Akulon® K224-PG6

Identification & Functionality

Chemical Family

Polyamides

Fillers Included

Glass Fiber

Polymer Name

Polyamide 6 (PA 6)

Reinforcement Form

Tape,

Unidirectional Fabric

Reinforcement Material

Glass Fibers

Composite Materials Functions

Resins, Binders & Matrix Materials

Plastics & Elastomers Functions

Resin

Technologies

Composite Materials,

Plastics

Product Families

Plastics — Engineering & Specialty Polymers

Polyamides

Composite Materials — Polymers & Resins

Thermoplastic Resins

Features & Benefits

Materials Features

Impact Modified,

Light Weight,

UL Flame Rated

Applications & Uses

Markets

Automotive & Transportation,

Consumer Goods

Applications

Consumer Goods — Appliances & Electronics

Automotive & Transportation — Automotive

Exterior & Body,

Interior,

Safety Systems

Consumer Goods — Lawn & Garden

Consumer Goods — Sports & Recreation

Plastics & Elastomers End Uses

Airbags,

Chainsaw Housings,

Door Panel,

Flooring,

Housings,

Inline Skate Frames,

Skibinding Fixations,

Wheel Housing Parts

Composites Processing Methods

Injection Molding

Plastics & Elastomers Processing Methods

Injection Molding

Airbag Containers Application Data

Details

Proven track record at various OEMs for more than 20 years with Akulon® PA6. High Speed Data enable optimal part designs.

Benefits

• Akulon® PA6 allows for 40-60% weight reduction versus metal
• Akulon® PA6 allows for reliable (safer since no metal bolts needed) and cost effective solutions versus metal (due to the possibility of function integration) and versus PA66 (PA6 more economical choice)
• Akulon® Ultraflow grades allow even for more cost effectiveness due to 25% cycle time advantage and due to high flowability enabling thinner walled designs

Chainsaw Housings Application Data

Details

When used for covers and housings Akulon® can stand up to drop test at -30 degrees. Just as important are its excellent surface characteristics – it holds paint very well and looks good.

Benefits

• Akulon® PA6 allows for reliable solutions, since it withstands drop test at –30°C
• Akulon® PA6 allows for cost effective solutions, since it is easy to process for both injection- and blow molding

Inline Skate Frames Application Data

Details

Akulon® UltraFlow PA6 yields faster molding than standard PA6 and enables thinner wall designs.

Benefits

• Akulon® PA6 offers the possibility for less weight and lower system costs through part and function integration, easier assembly and longer tool lives, in comparison with metals
• Akulon® PA6 allows for reliable solutions due to its good mechanical properties (stiffness and toughness) and due to its better surface appearance than PA66

Powertool Housings Application Data

Details

Akulon® UltraFlow PA6 yields faster molding than standard PA6 and enables thinner wall designs.

Benefits

• Akulon® PA6 allows for light weight and cost effective solutions compared to metals, also as a result of possible part and function integration, easier assembly and longer tool lives
• Akulon® PA6 allows for reliable solutions due to its better welding strength and surface appearance than PA66

Skibinding Fixations Application Data

Details

Akulon® UltraFlow PA6 yields faster molding than standard PA6 and enables thinner wall designs.

Benefits

• Akulon® PA6 allows for reliable solutions due to its good mechanical properties (stiffness and toughness) and due to its better surface appearance than PA66
• Akulon® PA6 allows for very cost effective solutions

Potential Applications

Envalior's polyamide-based UD tapes with endless carbon or glass fiber reinforcements are viable, lightweight alternatives to metals in several applications. UD tapes, tape-based 2D fabrics and crossplies are used in structural and semi-structural applications, as well as in the selective reinforcement of injection molded parts.

 

A demonstration vehicle door panel made by JLR from carbon fiber-reinforced PA410, as well as fabric sheets woven from the same UD tape (EU-sponsored ENLIGHT project). The UD tape products were thermo-formed and glued to make the panel, which is 60% lighter than state- of-the-art, steel-based designs, while still fulfilling safety requirements. The full composite door consists of structural panels and a tape-wound side impact beam over an extruded, permanent mandrel.

 

Maxion Wheels and Envalior successfully manufactured and tested (Rim Rolling Fatigue) thin-walled hybrid, steelcomposite automotive wheel-rim reinforced with UD tape (tape-winding) made from glass fiber-reinforced PA410. The hybrid wheel-rim is 2Kg lighter and 30% more fatigue-resistant than state-ofthe- art, steel design, whilst inert to road salts and battery acids.

 

A vehicle central-floor module from carbon fiber-reinforced PA410 made by FCA (EU-sponsored ENLIGHT project). The UD tapes based ply-books were thermoformed to the final shape. The composite part is 18% lighter than state-of-the-art, steel-based designs, while still fulfilling safety requirements. The composite strength and dimensional stability are not affected by the E-coating process, a requirement of BIW parts.

