 12, 000 h
155C ( 310F) 10, 000 h 6, 000 h
170C ( 335F) 5, 000 h 3, 000 h
185C ( 365F) 2, 500 h 1, 500 h
24
Mec hanic al properties
The mechanical properties of
polyamides depend in general on:
- the temperature of their environment
- the moisture content
- the aging time.
The main factor which influences the
absolute level of these properties is the
composition of the compound, particu-
larly the type and amount of reinforce-
ment and additives.
Stiffness. Due to its high crystallini-
ty, Stanyl

retains a high level of stiff-

ness up to temperatures very close to
its melting point. This provides wider
safety margins for critical applica-
tions in comparison with materials
like PA6, PA66, and polyesters. PPA
and PPS have a very high modulus at
room temperature but show a signifi-
cant drop in stiffness at elevated
temperatures [ above 100C ( 210F) ]
( see Figures 3, 4, and 25) . I n prac-
tice, Stanyl

has a higher stiffness at

temperatures > 100C ( 210F) .
The stiffness advantage offered by
Stanyl

at elevated temperatures can
be exploited by designing compo-
nents with reduced wall sections,
some 10 to 15% thinner than those
necessary for other engineering plas-
tics with the same level of glass fiber
reinforcement. The weight savings
achieved with Stanyl

not only reduces

the price difference between other
engineering plastics and Stanyl

, but is
also important for automotive and avia-
tion applications where weight savings
is a vital issue.
By adding reinforcements, stiffness lev-
els can be increased further ( see
Figure 26) .
Figure 24 Shear modulus of unreinforc ed polyamides.
Figure 25 Shear modulus of 30% (PPS 40%) glass fiber reinforc ed engineering plastic s.
Figure 26 Shear modulus of some Stanyl grades. (GF = glass fiber reinforc ed).
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25
Creep resistanc e. For optimum
performance and maximum lifetime,
engineering plastics which are sub-
jected to long-term loading must have
a high creep resistance ( i.e. low plas-
tic deformation under load) .
Stanyl

's high crystallinity results in an

excellent retention of stiffness at elevat-
ed temperatures [ above 100C ( 210F) ]
and hence in a creep resistance which
is superior to that of most engineering
plastics and heat-resistant materials.
Figure 27 shows the effect of glass-
fiber reinforcement on the creep mod-
ulus of Stanyl

at 140C ( 285F) .
Creep behavior is one of the factors
that limit the maximum application
temperature of a material. The maxi-
mum application temperature of
Stanyl

is 30C ( 85F) higher than that

of PA66 and well above that of PPA.
When Stanyl

and PA66 are compared

at the same temperature exposure,
several alternatives exist:
decrease the wall thickness by
using Stanyl ( with an equivalent
level of reinforcement)
reducing material usage and
cost
use a Stanyl

grade with a lower
level of reinforcement than is
possible with PA66 ( for equal wall
thicknesses)
giving greater design freedom
due to a higher elongation at
break
facilitating the use of snap-fits
lowering material consumption
per part due to a lower density.
Figure 27 Creep modulus of unreinforc ed polyamides.
Figure 28 Creep modulus of glass fiber reinforc ed (30% or 33%) engineering plastic s.
Figure 29 Relaxation behavior.
26
Toughness, fatigue, and wear
behavior. While tensile and flexural
strength decrease with increasing tem-
perature, toughness as measured by
elongation at break and impact resis-
tance increases. Therefore the critical
factor is usually the toughness perfor-
mance at lower temperatures. Due to
its fine crystalline structure, unrein-
forced Stanyl

exhibits extraordinary
impact resistance in comparison with
many other engineering plastics ( see
Figure 20) . Notched izod impact values
remain at a high level even at tempera-
tures below 0C ( 32F) .
The effect of different amounts of
glass fiber reinforcement is different
for both toughness parameters. With
increasing reinforcement percent-
ages, the elongation at break
decreases while the izod impact
resistance increases.
The izod impact resistance of glass-
fiber reinforced Stanyl

