AMODEL

®
polyphthalamide

design guide
version 3.1
Solvay Gives You
More Plastics with More Performance
than Any Other Company in the World
With over a dozen distinct families of high-performance and Our semi-crystalline aromatic polyamides:
ultra-performance plastics, Solvay Advanced Polymers gives
• Amodel polyphthalamide (PPA)
®

you more material choices to more perfectly match your

• Ixef polyarylamide (PA MXD6)
®
application needs. Plus, we give you more global support for
developing smart new designs.
Additional semi-crystalline polymers:
We offer hundreds of product formulations – including mod-
• Primef polyphenylene sulfide (PPS)
®

ified and reinforced resins – to help you tailor a solution to

• Xydar liquid crystal polymer (LCP)
®
meet your precise requirements. From physical properties
and processability, to appearance and agency approvals –
Our SolvaSpire™ family of ultra polymers:
our plastics deliver more solutions.
• KetaSpire polyetheretherketone (PEEK)
™

Our family of amorphous sulfone polymers:

• AvaSpire modified PEEK
™
• Udel polysulfone (PSU)
®

• PrimoSpire self-reinforced polyphenylene (SRP)

™ (1)
• Mindel modified polysulfone
®

• EpiSpire high-temperature sulfone (HTS)

™
• Radel R polyphenylsulfone (PPSU)
®

• Torlon polyamide-imide (PAI)

®
• Radel A polyethersulfone (PESU)
®

(1) Formerly Parmax SRP by Mississippi Polymer Technologies, Inc., a

• Acudel modified polyphenylsulfone
®
company acquired by Solvay Advanced Polymers.