Properties

Flame Rating

UL 94 HB

Mechanical Properties

	Value	Units	Test Method / Conditions
Tensile Modulus	8700 / 4750	MPa	ISO 527-1/-2
Tensile Modulus (40°C)	8900 / -	MPa	ISO 527-1/-2
Tensile Modulus (100°C)	3700 / -	MPa	ISO 527-1/-2
Tensile Modulus (120°C)	3500 / -	MPa	ISO 527-1/-2
Tensile Modulus (150°C)	3150 / *	MPa	ISO 527-1/-2
Tensile Modulus (160°C)	3050 / *	MPa	ISO 527-1/-2
Stress at Break	150 / 105	MPa	ISO 527-1/-2
Stress at Break (-40°C)	235 / -	MPa	ISO 527-1/-2
Stress at Break (100°C)	85 / -	MPa	ISO 527-1/-2
Stress at Break (120°C)	80 / -	MPa	ISO 527-1/-2
Stress at Break (150°C)	70 / *	MPa	ISO 527-1/-2
Stress at Break (160°C)	65 / *	MPa	ISO 527-1/-2
Strain at Break	5 / 10	%	ISO 527-1/-2
Strain at Break (at -40°C)	5 / -	%	ISO 527-1/-2
Strain at Break (at 120°C)	14.3 / -	%	ISO 527-1/-2
Strain at Break (at 150°C)	15.2 / *	%	ISO 527-1/-2
Strain at Break (at 160°C)	15.5 / *	%	ISO 527-1/-2
Flexural Modulus	8500 / 4900	MPa	ISO 178
Flexural Strength	250 / 140	MPa	ISO 178
Charpy Impact Strength (at +23°C)	95 / 110	kJ/m²	ISO 179/1eU
Charpy Impact Strength (at -30°C)	100 / 100	kJ/m²	ISO 179/1eU
Charpy Notched Impact Strength (at +23°C)	23 / 43	kJ/m²	ISO 179/1eA
Charpy Notched Impact Strength (at -30°C)	15 / 15	kJ/m²	ISO 179/1eA

Thermal Properties

	Value	Units	Test Method / Conditions
Temperature of Deflection Under Load (1.80 MPa)	200 / *	°C	ISO 75-1/-2
Temperature of Deflection Under Load (0.45 MPa)	215 / *	°C	ISO 75-1/-2
Coefficient of Linear Thermal Expansion (parallel)	0.2 / *	E-4/°C	ISO 11359-1/-2
Coefficient of Linear Thermal Expansion (normal)	0.9 / *	E-4/°C	ISO 11359-1/-2
Burning Behaviour (at 3 / * mm Nominal Thickness)	UL HB / *	class	IEC 60695-11-10
Burning Behaviour (at 0.75 / * mm Nominal Thickness)	HB / *	class	IEC 60695-11-10
Relative Temperature Index (Electrical, 0.75 / * mm)	65 / *	°C	UL746B
Relative Temperature Index (with impact, 0.75 / * mm)	65 / *	°C	UL746B
Relative Temperature Index (without impact, 0.75 / * mm)	65 / *	°C	UL746B

Electrical Properties

	Value	Units	Test Method / Conditions
Relative Permittivity (100Hz)	3.8 / 14	—	IEC 62631-2-1
Relative Permittivity (1 MHz)	3.5 / 4.5	—	IEC 62631-2-1
Dissipation Factor (100 Hz)	90 / 3000	E-4	IEC 62631-2-1
Dissipation Factor (1 MHz)	150 / 1200	E-4	IEC 62631-2-1
Volume Resistivity	1E13 / 1E11	Ohm*m	IEC 62631-3-1
Surface Resistivity	- / 1E14	Ohm	IEC 62631-3-2
Electric Strength	25 / 20	kV/mm	IEC 60243-1
Comparative Tracking Index	- / 600	V	IEC 60112

Rheological Calculation Properties

	Value	Units	Test Method / Conditions
Density of Melt	1110 / *	kg/m³	—
Thermal Conductivity of Melt	0.28 / *	W/(m K)	—
Specific Heat Capacity Melt	2830 / *	J/(kg K)	—
Effective Thermal Diffusivity	8.99E-8 / *	m²/s	—

Other Properties

	Value	Units	Test Method / Conditions
Water Absorption	5.7 / *	%	Sim. to ISO 62
Humidity Absorption	1.7 / *	%	Sim. to ISO 62
Density	1320 / -	kg/m³	ISO 1183

Rheological Properties

	Value	Units	Test Method / Conditions
Melt Volume-Flow Rate (at 275 / * °C, 5 / * kg)	20 / *	cm³/10min	ISO 1133
Melt Flow Index (at 5 / * kg)	24 / *	g/10min	ISO 1133
Molding Shrinkage (parallel)	0.39 / *	%	ISO 294-4
Molding Shrinkage (normal)	1 / *	%	ISO 294-4

Regulatory & Compliance

Certifications & Compliance

ISO 14001,

OHSAS,

REACH (Europe),

UL 94

OEM Specifications

BMW GS 93016,

CALLOUT ISO 16396-PA 6-I,GF30,M1,S14-090,

GM GMW17385P-PA6 GF 30,

TOYOTA TSM5603G,

VW 50180

OEM Standards

BMW,

Callout,

General Motors,

Toyota,

Volkswagen

Quality Standards

UL Yellow Card (E47960)