is also
unmatched ( see Figure 30) . This
makes Stanyl

the material of choice
for demanding applications like inlet-
manifold devices and facilitates further
assembly steps, for instance using
inserts and snap-fits.
Since this is combined with a very
high elongation at break ( see Figure
21 on page 30) , Stanyl

offers the best
solution for thin-walled parts, snap-fits,
film hinges, and insert molding such
as gears, pulleys, and dip switches.
The high crystallinity and fine crys-
talline structure of Stanyl lead to a
fatigue resistance superior to that of
most other engineering and heat-
resistant plastics ( see Figure 31) .
The fatigue resistance of Stanyl is
much better than that of PPA, PPS
and PA66. Fatigue resistance is par-
ticularly important for gears and
chain tensioners.
Figure 30 Impac t resistanc e of glass fiber reinforc ed engineering plastic s.
Figure 31 Fatigue resistanc e at 140C (F) of glass fiber reinforc ed engineering plastic s.
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Stanyl

also has an excellent abra-

sion ( or wear) resistance and outper-
forms many other engineering plas-
tics under most conditions. Figure 32
shows a comparison between
Stanyl

, PA66 and PO M with respect

to the Taber Abrasion Test ( ASTM
D1044) . Although the coefficients of
friction of standard grades of these
materials are quite similar, Stanyl

outperforms its competitors. The main

reason is its higher PV rating, which
permits higher pressures or velocities
to be used ( see Figure 33) . M odified
Stanyl

grades with even better wear

properties are available in unrein-
forced as well as glass fiber rein-
forced form. I ts smooth and tough
surface, combined with its stiffness at
elevated temperatures, make Stanyl

an ideal material for sliding parts.

These include valve lifter guides,
chain tensioners, and thrust washers.
Elec tric al properties,
flammability, and UL
c lassific ations
Stanyl

exhibits high levels of surface
and volume resistivity, dielectric
strength, and comparative tracking
resistance. The exact levels of these
properties depend on the specific
grade, temperature, and moisture
content. I n general these properties
are sufficiently retained at elevated
temperatures to fulfill critical applica-
tion requirements.
This fact, in combination with its very
high peak temperature resistance
and its high toughness level, makes
Stanyl

an excellent choice for com-

ponents which have to be soldered
onto a printed-circuit board ( PC B) .
A number of flame-retardant grades
have been developed, rated V-0
according to the Underwriters
Laboratories UL 94 classification
[ even at 0. 35 mm ( 0. 01 in) ] .
Figure 33 PV diagram.
Figure 32 Abrasion resistanc e.
28
The unmodified, unreinforced Stanyl
grades are rated V-2 and the glass
fiber reinforced grades without flame
retardant are rated HB. O ther classifi-
cations according to a number of UL
standards have been obtained for dif-
ferent Stanyl

grades.
I n the Table 3 on page 18 the most
important ratings according to UL
have been summarized. Noteworthy is
the class H [ 180C ( 355F) ] rating
according to UL 1446 for the glass
fiber reinforced grades of Stanyl

.
Chemic al resistanc e
Polyamides are well known for their
resistance to a wide range of chemi-
cals. Stanyl

is no exception.
Especially at higher temperatures its
resistance to oils and greases is
excellent ( see Figures 34 and 35) .
Stanyl

is therefore an ideal material
for applications under the hood in the
automotive industry and for other
industrial applications such as gears
and bearings.
Like all other polyamides, Stanyl

, too,
is attacked by strong mineral acids
and absorbs polar solvents. I nfor-
mation concerning the resistance of
Stanyl

to various chemicals and sol-

vents is available on request from your
local DSM sales office.
Figure 34 Influenc e of immersion in oil on flexural strength of 30% glass fiber
reinforc ed polyamides.
Figure 35 Retention of mec hanic al properties (of 30% glass fiber reinforc ed
polyamides) after immersion in hot oil.
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Designing With Nylons
Stanyl