mers
opoly
Fluor

LCP XD6
PA M P PA ides
,
P P S lty Polyam
ia
Spec

COC
, PPC
, PC,
ABS, PV PET 6,6
PMM PUR, PDC PBT, PA 6, PA HMW
A, PE ,
P
X, X L O POM TPV, PE U
PE TPO,
 Abbreviations used in this Manual
Abbreviation Meaning
ABS acrylonitrile-butadiene-styrene
ASTM American Society for Testing and Materials
AWG American Wire Gauge
Btu British thermal unit
CLTE coefficient of linear thermal expansion
CTI comparative tracking index
DAM “dry, as molded”
DSC differential scanning calorimetry
EMI electromagnetic interference
FD flow direction
GF glass filled
GR glass reinforced
HDT heat deflection (distortion) temperature
HS heat stabilized
HVATR high voltage arc tracking rate
HWI hot wire ignition
Hz Hertz
IR infrared
ISO International Organization for Standardization
kpsi kilo (1000) pounds per square inch
MF mineral filled
NBS National Bureau of Standards
PA polyamide
PEI polyetherimide
PEEK polyetheretherketone
PET polyethylene terephthalate
PLC Performance Level Class (UL 746A)
PPA polyphthalamide
PPS polyphenylene sulfide
psi pounds per square inch
RFI radio frequency interference
RH relative humidity
RTI relative thermal index
SI International System of Units
TD transverse direction
TMA thermomechanical analysis
UL Underwriters Laboratories Inc.
UV ultraviolet radiation
 Table of Contents
Introduction· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1
Chemistry - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Crystallinity · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1
Amodel PPA Base Resin Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1
Moisture Effects · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-3
Amodel Resin Property Tables · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1
Nomenclature- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Product Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Typical Property Tables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
Typical Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3
Glass-Reinforced Grades - Mechanical Properties - US units· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-4
Glass-Reinforced Grades - Mechanical Properties - SI units · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-5
Glass-Reinforced Grades - Thermal, Electrical, and General Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6
Toughened Grades - Mechanical Properties - US units · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-7
Toughened Grades - Mechanical Properties - SI Units · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-8
Toughened Grades - Thermal, Electrical, and General Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-9
Toughened Glass-Reinforced and Flame Retardant Grades - Mechanical Properties - US units · · · · · · · · · · · · · · · 2-10
Toughened Glass-Reinforced and Flame Retardant Grades - Mechanical Properties - SI units· · · · · · · · · · · · · · · · 2-11
Toughened Glass-Reinforced and Flame Retardant Grades - Thermal, Electrical, and General Properties · · · · · · · 2-12
Mineral and Mineral/Glass Filled Grades - Mechanical Properties - US units · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-13
Mineral and Mineral/Glass Filled Grades - Mechanical Properties - SI units· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-14
Mineral and Mineral/Glass Filled Grades - Thermal, Electrical, and General Properties · · · · · · · · · · · · · · · · · · · · · 2-15
Mechanical Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1
Short-term Mechanical Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Tensile Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1
Test Methods · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1
Tensile Property Comparison · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2
Tensile Properties for GR PPA vs. Temperature · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3
Tensile Properties of A-1000 GR Grades at Elevated Temperatures· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-4
Flexural Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5
Test methods · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5
Flexural Property Comparison · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5
Flexural Properties at Elevated Temperatures · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-6
Shear Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-7
Compressive Strength and Modulus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-8
Impact Strength · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9
Izod (Cantilevered Beam) Impact· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9
Izod Impact Property Comparison · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9
Charpy (Supported Beam) Impact · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-10
Falling Weight Impact Properties· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-11
Poisson’s Ratio · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-11
Long-term Mechanical Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Creep · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-2
Tensile Creep · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3
Isochronous Stress/Strain Curves · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-4
Tensile Creep Rupture · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-5
Flexural Creep· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-5
Compressive Creep· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-6
Fatigue Resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-6
Fatigue Strength of Amodel resin · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-6
Moisture Effects · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-8
Significance of Moisture Absorption · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-8
Moisture Absorption and Glass Transition Temperature (Tg) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-8
Absorption Amount · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-9
i
 Table of Contents - continued
Effect of Moisture on Strength and Stiffness · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-9
Dimensional Change due to Moisture · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-9
Dimensional Change Compared to PA 66 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10
Thermal Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Heat Deflection Temperature - HDT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-1
Deflection Temperature Values for Amodel Resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2
Coefficient of Linear Thermal Expansion · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2
Thermal Conductivity · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-4
Thermal Conductivity of Amodel PPA Resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-4
Specific Heat· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-5
Thermal Stability· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6
Thermogravimetric Analysis (TGA)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6
Thermal Aging · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6
Relative Thermal Index (UL)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6
Combustion Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-8
Glow Wire Testing· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-8
Relative Thermal Indices of Amodel PPA Grades · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-8
Smoke Density Test (NBS) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-9
Vertical Flammability per UL 94· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-10
Horizontal Burning Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-10
20 MM Vertical Burn Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-10
500 W Vertical Burning Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-10
UL94 Ratings of Amodel PPA Grades· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-11
Electrical Properties- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Dielectric Breakdown Voltage and Strength - ASTM D 149 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1
Volume Resistivity - ASTM D 257 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1
Surface Resistivity - ASTM D 257 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1
Dielectric Constant - ASTM D 150· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-2
Dissipation Factor - ASTM D 150 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-2
UL 746A Short-Term Properties · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-2
High-Voltage, Low-Current, Dry Arc Resistance - ASTM D 495 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-2
Comparative Tracking Index (CTI) - ASTM D 3638· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
High-Voltage Arc-Tracking-Rate (HVTR) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
Hot Wire Ignition (HWI) - ASTM D 3874 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
High-Current Arc Ignition (HAI) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
High-Voltage Arc Resistance to Ignition · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4
UL 746A Properties of Amodel Resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4
UL Relative Thermal Indices · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4
UL 746A Property PLC for Amodel PPA Grades · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4
Environmental Resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-1
Chemical Resistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Chemical Compatibility · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-5
Gamma Radiation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6
Design Information · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-1
Mechanical Design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2
Maximum Stress and Deflection Equations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-3
Area and Moment Equations for Selected Cross-Sections · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-4
Using Classical Stress/Strain Equations· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-5
Deflection Calculations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-6
Stress calculations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-6
Reinforcing Fiber
Orientation Considerations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-6
Designing for Equivalent Part Stiffness · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-7
Changing Section Thickness · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-7
ii
 Table of Contents - continued
Adding Ribs to Maintain Stiffness · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-8
Designing for Sustained Load · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-9
Calculating Deflection · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-9
Calculating Allowable Stress - Creep Rupture · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-10
Considering Stress Concentrations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-11
Considering Thermal Stresses· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-12
Loss of Bolt Tightness Due to Creep · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-13
Designing for Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-14
Interference or Press Fits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-14
Calculating the Allowable Interference · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-14
Mechanical Fasteners · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-15
Self-tapping Screws · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-15
Improving Torque Retention · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-16
Tightening Torque· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-16
Pull out force calculation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-16
Threaded Inserts· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-17
Molded-in Threads · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-18
Designing with Snap Fits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-18
Straight Cantilever Beam Equation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-18
Tapered Cantilever Beam Equation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-19
Designing for Injection Molding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-20
Wall Thickness · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-20
Wall Thickness Variation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-20
Draft Angle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-21
Ribs · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-21
Coring· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-22
Bosses · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-22
Undercuts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-23
Secondary Operations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-1
Welding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
Hot Plate Welding · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-1
Vibrational Welding · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-1
Spin Welding· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-2
Ultrasonic Welding · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-2
Adhesive Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-3
Coatings and Surface Finishes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4
Vacuum Metallizing· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-4
Laser Marking· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-4
Inkjet Printing · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-4
Painting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-4
Overmolding · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-5