Technical Details & Test Data

Chemical Resistance

Chemical Type	Chemical Name	Resistance
Other	Acetaldehyde (40% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Acetamide (50% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Acetamide (50% by mass) at >140°C	not resistant
Other	Acetic acid (10% by mass) at 100°C	not resistant
Other	Acetic acid (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Acetic acid (95% by mass) at 23°C	not resistant
Ketones	Acetone at 23°C	resistant
Other	Acetophenone at 23°C	resistant
Other	Acetyl chloride at 23°C	not resistant
Other	Acetylene at 23°C	resistant
Other	Acrylic acid at 23°C	not resistant
Other	Aliphatic amines at 23°C	resistant
Other	Aliphatic hydrocarbons at 23°C	resistant
Other	Alkylbenzenes at 23°C	resistant
Other	Allyl alcohol at 23°C	limited resistant, tests necessary to verify
Other	Aluminum acetate (saturated) at 23°C	resistant
Other	Aluminum chloride (10% by mass) at 23°C	resistant
Other	Aluminum hydroxide (saturated) at 23°C	resistant
Other	Aluminum salts of mineral acids (saturated) at 23°C	limited resistant, tests necessary to verify
Other	Aluminum trichloride (10% by mass) at 23°C	resistant
Other	Amino acids (saturated) at 23°C	resistant
Other	Ammonia at 23°C	resistant
Other	Ammonium chloride (35% by mass) at 100°C	limited resistant, tests necessary to verify
Other	Ammonium chloride (35% by mass) at 23°C	resistant
Other	Ammonium salts of mineral acids (10% by mass) at 23°C	resistant
Other	Ammonium salts of mineral acids (10% by mass) at 50°C	limited resistant, tests necessary to verify
Other	Ammonium thiocyanate (saturated) at 23°C	resistant
Other	Amyl acetate at 100°C	not resistant
Other	Amyl acetate at 23°C	resistant
Other	Amyl alcohol at 23°C	resistant
Other	Aniline at 23°C	not resistant
Other	Anodizing liquid (HNO3/H2SO4) at 23°C	limited resistant, tests necessary to verify
Other	Antimony trichoride (saturated) at 23°C	not resistant
Other	Aqua Regia (HCl/HNO3) at 23°C	not resistant
Other	Aromatic hydrocarbons at 23°C	resistant
Other	Bariumsalts of mineral acids at 23°C	limited resistant, tests necessary to verify
Other	Benzaldehyde at 23°C	limited resistant, tests necessary to verify
Other	Benzene at 23°C	resistant
Other	Benzene at 80°C	resistant
Other	Benzoic acid (20% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Benzoic acid (saturated) at 23°C	not resistant
Other	Benzyl alcohol at 23°C	limited resistant, tests necessary to verify
Other	Beverages at 23°C	resistant
Other	Bleaching agent (NaOCl) at 23°C	not resistant
Other	Boric acid (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Boron trifluoride at 23°C	not resistant
Other	Brake fluids (DOT 3/4) at 23°C	limited resistant, tests necessary to verify
Other	Bromine water (saturated) at 23°C	not resistant
Other	Bromochlorodifluoromethane at 23°C	resistant
Other	Bromotrifluoromethane at 23°C	resistant
Other	Butadiene at 23°C	resistant
Other	Butane at 23°C	resistant
Other	Butanediols at 23°C	resistant
Other	Butanediols at >140°C	limited resistant, tests necessary to verify
Other	Butanols at 23°C	resistant
Other	Butene glycol at 23°C	resistant
Other	Butene glycol at >160°C	limited resistant, tests necessary to verify
Other	Butene-1 at 23°C	resistant
Other	Butter at 23°C	resistant
Other	Butyl acetate at 23°C	resistant
Other	Butyl acrylate at 23°C	resistant
Other	Butyl glycolate at 23°C	resistant
Other	Butyl phthalate at 23°C	resistant
Other	Butyric acid (20% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Butyrolactone at 23°C	resistant
Other	Butyrolactone at >90°C	limited resistant, tests necessary to verify
Other	Calcium chloride (10% by mass) at 100°C	limited resistant, tests necessary to verify
Other	Calcium chloride (10% by mass) at 23°C	resistant
Other	Calcium chloride (alcoholic) (20% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Calcium chloride (saturated) at 100°C	not resistant
Other	Calcium chloride (saturated) at 23°C	resistant
Other	Calcium chloride (saturated) at 60°C	limited resistant, tests necessary to verify
Other	Calcium hydroxide (saturated) at 23°C	resistant
Other	Calcium hypochloride (saturated) at 23°C	not resistant
Other	Camphor (alcoholic) (50% by mass) at 23°C	resistant
Other	Caprolactam (50% by mass) at 23°C	resistant
Other	Caprolactam (50% by mass) at >150°C	limited resistant, tests necessary to verify
Other	Carbon disulfide at 23°C	resistant
Other	Carbon disulfide at 60°C	not resistant
Other	Carbon tetrachloride at 23°C	resistant
Other	Casein at 23°C	resistant
Other	Chloral hydrate at 23°C	not resistant
Other	Chloramines (10% by mass) at 23°C	not resistant
Other	Chlorinated biphenyls at 80°C	limited resistant, tests necessary to verify
Other	Chlorine water at 23°C	not resistant