PA46 are crystalline engineer-
ing thermoplastics. Their highly sym-
metrical molecular chain structure
leads to a high degree of crystallinity
and high rate of crystallization. This
gives Stanyl

a decisive technical
edge over other semi-crystalline engi-
neering thermoplastics such as nylon
6, 6/6, PPA, and polyesters in the per-
formance areas of heat resistance,
shear modulus at elevated tempera-
tures, wear and friction, fatigue resis-
tance, and cycle time.
Due to its unique combination of prop-
erties, Stanyl

can compete across a

wide range of the engineering plastics
market. For instance, some applica-
tions which might be designed in
nylon 6 or 6/6 may actually be more
economical to produce in Stanyl

if
Stanyl

s faster crystallization rates

can be used to advantage by reduc-
ing cycle times enough to more than
offset the higher cost of Stanyl

. O n
the other hand, Stanyl

is often used in
applications originally thought to be
reserved for high temperature amor-
phous resins such as PES, due to
these resins high continuous use tem-
perature ratings. I n fact, Stanyls
higher deflection temperatures under
load and higher shear modulus at ele-
vated temperatures make it the better
choice. I n recent times, Stanyl

s high
flow characteristics have allowed it to
work in application areas once
reserved only for LCPs.
Produc t design
The product designer should always
keep in mind the unique requirements
of Stanyl

when designing a new

application for this product. Like all
engineering plastics, Stanyl

shrinks
when it cools during the molding
process. I ts surface appearance is
affected by the surface of the mold
and the processing conditions used in
the molding process. M echanical
properties can be compromised if
proper processing guidelines are not
followed. Notch sensitivity can lead to
premature failure if sharp corners are
designed into the product. Each of
these requirements will be addressed
in the following text.
Dimensions. All thermoplastic mate-
rials exhibit mold shrinkage to some
degree. As unreinforced material,
Stanyl

generally shrinks more than

typical amorphous materials in the
realm of 2.0% . The addition of glass
reinforcement reduces this value to
0.2% to 0.9% , depending on the glass
fiber loading ( see Figure 13) .
M oisture absorption plays a major role
in the prediction of dimensions in
Stanyl

materials. M oisture absorption

is a time and humidity dependent,
reversible process which continues
until equilibrium is reached.
The designer should anticipate the
humidity conditions in which the
product will be used. Like shrink-
age, the moisture absorption of rein-
forced grades differs from those of
unfilled grades.
Unfilled and mineral filled Stanyl

grades are generally isotropic with

respect to shrinkage; that is to say,
shrinkage in the direction of flow is
more or less equal to shrinkage
across flow. G lass reinforced grades
on the other hand, show anisotropic
properties. Due to fiber orientation,
shrinkage values across the direction
of flow are often substantially
greater on the order of 50% to 100%
greater than shrinkage values in the
direction of flow. This is the basic rea-
son for the warpage which often
occurs in parts molded with glass
reinforced crystalline materials.
Figure 13 Perc ent shrinkage with respec t to glass c ontent.
30
Surfac e appearanc e. Some
Stanyl

grades are capable of a high
level of reproduction of the mold sur-
face. As a general rule, unfilled
grades offer the best reproduction
and glass reinforced the worst.
M ineral filled or glass/mineral filled
grades typically fall somewhere in
between. These guidelines are par-
ticularly true of high gloss molds.
O ften textures can be used to hide
the surface imperfections inherent to
molding Stanyl

. Higher mold tem-

peratures always improve the repro-
duction of the mold surface.
Wall thic knesses. Performance
and spatial requirements typically
determine the wall thickness of a
given part. Wall thickness should be
minimized with discretion to shorten
molding cycles, reduce part weight,
and optimize material usage. The
minimum wall thickness which can be
used in injection molding depends on
the size geometry of the part and on
the flow behavior of the material.
Stanyl