iii
 may be used to distinguish these polymers from those of
Introduction solely aliphatic raw materials.
Polyamide 6,T produced by the condensation of
Amodel polyphthalamide (PPA) resins were commercialized hexamethylene diamine with terephthalic acid, has long
in 1991. Polyphthalamide resin technology can produce a been recognized for its excellent dimensional stability, low
wide range of polymers that includes both semi-crystalline moisture absorption, high strength, and heat resistance. The
and amorphous resins. Since 1991, several base polymer fundamental problem preventing its commercialization has
formulations have been commercialized to meet specific been that its high crystalline melting point of 370°C (698°F)
industry needs. All of the commercial Amodel products are is above its thermal decomposition temperature. Therefore,
semi-crystalline. it cannot be processed by most conventional melt process-
The semi-crystalline grades of Amodel PPA resins have ing techniques, such as injection molding or extrusion. In
excellent mechanical properties, outstanding dimensional addition, its melting point, among other factors, complicates
stability, exceptional elevated thermal performance, and the polymerization process.
good processing characteristics. Amodel resins bridge the The basic polyamide 6,T technology has been modified by
cost/performance gap between the high-volume, moder- adding comonomers to produce the Amodel family of
ate-performance engineering resins, such as thermoplastic polyphthalamide (PPA) resins which are composed of propri-
polyesters and aliphatic nylons, and the low-volume, etary compositions of matter. Varying the amount and nature
high-cost specialty thermoplastics, such as of the comonomers leads to a family of resins. All of these
polyetheretherketone (PEEK). resins have melting points lower than polyamide 6,T and
The Amodel product portfolio contains well over 100 differ- exhibit rapid crystallization. The thermal properties of the
ent grades. Each grade has been designed to have a unique Amodel PPA base resins are shown in Table 1-1.
balance of properties that are important for specific applica- These base resins when combined with mineral, glass-fiber,
tion and processing requirements. Applications for Amodel and/or other compounding ingredients provide a wide range
PPA have been developed in a wide range of industries of injection molding compounds that offer an excellent bal-
including automotive / transportation, industrial equipment, ance of processing and thermal/mechanical performance.
water handling, telecommunications, electrical / electronic, Compounds based on A-1000 base resin require molds
coatings and composites, food service, and consumer using oil for temperature control, but compounds based on
goods. the other base resins can be processed using water con-
This manual is intended to be an easy to use reference tool trolled molds.
for designers and fabricators interested in Amodel PPA as a
solution to their material needs. It includes property data for Table 1-1
select grades of the portfolio as well as part design and pro-
Amodel PPA Base Resin Properties
cessing recommendations.
Base Tg Tm
Chemistry Resin °C °F °C °F
A-1000 123 253 313 595
Amodel resins are classified in the general chemical family
known as polyamides. Polyamides may be produced by the A-4000 100 212 325 617
reaction of a difunctional organic acid with a difunctional A-5000 89 192 294 561
amine, or the self-condensation of either an ω-amino acid A-6000 88 190 310 590
or a lactam. Polyamides can be produced from a wide vari-
ety of acids and amines, and a number of polyamides are Crystallinity
commercially important.
Thermoplastics are often divided into two classes, amor-
A naming convention for polyamides has evolved. The con- phous and semi-crystalline. One of the major differences
vention is to name the polyamide using the number of car- between amorphous and semi-crystalline polymers is the
bon atoms in the monomers with the diamine component way their properties change in response to changes in tem-
first. Thus, a polyamide made from hexamethylene diamine perature. Figure 1-1 shows a typical response of modulus to
and adipic acid is called polyamide 66 or nylon 66, and one temperature change for amorphous and semi-crystalline
made from hexamethylene diamine and dodecanedioic acid polymers.
would be nylon 6,12.
When the temperature is raised, the modulus of amorphous
When an aromatic diacid is used instead of an aliphatic polymers generally decreases slowly until the glass transi-
diacid, the nomenclature is modified to reflect the isomeric tion temperature ( Tg ) is reached. At temperatures above
form of the aromatic diacid, and the term polyphthalamide the Tg, the modulus decreases rapidly. Therefore,
1– 1 Solvay Advanced Polymers, L.L.C.
amorphous thermoplastics are rarely used at temperatures Figure 1-1
higher than their glass transition temperature. Modulus Changes with Temperature
In the case of semi-crystalline polymers, the modulus also
gradually decreases with increasing temperature. At or near
the glass transition temperature, the modulus decreases
rapidly to a lower but still useful level. Continuing to
increase the temperature causes the modulus to remain at
or near this new level (the crystalline plateau) until the melt-
ing point temperature (Tm ) is reached. At Tm, the modulus
decreases rapidly again. Semi-crystalline polymers are often
used at temperatures above their glass transition tempera-
tures, but below their melting points, particularly when they
are modified with glass fibers and/or mineral fillers.
When semi-crystalline polymers are processed, the amount
of crystallinity can be affected by processing conditions. For
example, Amodel A-1000 PPA based products require mold
surface temperatures of at least 135°C (275°F) for develop-
ment of the maximum amount of crystallinity during injec-
tion molding. Products based on Amodel A-4000 or A-6000
base resin will give high crystallinity at mold temperatures
of about 80°C (176°F).
Above the Tm, a semi-crystalline polymer melts, changing
from the solid state to the liquid state.
The thermal capability of a semi-crystalline polymer is
defined to a large extent by its Tg and Tm, as these values
indicate the temperature ranges where the polymer has
high stiffness (below Tg), moderate stiffness (between Tg
and Tm), or no useful stiffness (above Tm). Figure 1-2
shows the modulus versus temperature behavior of the
Amodel base resins as measured by dynamic mechanical
analysis (DMA).