Other	Chloroacetic acid (10% by mass) at 23°C	not resistant
Other	Chlorobenzene at 23°C	resistant
Other	Chlorobenzene at 50°C	resistant
Other	Chlorobromomethane at 23°C	limited resistant, tests necessary to verify
Other	Chlorodifluoroethane at 23°C	resistant
Other	Chlorodifluoromethane at 23°C	resistant
Other	Chlorofluoroethylene at 23°C	resistant
Other	Chloroform at 23°C	not resistant
Other	Chlorosulfonic acid (10% by mass) at 23°C	not resistant
Other	Chromic acid (1% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Chromic acid (10% by mass) at 23°C	not resistant
Other	Chromyl chloride at 23°C	not resistant
Other	cis-2-butene at 23°C	resistant
Other	Citric acid (10% by mass) at 23°C	resistant
Other	Citric acid (20% by mass) at 80°C	limited resistant, tests necessary to verify
Other	Cobalt salt (20% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Copper sulfate (10% by mass) at 23°C	resistant
Other	Copper(II) salt (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Cresols at 23°C	not resistant
Other	Cycloalcohols (incl their esters) at 23°C	resistant
Other	Cycloalkanes at 23°C	resistant
Other	Cycloalkanones at 23°C	resistant
Other	Cyclohexanol at 23°C	limited resistant, tests necessary to verify
Other	Decalin at 23°C	resistant
Other	Developer (photografic) at 23°C	resistant
Other	Dibutyl phthalate at 23°C	resistant
Other	Dibutyl phthalate at 60°C	resistant
Other	Dichlorobenzene at 23°C	resistant
Other	Dichloroethane at 23°C	resistant
Other	Dichloroethylene at 23°C	resistant
Other	Dichlorofluoromethane at 23°C	resistant
Other	Dichlorotetrafluoroethane at 23°C	resistant
Ethers	Diethyl ether at 23°C	resistant
Other	Diethylene glycol at 23°C	resistant
Other	Diethylene glycol at >140°C	not resistant
Other	Difluoromethane at 23°C	resistant
Other	Dimethyl acetamide at 23°C	resistant
Other	Dimethyl acetamide at >150°C	not resistant
Other	Dimethyl ether at 23°C	resistant
Other	Dimethylamine at 23°C	resistant
Other	Dimethylformamide at 23°C	resistant
Other	Dimethylformamide at 90°C	limited resistant, tests necessary to verify
Other	Dimethylsilane at 23°C	resistant
Other	Dimethylsulfoxide at 125°C	not resistant
Other	Dimethylsulfoxide at 23°C	resistant
Other	Dioctyl phtalate at 23°C	resistant
Other	Dioxan at 23°C	resistant
Other	Dioxan at 60°C	resistant
Other	Diphenyl ether at 80°C	resistant
Other	Dipropyl ether at 23°C	resistant
Other	Edible fats waxes and oils at 100°C	resistant
Other	Electroplating bath (acidic) at 23°C	not resistant
Other	Electroplating bath (alkali) at 23°C	resistant
Other	Ethane at 23°C	resistant
Alcohols	Ethanol at 23°C	resistant
Other	Ethyl Acetate at 23°C	resistant
Other	Ethyl chloride at 23°C	resistant
Other	Ethylene at 23°C	resistant
Other	Ethylene carbonate at 100°C	not resistant
Other	Ethylene carbonate at 50°C	resistant
Other	Ethylene chlorohydrin at 23°C	limited resistant, tests necessary to verify
Other	Ethylene glycol at 100°C	not resistant
Other	Ethylene glycol at 23°C	resistant
Other	Ethylene oxide at 23°C	resistant
Other	Ethylene oxide at >80°C	not resistant
Other	Ethylenediamine at 23°C	resistant
Other	Fatty acids at 23°C	resistant
Other	Fatty alcohols at 23°C	resistant
Other	Ferric chloride (2,5% by mass) at 100°C	not resistant
Other	Ferric chloride (2,5% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Fixer (photografic) at 23°C	resistant
Other	Fluorinated hydrocarbons at 70°C	resistant
Other	Fluorine at 23°C	not resistant
Other	Formaldehyde (30% by mass) at 23°C	resistant
Other	Formamide at 23°C	resistant
Other	Formamide at >150°C	not resistant
Other	Formic acid (10% by mass) at 23°C	not resistant
Other	Formic acid (10% by mass) at 50°C	not resistant
Other	Fruit juices at 23°C	resistant
Other	Fuel; Diesel at 85°C	resistant
Other	Fuel; FAM 1A at 23°C	resistant
Other	Fuel; FAM 2A at 23°C	resistant
Other	Fuel; Gasoline at 85°C	resistant
Other	Furfural at 23°C	resistant
Other	Furfuryl alcohol at 23°C	resistant
Other	Glycerol at 170°C	not resistant
Other	Glycerol at 23°C	resistant
Other	Glycolic acid (30% by mass) at 23°C	not resistant
Other	Glycols at 23°C	resistant
Other	Grease (based on ester oils) at <100°C	limited resistant, tests necessary to verify
Other	Grease (based on metal soaps) at <100°C	resistant
Other	Grease (based on polyphenylester) at <100°C	resistant
Other	Hardening oils at 23°C	resistant
Other	Heating oils at 23°C	resistant
Other	Heptane at 23°C	resistant
Other	Hexachlorobenzene at 80°C	resistant
Other	Hexachloroethane at 23°C	resistant
Other	Hexafluoroisopropanol at 23°C	not resistant
Other	Hexane at 23°C	resistant
Other	Hydraulic fluids at 100°C	resistant
Other	Hydrobromic acid (10% by mass) at 23°C	not resistant
Other	Hydrochloric acid (10% by mass) at 23°C	not resistant