PA46 can be molded in wall

thicknesses as small as 0. 25 mm
( 0. 01 in) in flow lengths less than 100
times the wall thickness.
Uniform wall thickness assists consis-
tent, even filling of the mold, results in
more predictable shrinkage and war-
page, and produces better mechani-
cal properties. When varying wall
thicknesses are unavoidable for rea-
sons of design, gradual transitions
should be used.
Corners and radii. Sharp internal
corners and the resulting stress risers
are among the most common causes
of structural plastic product failure. All
nylons are somewhat notch sensitive
and glass reinforced versions are par-
ticularly susceptible.
The stresses arising from internal cor-
ners can be minimized by the use of
generous radii. As a general rule,
internal radii equal to one half the wall
thickness best distributes the loads
over the surface of the part. Smaller
radii cause stress concentrations while
larger ones do not significantly help
and may actually reduce performance.
External corners should maintain a
constant wall thickness around the
radius of the internal corner. This
reduces variations in wall thickness
and helps prevent warpage, sinks
and voids.
Ribbing. Ribs provide a number of
advantages to the part designer. They
may increase both the strength and
stiffness of the part. By eliminating
heavy cross sections, they can reduce
weight and shorten cycle times, both
of which can substantially reduce
costs. Ribs are not without their prob-
lems, however. Sink marks may
appear on the surface opposite the
ribs. O ften these can be hidden by
the strategic use of texture. Ribs may
also cause stress at their intersection
with the wall of the part if proper
design rules are not followed.
I n short, while ribs can be a helpful tool
for the product designer, they should
only be used when they are necessary
to provide the mechanical performance
required for the application.
Tooling design
G ood product design does not ensure
the success of a project if the tool is
not properly designed and construct-
ed. Stanyl

PA46 is almost always

used in applications where functionali-
ty is the key requirement. Since these
parts tend to be expensive, it is essen-
tial that the molds produce high quality
parts in a very efficient manner. This
can only be achieved if the tool is
designed and built to the correct stan-
dards using high quality tool steels.
Gates and runners. Stanyl

PA46
requires similar gate and runner sys-
tems as other nylons. For unfilled
Stanyl

, the runners can be very

small to save material scrap and
reduce cycle times. Larger parts
and/or more highly filled materials
typically require more generous
gates and runners. All types of gates
have been used, however sub-gates
are the most common because of
their automatic de-gating capability.
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Hot runners. Hot runners are very
popular today because they eliminate
de-gating operations, allow more
design freedom for gate positioning,
reduce scrap and reduce cycle times.
The disadvantages to hot runner use
are the startup problems associated
with getting these systems on cycle
and degraded material in the manifold
system from long residence times,
poor design or improper startup/shut-
down practices.
M ost of the major hot manifold manu-
facturers have built manifolds which
have been successfully used with
Stanyl

PA46, however, open, exter-

nally heated systems work best. This
allows the melt to pass freely through
the system without excessive shear,
wear, or opportunities for the material
to hang-up.
Regardless of the type of system
used, the system must have several
distinct characteristics including:
- precise temperature control
- sufficient heating capacity
- correct gate size and location
- proper insulation at the tip of
the nozzle
- minimal residence time in
the manifold.
Venting. Like all engineering thermo-
plastics, Stanyl

PA46 requires venting
to allow gasses to exit the mold as the
cavities are filled. Vents should be
strategically placed to allow these
gases to escape at any point in the
cavity where gas may be trapped or
at the ends of fill. Vents should be
0.018 - 0.023mm ( 0.0007 0.0009 in)
deep with a minimum of 0.75mm
( 0.03 in) land. Secondary vents
( relief) should be the same width as
the primary vent and 0.5mm ( 0.02 in)
deep. All vents must eventually
exhaust to the atmosphere.
Shrinkage and warpage. Due to
the high degree of crystallinity which
Stanyl

PA46 can achieve, predicting

shrinkage and warpage is extremely
difficult. Linear shrinkage information
is available on the individual product
data sheets, which can be found at
www.dsmep.com. The tool designer
should always keep in mind that glass
fiber reinforced versions exhibit a high
level of anisotropy.
CAE simulation tools can be of particu-
lar value in determining the flow pat-
terns within complex parts. O n the
other hand, extremely critical parts,
such as gears, should always be proto-
typed before permanent tooling is built.
I n order to accurately predict shrinkage
and warpage it is essential that proto-
type tooling and production tooling use
the same gate and runner system.
32
Mac hinery
Stanyl

can considerably reduce
cycle times in comparison with other
engineering plastics due to its very
fast crystallization ( see Figure 14) .
Stanyl