Figure 1-2
Modulus versus Temperature for Amodel Base Resins

Amodel PPA Design Guide 1– 2 Chemistry

Moisture Effects Figure 1-3

Like other polymers, polyphthalamide resins absorbs mois- Effect of Moisture Content on Tg
ture from the environment. In general, polyphthalamides will
absorb less water than aliphatic polyamides, like PA 66, and
they will absorb the moisture at a slower rate.
When an article made from Amodel grade based on A-1000
base resin reaches equilibrium with a 100% relative humid-
ity (RH) atmosphere, the increase in weight due to moisture
absorption will be roughly 5 to 6 percent of the
polyphthalamide resin weight.
Figure 1-3 compares the glass transition temperatures of
Amodel A-1000 resin and PA 66 at a range of moisture con-
tents. These materials absorb moisture at different rates and
they have different maximum moisture adsorption amounts.
The most useful and practical comparison is achieved by
plotting the Tg versus the equilibrium moisture content at
various relative humidities.
Comparing dry PA 66 to dry Amodel A-1000 resin, Amodel
resin has a Tg advantage of about 60°C (108°F). If the com-
parison is made at the 50% RH equivalent moisture content,
Figure 1-4
the Tg advantage of Amodel resin is about 89°C (160°F).
The exceptional dimensional stability and property retention Dimension Change vs. Water Immersion Time
of Amodel polyphthalamide is due largely to the higher Tg
and the fact that the Tg remains well above room tempera-
ture, even at the moisture content appropriate for 100% RH.
The Tg of PA 66, on the other hand, falls to -15°C (5°F) at
moisture contents consistent with equilibria at 50 to 60%
RH.
Figure 1-4 compares the dimensional change of Amodel
A-1000 resin to that of PA 66 after being immersed in water
at 23°C (73°F). Results shown are for 3.2 mm (0.125 in.)
thick plaques. After one year (about 8,800 hours), the
dimensional change of the PA resin is approximately three
times that of the PPA resin.
Not only do polyphthalamides absorb less moisture than
typical polyamides, they do so much more slowly. The diffu-
sion coefficient for water in Amodel A-1000 resin is approxi-
mately 20% of that for PA 66 at 23°C (73°F).

Crystallinity 1– 3 Solvay Advanced Polymers, L.L.C.