Other	Hydrochloric acid (20% by mass) at 23°C	not resistant
Other	Hydrochloric acid (conc.% by mass) at 23°C	not resistant
Other	Hydrofluoric acid (40% by mass) at 23°C	not resistant
Other	Hydrofluoric acid (5% by mass) at 23°C	not resistant
Other	Hydrogen at 23°C	resistant
Other	Hydrogen peroxide (0.5% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Hydrogen peroxide (1% by mass) at 23°C	not resistant
Other	Hydrogen peroxide (3% by mass) at 23°C	not resistant
Other	Hydrogen peroxide (30% by mass) at 23°C	not resistant
Other	Hydrogen sulfide (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Hydroiodic acid at 23°C	not resistant
Other	Hydroquinone (5% by mass) at 23°C	not resistant
Other	Impregnating oils at 23°C	resistant
Other	Ink at 23°C	resistant
Other	Iodine (alcoholic) at 23°C	not resistant
Other	Iron(III)chloride (acidic) (10% by mass) at 23°C	not resistant
Other	Iron(III)chloride (neutral) (10% by mass) at 23°C	resistant
Other	Iron(III)chloride (saturated) at 23°C	not resistant
Other	Iron(III)thiocyanate (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Isocyanates (aromatic) at 23°C	resistant
Other	Isooctane at 80°C	resistant
Other	Isopropanol at 23°C	resistant
Other	Isopropanol at 60°C	resistant
Other	Ketones (aliphatic) at 23°C	resistant
Other	Lactic acid at 10°C	resistant
Other	Lactic acid at 90°C	not resistant
Other	Lead acetate (10% by mass) at 23°C	resistant
Other	Linseed oil at 23°C	resistant
Other	Lithium bromide (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Lithium chloride (20% by mass) at 23°C	not resistant
Other	Lithium hydroxide (10% by mass) at 23°C	resistant
Other	Lithium hydroxide (10% by mass) at 80°C	not resistant
Other	Lubricating oil (gear) at <130°C	resistant
Other	Lubricating oil (hydraulics) at <130°C	resistant
Other	Lubricating oil (transformers) at <130°C	resistant
Other	Magnesium hydroxide (10% by mass) at 23°C	resistant
Other	Magnesium salts (10% by mass) at 23°C	resistant
Other	Maleic acid (25% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Maleic acid (saturated) at 23°C	resistant
Other	Manganese salts (10% by mass) at 23°C	resistant
Other	Mercury at 23°C	resistant
Other	Mercury(II)chloride (saturated) at 23°C	not resistant
Other	Methane at 23°C	resistant
Alcohols	Methanol at 23°C	resistant
Other	Methyl acetate at 23°C	resistant
Other	Methyl chloride at 23°C	resistant
Other	Methyl ethyl ketone at 23°C	resistant
Other	Methyl formate at 23°C	resistant
Other	Methyl glycol at 23°C	resistant
Other	Methylamine at 23°C	resistant
Other	Methylaniline at 23°C	resistant
Other	Methylbromide at 23°C	resistant
Other	Methylene chloride at 23°C	limited resistant, tests necessary to verify
Other	Methylpyrrolidone at 23°C	resistant
Other	Milk at 23°C	resistant
Other	n-Butyl ether at 23°C	resistant
Other	n-Butyl glycol at 23°C	resistant
Other	Naphtha at 23°C	resistant
Other	Naphthalene at 23°C	resistant
Other	Naphthalenesulfonic acids at 23°C	not resistant
Other	Naphthenic acids at 23°C	resistant
Other	Naphthols at 23°C	not resistant
Other	Nickel nitrate (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Nickel salts (10% by mass) at 23°C	resistant
Other	Nitric acid (10% by mass) at 23°C	not resistant
Other	Nitric acid (2% by mass) at 23°C	not resistant
Other	Nitric acid (20% by mass) at 23°C	not resistant
Other	Nitric acid (conc.% by mass) at 23°C	not resistant
Other	Nitrobenzene at >100°C	not resistant
Other	Nitrocellulose lacquers (non-alcoholic) at 23°C	resistant
Other	Nitrotoluene at >100°C	not resistant
Other	Nitrous oxide at 23°C	resistant
Other	Octane at 23°C	resistant
Other	Octene at 23°C	resistant
Other	Oil (Shell 10W40) at 23°C	resistant
Other	Oil (transformers, switchgear) at 50°C	resistant
Other	Oils (vegatable, mineral, ethereal) at 23°C	resistant
Other	Oleic acid at 23°C	resistant
Other	Oleum (H2SO4+SO3) at 23°C	not resistant
Other	Oxalic acid (10% by mass) at 80°C	not resistant
Other	Ozone at 23°C	not resistant
Other	Paint solvents at 23°C	resistant
Other	Palmatic acid at 80°C	resistant
Other	Paraffin at 23°C	resistant
Other	Peracetic acid at 23°C	not resistant
Other	Perchloric acid (10% by mass) at 23°C	not resistant
Other	Petroleum at 23°C	resistant
Other	Petroleum ether and solvents at 80°C	resistant
Other	Phenol (conc.% by mass) at 23°C	not resistant
Other	Phenol at >40°C	not resistant
Other	Phenyl ether at 23°C	not resistant
Other	Phenyl ethyl alcohol at >160°C	not resistant
Other	Phosphate sol. (neutral, alkaline) (10% by mass) at 23°C	resistant
Other	Phosphine at 23°C	resistant
Other	Phosphoric acid (10% by mass) at 23°C	not resistant
Other	Phosphoric acid (conc.% by mass) at 23°C	not resistant
Other	Polyols at 23°C	resistant
Other	Potassium chloride (10% by mass) at 23°C	resistant