PA46 can be processed on
standard plastic processing equip-
ment. Typically, general-purpose
screw designs with compression
ratios of approximately 2. 5:1 with
sliding check rings work best. For
unreinforced grades, nylon or
reversed taper nozzles work well,
while reinforced grades typically do
better with general purpose, free
flowing nozzles. These tend to
reduce shear and provide better
mechanical properties and, since the
reinforcement inhibits drool, the
reverse taper of a nylon nozzle
doesnt add much benefit.
Auxiliary equipment. The key
pieces of auxiliary equipment include
the material dryer, mold heater, and
scrap granulator. Dryers must be
sized to handle the throughput rate of
the molding machine used. The key
requirement of the dryer, however, is
its ability to maintain a dew point
between -40 and -30C ( -40 and
-20F) . Dew points above this level
do not facilitate drying. Both vacuum
and desiccant bed dryers have been
successfully used with Stanyl

.
M old heat may be provided via
water, oil, or electricity. G enerally
speaking, the minimum temperature
requirements of Stanyl

, 80C ( 180F)
may be met with water. O n the other
hand, for higher crystallinity, and
therefore superior mechanical prop-
erties, Stanyl

often is molded at tem-
peratures in the range of 100 to
135C ( 212 to 275F) . O il or electric
heat are typically used in these tem-
perature ranges. Superior surface fin-
ish can be achieved by using even
higher mold temperatures. Best
replication of the mold surface can
be achieved by using mold tempera-
tures in the range of 150 to 165C
( 300 to 330F) .
Proc essing Nylon
Figure 14 Cyc le times examples of various glass fiber reinforc ed engineering plastic s.
Aliphatic polyamides ( PA6 and PA66) 25 - 40%
Semi-aromatic polyamides ( PPA) 30 - 45%
Polyesters 30 - 45%
PPS 30 - 50%
Stanyl

versus
Table 4 Potential c yc le time reduc tion.
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Scrap granulators should be able to
produce uniform particles which can
be blended with virgin pellets without
adversely affecting the homogeneity
of the melt. I n order to achieve this,
the granulator screen should be
sized accordingly. Additionally, the
blades must be kept sharp enough to
cut the scrap without producing
excessive fines. For recommended
temperature settings for injection
molding of Stanyl

refer to data pro-

cessing sheet located on the website
at www. dsmep. com.
Material handling
Stanyl

granules are supplied dry in
airtight moisture proof packing.
When working with nylons, it is impor-
tant to prevent moisture absorption
before molding. Stanyl

is hygro-
scopic and absorbs moisture from
the air relatively quickly ( see Figure
15) . Although Stanyl

absorbs more
moisture than PA66, the resulting
dimensional change at equilibrium is
of a similar order ( see Figure 16) .
At room temperature moisture
absorption will lower stiffness and
strength while increasing toughness.
At temperatures above 78C ( 172F)
( the glass transition temperature of
PA46) the effect of moisture absorp-
tion on the stiffness of Stanyl

is neg-
ligible ( see Figure 17) .
Figure 15 Water absorption of Stanyl

PA46.
Figure 16 Dimensional c hange in length direc tion due to moisture absorption.
34
Should moisture absorption occur
prior to molding, there can be an
adverse effect on the quality of the
molding. During storage, containers
should be kept closed and undam-
aged. During molding the following
measures are recommended:
- preheat the hopper
- open the container just before fill-
ing the hopper
- close the container securely if all
the contents have not been used
- keep the hopper closed
- bring cold granules up to ambient
temperature in the molding shop
while keeping containers shut.
Every lot of Stanyl

is tested for mois-

ture content and viscosity. A certifi-
cate with the relevant lot data can be
delivered with the materials. Stanyl