Amodel Resin Property Tables
Amodel PPA resins are typically combined with reinforce- natural and black. Other colors can often be provided. Dis-
ments, fillers, impact modifiers, flame retardants, colorants, cuss your color requirements with your Solvay
and other additives to achieve a wide range of performance representative.
profiles. Currently the family contains over 100 commercial
grades. This document provides detailed property informa- Nomenclature
tion on 19 grades that were selected to be representative of
the product family. Your Solvay representative can help you The grade designations used for Amodel PPA resins are
select the most cost-effective material for your application. designed to communicate important compositional informa-
tion. The nomenclature system is illustrated in Table 2-1.
The base polymers are translucent white due to crystallinity,
and the natural color of a specific product will vary depend-
ing on the additives used. Most grades are available in
Table 2-1
Amodel Resin Nomenclature System
Position Characteristic Meaning/Example
1st letter Product Family A = Amodel
Next letter(s) Optional descriptor F = flame retardant
P = paintable/plateable
S = structural
T = toughened
- hyphen
1st digit Base resin 1 = A-100x base resin
4 = A-400x base resin
5 = A-500x base resin
6 = A-600x base resin
9 = A-900x base resin
2nd digit Filler or reinforcement type 0 = unfilled
1 = glass
2 = mineral A
3 = mineral A + glass
4 = mineral B
5 = mineral B + glass
6 = carbon or graphite fiber
9 = glycol resistant
3rd and 4th digits Filler or reinforcement amount 33 = 33% by weight
45 = 45% by weight
etc.
Space
Next 1 or 2 letters Suffix HN = heat stabilized, not lubricated
HS = heat stabilized
HSL = heat stabilized and lubricated
L = lubricated, not heat stabilized
NL = neither lubricated nor heat stabilized
V0 = UL 94 V0 at 0.032 in. (0.8 mm)
V0 Z = UL 94 V0 at 0.032 in. (0.8 mm) enhanced
processing
Space
Next 2 letters Color Code NT = natural, unpigmented
BK = black
WH = white
etc

Amodel PPA Design Guide 2– 1 Amodel Resin Property Tables

 recommended that you contact a Solvay Advanced Polymers
Product Selection representative before making a final product selection deci-
Solvay Advanced Polymers has the broadest and deepest sion. Additional product selection resources and technical
portfolio of PPA resins in the industry. Table 2-2 shows the data can be found on the website.
relative performance of several Amodel products to assist
you in selecting the right product for your specific applica-
tion. The products listed here are a good representation of
the portfolio. However, there are many other grades not
listed and one of these may be the perfect fit for you. It is
Table 2-2
Relative Ranking of Selected Properties for Major Amodel PPA Grades

re
atu
per
ed
C

ity
100

Tem
tch
T
T

rav
R

No
at
at
at

G
tio
ess
ess
th

t-

fic
eng

flec
pac

eci
ffn
ffn
Str

Sti
Sti

De

Sp
Im
Glass-Reinforced Grades
A-1133 HS 9 6 8 4 7 6

A-1145 HS 9 8 8 7 7 7

A-6135 HN 8 7 6 5 8 4

AS-4133 HS 7 6 5 4 9 4

Toughened Grades
AT-1002 HS 2 2 2 8 2 1

ET-1000 HS 1 1 1 9 1 1

Toughened Glass-Reinforced Grades

AT-1116 HS 5 4 4 7 4 3

AT-6115 HS 4 3 3 6 4 3

Flame Retardant Grades

AFA-6133 V0 Z 6 8 7 5 6 8

Mineral and Mineral/Glass Filled Grades

A-1240 L 3 4 4 2 3 6

A-1565 HS 4 9 9 1 5 10

AS-1566 HS 8 9 9 3 6 9

Properties ranked from 1 to 10, 10 being highest

Product Selection 2– 2 Solvay Advanced Polymers, L.L.C.