Other	Potassium chloride (10% by mass) at 70°C	resistant
Other	Potassium nitrate (10% by mass) at 23°C	resistant
Other	Potassium permanganate (1% by mass) at 23°C	not resistant
Other	Potassium thiocyanate (saturated) at 23°C	not resistant
Other	Propane at 23°C	resistant
Other	Propanol at 23°C	resistant
Other	Propanol at >100°C	not resistant
Other	Propene at 23°C	resistant
Other	Propionic acid (5% by mass) at 23°C	resistant
Other	Propionic acid (50% by mass) at 23°C	not resistant
Other	Pyridine at 23°C	resistant
Other	Pyrocatechol at 23°C	not resistant
Other	Pyrrolidone at 23°C	resistant
Other	Rainwater (acidic) at 23°C	resistant
Other	Refrigerator oil at 23°C	resistant
Other	Resorcinol (alcoholic) (50% by mass) at 23°C	not resistant
Other	Road salts at 23°C	resistant
Other	Salicylic acid (saturated) at 23°C	resistant
Other	Seawater at 23°C	resistant
Other	Silane at 23°C	resistant
Other	Silicone oils at <80°C	resistant
Other	Silver nitrate (10% by mass) at 23°C	resistant
Other	Soap solution (10% by mass) at 80°C	resistant
Other	Sodium bichromate (10% by mass) at 23°C	resistant
Other	Sodium bichromate (5% by mass) at 23°C	resistant
Other	Sodium carbonate (10% by mass) at 23°C	resistant
Other	Sodium chlorate (10% by mass) at 23°C	resistant
Other	Sodium chloride (10% by mass) at 23°C	resistant
Other	Sodium chloride (saturated) at 23°C	resistant
Other	Sodium cyanide (10% by mass) at 23°C	resistant
Other	Sodium dichromate (10% by mass) at 23°C	resistant
Other	Sodium dodecylbenzenesulfonate at 23°C	resistant
Other	Sodium hydrogen carbonate (10% by mass) at 23°C	resistant
Other	Sodium hydrogen sulfate (10% by mass) at 23°C	resistant
Other	Sodium hydrogen sulfite (10% by mass) at 23°C	resistant
Other	Sodium hydroxide (10% by mass) at 23°C	resistant
Other	Sodium hydroxide (10% by mass) at 80°C	not resistant
Other	Sodium hypophosphite (10% by mass) at 23°C	resistant
Other	Sodium lauryl sulfate (30% by mass) at 23°C	resistant
Other	Sodium lignosulfonate at 23°C	resistant
Other	Sodium nitrilotriacetate (10% by mass) at 23°C	resistant
Other	Sodium oleate at 23°C	resistant
Other	Sodium pentachlorophenolate at 23°C	resistant
Other	Sodium pyrosulfite (10% by mass) at 23°C	resistant
Other	Sodium salts (nitrate, sulfate) (10% by mass) at 23°C	resistant
Other	Soldering fluid at 23°C	not resistant
Other	Stearate at 23°C	resistant
Other	Stearic acid at 23°C	resistant
Other	Styrene at 80°C	resistant
Other	Sulfonates (10% by mass) at 23°C	resistant
Other	Sulfur at 23°C	resistant
Other	Sulfur dioxide (dry) at 23°C	resistant
Other	Sulfur hexafluoride at 23°C	resistant
Other	Sulfuric acid (2% by mass) at 23°C	not resistant
Other	Sulfuric acid (30% by mass) at 23°C	not resistant
Other	Sulfuric acid (50% by mass) at 23°C	not resistant
Other	Sulfuric acid (conc.% by mass) at 23°C	not resistant
Other	Tartaric acid (10% by mass) at 23°C	resistant
Other	Tetrachloroethylene at 80°C	not resistant
Other	Tetrachloromethane at 23°C	resistant
Other	Tetrafluoromethane at 23°C	resistant
Other	Tetrafluoropropanol at 23°C	not resistant
Other	Tetrahydrofuran at 23°C	resistant
Other	Tetralin at 23°C	resistant
Other	Tetramethylenesulfone at 23°C	resistant
Other	Toluene at 100°C	resistant
Hydrocarbons	Toluene at 23°C	resistant
Other	Transformer oil at 23°C	resistant
Other	Trichloroacetic acid (50% by mass) at 23°C	not resistant
Other	Trichloroethane at 45°C	resistant
Other	Trichloroethanol at 23°C	not resistant
Other	Trichloroethylene at >40°C	not resistant
Other	Trichlorotrifluoroethane at 23°C	resistant
Other	Trietanolamine at 23°C	resistant
Other	Trifluoroethanol at 23°C	not resistant
Other	Trimethylamine at 23°C	resistant
Other	Turpentine oil at 23°C	resistant
Other	Turpentine substitute at 23°C	resistant
Other	Uranium fluoride at 23°C	not resistant
Other	Urea (20% by mass) at 23°C	resistant
Other	Uric acid (20% by mass) at 23°C	resistant
Other	Urine at 23°C	resistant
Other	Vaseline (acid free) at 23°C	resistant
Other	Vinyl bromide at 23°C	resistant
Other	Vinyl chloride at 23°C	resistant
Other	Vinyl fluoride at 23°C	resistant
Other	Water (chlorinated) at 80°C	resistant
Other	Water at 23°C	resistant
Other	Wax at 80°C	resistant
Other	Xylene at 100°C	resistant
Other	Xylene at 23°C	resistant
Other	Yeast at 23°C	resistant
Other	Zinc bromide (30% by mass) at 23°C	not resistant
Other	Zinc chloride (10% by mass) at 23°C	limited resistant, tests necessary to verify
Other	Zinc chloride (37% by mass) at 23°C	not resistant
Other	Zinc chloride at 23°C	resistant
Other	Zinc iodide (30% by mass) at 23°C	not resistant
Other	Zinc nitrate (30% by mass) at 23°C	not resistant
Other	Zinc thiocyanate (30% by mass) at 23°C	not resistant
Other	Zinc(II)salts of mineral acids (10% by mass) at 23°C	limited resistant, tests necessary to verify