PA46 nylons are packaged at a maxi-

mum level of 0. 08% moisture content.
The ideal processing content is
0. 02% or less. M oisture contents of
between 0. 02% and 0. 05% are
acceptable. Higher levels can have
a dramatic effect on both flow and
mechanical properties.
Regrind. Regrind can often be a
source of processing problems. The
keys to successful use of regrind are:
Particle size similar to that of the vir-
gin pellets; Regrind is kept clean and
dry. For best results, regrind content
should be limited to 20% , however,
some Stanyl grades have UL ratings
up to 100% regrind.
Safety. Under normal conditions,
Stanyl

does not present a toxic haz-

ard through skin contact or inhala-
tion. During processing, contact with
the polymer melt and inhalation of the
fumes should be avoided. A material
safety data sheet can be requested
from DSM customer service.
Proc essing c onditions
The injection-molding unit should
always be clean upon startup.
Cleaning can be carried out by purg-
ing with HDPE or a number of com-
mercially available purging com-
pounds. O nly purging compounds
capable of withstanding the high pro-
cessing temperatures of Stanyl

[ up to
320C ( 610F) ] should be used.
I n order to establish the optimum pro-
cessing temperatures, one should be
aware of the upper and lower temper-
ature limits for the processing of
Stanyl

. Like other nylons, Stanyl

degrades at melt temperatures above

330C ( 625F) even at short residence
times. Lower temperatures increase
the allowable residence time.
The temperature of the melt is depen-
dent upon the setting of the barrel
temperatures, the screw configura-
tion, the screw speed and the back-
pressure. Therefore it is essential to
measure the actual melt temperature
after the injection molding process
has been running on line for some
time and the processing conditions
have been stabilized.
Figure 17 Influenc e of moisture uptake on shear modulus of glass fiber reinforc ed
polyamides.
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Barrel temperatures. Due to the
high melting point and high crys-
tallinity of Stanyl

, barrel tempera-
tures need to be set high enough to
provide a homogeneous melt without
getting too near the degradation
point of Stanyl

at 330C ( 625F) .
Sc rew rotation speeds. Like
most polyamides, Stanyl

has excel-
lent flow properties due to its relative-
ly low melt viscosity. The effect of
screw rotation speed on the amount
of shear which is transmitted to the
melt is relatively low and high screw
speeds can generally be used with-
out harm to the polymer. With glass
reinforced grades, care should be
taken not to reduce the glass fiber
length. The lowest screw speed
which allows the screw to recover
within the cooling portion of the cycle
should always be selected.
Bac k pressure. Effective back
pressure of 7. 5 bar ( 100 psi) is rec-
ommended for processing Stanyl to
homogenize the melt and prevent
gas entrapment. I f back pressure is
set too high, [ ~ 20 bar ( 300 psi) ] it
may cause increased screw recovery
time, nozzle drool and reduction of
glass fiber length.
Injec tion speeds/pressures.
Due to the fast solidification of
Stanyl

, high injection speeds are

required in order to obtain good
packing and surface finish.
G enerous mold venting is therefore
necessary to avoid burning at the
end of the flow path.
Holding pressure/holding time.
For optimum appearance and dimen-
sional control, holding time plays an
important role. I n principle, the hold-
ing time should be the time it takes
for the gate to freeze. I n general, the
holding time of Stanyl

is very short
compared to other engineering plas-
tics due to its fast solidification. Sink
marks and voids caused by volumet-
ric shrinkage can be reduced by
adequate holding time and pressure,
however the holding pressure should
not be so high that stresses are
induced. O ne method of determining
the correct level is by increasing the
holding pressure until no sink marks
are visible. After completely cooling
down, the part is then cut open at its
thickest cross section and inspected
for voids. I f necessary, the holding
pressure is increased.
O ne method to determine proper
holding time is to weigh the parts
without the sprue and increase hold-
ing time until constant weight is
achieved. A more sophisticated
method is to use pressure transduc-
ers in the cavity to determine the
exact moment of gate freeze-off.
This method was used to demon-
strate that a 3. 2mm ( 1/8 in) UL bar
molded of Stanyl

needed only half

the holding time of a similar nylon 6/6
part. This, combined with higher
mold ejection temperatures, explains
the very short cycle times compared
to other engineering plastics.
36
Mold temperature/c ooling time.
Because of the fast solidification of
Stanyl

, the cooling time is very short.

For this reason screw recovery time
will generally be the determining step
for the cycle time. Processing Stanyl

can in principle be done on a wide

range of mold temperatures. M old
temperatures above 80C ( 180F) are
recommended for good dimensional
stability and flow properties. To
reduce post-mold shrinkage, increase
flow performance, increase weld line
strength, increase toughness and
improve surface appearance, the
mold temperature may be increased
up to 120C ( 250F) or even higher.
Mold ejec tion. Stanyl

generally
does not stick to mold surfaces and
has good ejection properties. Due to
the high crystallization rate, the sur-
face solidifies very fast and has a high
stiffness at high temperatures. There-
fore, Stanyl

can be ejected at relative-
ly high temperatures, such as 200C
( 390F) , resulting in short cycle times.
Cyc le interruptions. When a short
break during production is expected,
the hopper should be closed, the bar-
rel emptied, and the screw put into
the forward position. Barrel tempera-
tures may be maintained. For cycle
interruptions of one to two hours, the
same procedure should be used,
however the barrel temperatures
should be lowered to 260C ( 500F) .
When starting up, first purge with
fresh material. For flame retardant
grades purge the barrel with HDPE
before allowing the machine to sit idle.
Shutdown/c leanup. Empty the
hopper and purge the screw with high
melt viscosity HDPE. Lower the barrel
temperatures during purging to the
required level of the next polymer to
be processed.
Sec ondary-treatment
Plastic parts are often subjected to a
finishing operation after the actual
production step. This can be a func-
tional operation such as machining,
gluing, welding, screwing or snap fit-
ting, or a decorative treatment, such
as vacuum metallization, electroplat-
ing, lacquering, printing or laser mark-
ing. For more information on these
treatments please refer to the sec-
ondary-treatment technical articles on
the DSM web site at www.dsmep.com.
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P

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A

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T

I

C

S
Akulon

Nylon 6 and 6/6 in both unreinforced and reinforced

nylons grades, including flame retardant products.
Arnite

Unreinforced, reinforced, and flame retardant grades offering

therm oplastic polyester dimensional stability and low moisture absorption with good
chemical resistance.
Arnitel

High performance elastomers based on polyester.

copolyester elastom ers
Elec trafil

Electrically conductive thermoplastic materials providing ESD and

conductive therm oplastics EM I shielding.
Fiberfil

Reinforced and filled polypropylenes.

reinforced & filled therm oplastics
Nylatron

I nternally lubricated nylons to enhance wear and friction properties.

lubricated therm oplastics
Plaslube

I nternally lubricated nylons to enhance wear and friction properties.

lubricated therm oplastics
Stanyl

High temperature nylon which bridges the price-performance gap

PA46 between traditional nylons and high-performance materials.
Xantar

Unreinforced, reinforced, and flame retardant grades with outstanding

polycarbonate impact resistance, dimensional stability, and high heat deflection
temperature.
DSM EP - Americ as Produc t Portfolio
1-800-333-4237
www.dsmep.com
2002 DSM Engineering Plastics Printed in the USA 11/02 2,500
Akulon

, Arnite

, Arnitel

, Electrafil

, Fiberfil

, Nylatron

, Plaslube

, Stamylan

, Stanyl

, Stapron

, Xantar

, and Yparex

are registered trademarks of DSM Engineering Plastics.

North Americ a
DSM Engineering Plastics
P.O. Box 3333
2267 West Mill Road
Evansville, IN 47732-3333
Tel. 812 435 7500
Fax 812 435 7702
www.dsmep.com
Europe
DSM Engineering Plastics
Poststraat 1
6130 AA Sittard
The Netherlands
Tel. 31 46 477 04 50
Fax 31 46 477 3959
www.dsmep.com
Asia Pac ific
DSM Engineering Plastics
10A, China Overseas Building
No. 25 Chongqing Zhong Road
Shanghai 200020
Tel. 86 21 6386 3080
Fax 86 21 6386 2198
www.dsmep.com