Creep Modulus-Time 120°C (dry)

Envalior's Automotive Weight Loss Factory

Extreme light weighting of automobiles is the most efficient technology for reducing emissions and enhancing mileage. The Envalior Weight Loss Factory utilizes unidirectional, continuous fiber-reinforced, thermoplastic tapes as the fundamental building block of such light weight composite materials.

Our strategy extends well beyond just manufacturing the composite tapes. We also develop and specify processes such as Automatic Tape Placement (ATP), tape winding and tape-insert over-molding. and the necessary computer aided engineering (CAE) for part design and manufacturing process specifications. Envalior is active in the industry in specifying and standardizing composite material testing and quality specifications.

 

UD tape processes

 

UD tape manfucaturing process

1. Tape winding of parts with rotational symmetry (cylinders, tubes, box-beams etc.).
2. Automatic Tape Laying (ATL) (panels, sheets, etc.)
   • ATL panels are thermoformed to net shape
   • ATL panels are over-molded with structural features (ribs, etc.).
3. Hybrid metal-composite construction (composite patches glued to metal).

 

Technology and support

Design and CAE

• FEM analyzes (static & high-strain)
• Thermoforming and over-molding simulation
• UD tape winding and simulation
• Mold flow analyzes (injection-molding)

In-house macro & micro structural analysis of UD tapes

• Material-modeling and micro-mechanics
• Micro CT scans (void content, fiber-filament orientation, fiber-matrix adhesion, etc.)
• SEM micrography
• Tensile, flexural and impact testing.

Bonding

• Composite to plastic
• Composite to metal (with and without adhesives). 

Machinery for Injection Molding

Akulon® grades can be processed on general injection molding machines.
Screw Geometry

• Typically 3-zone screw designs with volumetric compression ratios of approximately 2.5 work fine.

Steel Type

• Abrasive & corrosion resistant tool steels which are normally used for glass and/or mineral reinforced, flame retardant materials are also to be used for Akulon® polymers in tools, nozzles and screws.

Nozzle Temperature Control

• The use of an open nozzle with good temperature control and an independently-controlled thermocouple nearby the tip and heater bands with sufficient output is recommended.

Hot Runner Layout

• Try to achieve a close contact with your hot runner supplier and Envalior as the material supplier, to be sure that the right hot runner system is chosen.
• When processing Akulon® with hot runners, keep in mind these basic rules:

1. Central bushing heated separately
2. Only use external heated system
3. Manifold heated from both sides
4. Tip with thermocouple in front (near gate)
5. Very accurate temperature control in the gate area

Temperature Settings For Injection Molding

Mold Temperature

• Akulon® can be used with a wide range of tool temperatures (50 - 80°C / 122 - 176°F). However, we recommend a low mold temperature for parts with thick walls and a high mold temperature for good dimensional stability, flow properties and surface esthetics.
• Furthermore, for impact modified grades (P in the grade coding) a low mold temperature can prevent mold sticking, resulting in a better surface appearance.

Barrel Temperature

• Optimal settings are governed by barrel size and residence time. Furthermore, the level of glass and/or mineral reinforcement and the presence or absence of flame retardant have to be taken into account.

 

Mold/Tool	Measured melt	Nozzle	Front	Center	Rear
50 - 80°C 122 - 176°F	245-265°C 473-509°F	235-255°C 455-491°F	235-250°C 455-482°F	230-240°C 446-464°F	225-235°C 437-455°F

Melt Temperature

• To generate a good and homogeneous melt, the melt temperature should always be above 245°C / 473°F. Optimal mechanical properties will be achieved at melt temperatures between 245-265°C / 473-509°F.
• We advise to frequently measure the melt temperature by pouring the melt in a Teflon cup and inserting a thermo probe into the melt.

Hot Runner Temperature

• A hot runner temperature set to the same level as the nozzle temperature should work fine and not lead to excessive overheat of the Akulon® grade. When starting up, an increased tip temperature may be necessary to overcome a frozen nozzle.

Creep Modulus-Time 23°C (cond.)

General Processing Settings For Injection Molding

Screw Rotation Speed

• To realize a good and homogeneous melt, it is advised to set a screw rotation speed resulting in a plasticizing time that is just within the cooling time.
• The rotational speed of the screw should not exceed 6500 / D RPM (where D is the screw diameter in mm).

Back Pressure

• Back pressure should be between 30-100 bars effective. Keep it low in order to prevent nozzle-drooling, excessive shear heating and long plasticizing times.

Injection Speed

• Moderate to high injection speeds are required in order to prevent premature crystallization in the mold during injection phase and to obtain a better surface finish. Adequate mold venting is required to avoid burning at the end of the flow path (due to diesel effect).

Decompression

• In order to prevent nozzle drool after plasticizing and retracting the nozzle from the mold, a short decompression stroke can be used. However, to prevent oxidation of the melt, which may result in surface defects on the parts, it is recommended to keep this as short as possible.

Injection Pressure

• The real injection pressure is the result of the flowability of the material (crystallization rate, flow length, wall thickness, filling speed). The set injection pressure should be high enough to maintain the set injection speed (use set injection pressure higher than the peak pressure if possible). Tooling air vents must be effective to allow optimum filling pressure and prevent burn marks.

Holding Time

• Effective holding time is determined by part thickness and gate size. Holding time should be maintained until a constant product weight is achieved.

Holding Pressure

• The most adequate holding pressure is the level whereby no sinkmarks or flash are visible. A too high holding pressure can lead to stresses in the part.

Cooling Time

• Actual cooling time will depend on part geometry and dimensional quality requirements as well as the tool design (gate size).

Creep Modulus-Time 90°C (dry)

Melt Residence Time For Injection Molding

The optimal Melt Residence Time (MRT) for Akulon® K224-PG6 is ≤ 4 minutes with preferably at least 50% of the maximal shot volume used. The MRT should not exceed 6 minutes.

A formula to estimate the MRT is described below:
MRT = (∏D³ρ/m) * (t/60)
Whereas:
MRT = Melt Residence Time [minutes]
D = Screw Diameter [cm]
p = Melt Density [g/cm3)
m = Shot Weight [g]
t = Cycle Time [s]

Please note: In the calculation above, the hotrunner volume has not been taken into account. When a hotrunner is part of the setup, please add the hotrunner volume to the calculation.

Dynamic Shear Modulus (G)-Temperature (dry)

Dynamic Tensile Modulus (E)-Temperature (dry)

Startup/Shut Down/Cleaning For Injection Molding

• Production has to be started and stopped with a clean machine. Cleaning can be done with Akulon® K224-PG6, applicable cleaning agents or HDPE. Hot runners can also be cleaned and put out of production cleaning them with
  Akulon® K224-PG6.

Specific Volume-Temperature (pvT)

Production Breaks For Injection Molding

• During production breaks longer than a few minutes, we advise emptying the barrel. The temperature of the barrel and the hot runner [if applicable) should be reduced to a level far enough below the melting point of the compound in order to stop decomposition of the compound.
• When the hot runner, nozzle, or even the screw is blocked, be aware that under these conditions a sudden outburst of molten material can take place. Always wear personal safety protections for hand/eye/body.

Stress-Strain (cond.)

Stress-Strain (dry)

Viscosity-Shear Rate

Packaging & Availability

Packaging Type

Bags,

Boxes,

Silos,

Super Sacks

Storage & Handling

Material Handling For Injection Molding

Storage

• In order to prevent moisture pick up and contamination, supplied packaging should be kept closed and undamaged. For the same reason, partial bags should be sealed before re-storage. Allow the material that has been stored elsewhere to adapt to the temperature in the processing room while keeping the bag closed.

Packaging

• Akulon® grades are supplied in airtight, moisture- proof packaging.

Moisture Content as Delivered

• Akulon® grades are packaged at a moisture level ≤ 0.15 w%.

Conditioning Before Molding

• To prevent moisture condensing on granules, bring cold granules up to ambient temperature in the molding shop while keeping the packaging closed.

Moisture Content Before Molding

• Akulon® is delivered at molding moisture specification (≤ 0.15 w%). We advise to pre-dry to overcome the fluctuation from package to package (see drying section below). Furthermore, pre-drying is required in case the material is exposed to moisture before molding (prolonged storage or open/damaged packaging). Moisture content can be checked by water evaporation methods or manometric methods (ISO 15512).

Drying

• Akulon® grades are hygroscopic and absorb moisture from the air relatively quickly. Moisture absorption is fully reversible under the following drying conditions without compromising material quality. Preferred driers are dehumidified driers with dew points maintained between -30 and -40°C / -22 and -40°F. Vacuum driers with N, purge can also be used. Hot air ovens or hopper driers are not suitable for pre-drying Akulon® grades; the use of such driers may result in non-optimum performance. 

Moisture content	Time	Temperature
[%]	[h]	[°c]	[°F]
0.1-0.2 and as delivered	2-4	80	176
0.2-0.5	4-8	80	176

Drier types that are not de-humidified can be operated until 100°C but care has to be taken with natural/light colors for which a color change might be observed upon drying depending on time/temperature exposure.

Regrind

• Regrind can be used taking into account that this regrind must be clean/low dust content/not thermally degraded/dry, of same composition and similar particle size as the original material. The acceptable level of regrind depends on the application requirements (e.g. UL Yellow Card). Be aware that regrind can cause some small color deviations.