Typical Property Tables
Typical Properties
The typical property data contained in the following short
term property tables fall within the normal range of product
properties. Actual properties of individual batches will vary
within specification limits.
These values should not be used to establish specification
limits, nor should they be used alone as the basis for part
design.
Accelerated Moisture Conditioning
In general, polyamides absorb moisture from the atmo-
sphere, and the absorbed moisture can affect some proper-
ties. To provide the design engineer with more relevant
property information, polyamide suppliers customarily list
properties as molded (dry) and also after moisture absorp-
tion. The convention is to list a 50%RH value, that is
intended to provide the property value after the material has
achieved equilibrium with a 50% relative humidity environ-
ment. This convention is appropriate for polyamide 66,
because that polymer absorbs moisture quickly and many
properties change significantly due to moisture.
This approach is really not appropriate for polyphthalamides,
because these materials absorb moisture slowly and most
properties don’t change significantly due to moisture con-
tent. However to be consistent with the industry, values after
moisture absorption were generated. The correct way of
preparing the samples with absorbed moisture is to place
them in a 50%RH environment and wait until constant
weight , i.e. moisture equilibrium is reached. The moisture
absorption rate of Amodel PPA is so slow, that over two
years would be required. So a method of accelerating the
moisture absorption was developed.
The accelerated moisture conditioning method used was to
boil the test specimens in an aqueous solution containing 80
grams of potassium acetate per 100 grams of water for 96
hours. This procedure was developed empirically to approxi-
mate the moisture uptake of samples that were placed in a
constant humidity chamber until equilibrium was achieved.
Because the temperatures involved in this conditioning are
between 100° and 130°C (212° and 266°F), some anneal-
ing takes place, and the 50% RH modulus values are some-
times a few percent higher than the “dry, as molded”
values.
In addition, exposure to the aqueous conditioning media at
these relatively high temperatures combined with an expo-
sure time of 96 hours results in some hydrolysis of the
glass/resin matrix interface. In many cases, the properties
that depend on glass/resin adhesion, such as tensile
strength, notched Izod, etc., are about 10% lower than
would have been obtained had the samples been allowed to
condition to 50%RH in air at room temperature.
Amodel PPA Design Guide 2– 3 Product Selection
Table 2-3
Glass-Reinforced Grades - Mechanical Properties - US units
Method A-1133 A-1145 A-6135 AS-4133
Property Temperature ASTM ISO Units HS HS HN HS
Tensile Strength 23°C (73°F) D 638 kpsi 32.0 37.5 29.4 29.0
Tensile Strength 50%RH* 23°C (73°F) D 638 kpsi 28.0 33.0 25.5 25.0
Tensile Strength 23°C (73°F) 527 kpsi 33.8 38.1 30.6 30.6
Tensile Strength 100°C (212°F) 527 kpsi 21.5 25.1 17.6 18.1
Tensile Strength 150°C (302°F) 527 kpsi 11.5 12.3 13.4 12.7
Tensile Strength 175°C (347°F) 527 kpsi 10.4 11.0 11.9 11.5
Tensile Elongation 23°C (73°F) D 638 % 2.5 2.6 1.9 2.5
Tensile Elongation 50%RH 23°C (73°F) D 638 % 2.1 2.1 2.1 2.2
Tensile Elongation 23°C (73°F) 527 % 2.5 2.7 2.0 2.6
Tensile Elongation 100°C (212°F) 527 % 2.9 2.5 4.3 4.3
Tensile Elongation 150°C (302°F) 527 % 8.7 7.2 4.9 6.6
Tensile Elongation 175°C (347°F) 527 % 8.5 6.5 4.7 6.6
Tensile Modulus 23°C (73°F) D 638 Mpsi 1.90 2.50 2.00 1.70
Tensile Modulus 50%RH 23°C (73°F) D 638 Mpsi 1.90 2.50 1.77 1.70
Tensile Modulus 23°C (73°F) 527 Mpsi 1.94 2.44 1.67 1.83
Tensile Modulus 100°C (212°F) 527 Mpsi 1.57 1.62 1.06 0.99
Tensile Modulus 150°C (302°F) 527 Mpsi 0.97 1.16 0.91 0.77
Tensile Modulus 175°C (347°F) 527 Mpsi 0.62 0.78 0.77 0.70
Flexural Strength 23°C (73°F) D 790 kpsi 46.0 52.6 45.0 42.0
Flexural Strength 50%RH 23°C (73°F) D 790 kpsi 36.9 42.7 36.1 35.0
Flexural Strength 23°C (73°F) 178 kpsi 46.3 54.7 43.5 42.9
Flexural Strength 100°C (212°F) 178 kpsi 33.0 38.7 24.7 25.6
Flexural Strength 150°C (302°F) 178 kpsi 13.5 16.1 17.8 16.1
Flexural Strength 175°C (347°F) 178 kpsi 11.5 13.7 16.2 14.4
Flexural Modulus 23°C (73°F) D 790 Mpsi 1.65 2.00 1.65 1.60
Flexural Modulus 50%RH 23°C (73°F) D 790 Mpsi 1.65 2.00 1.59 1.60
Flexural Modulus 23°C (73°F) 178 Mpsi 1.68 2.31 1.65 1.51
Flexural Modulus 100°C (212°F) 178 Mpsi 1.42 1.89 0.96 1.04
Flexural Modulus 150°C (302°F) 178 Mpsi 0.58 0.78 0.71 0.67
Flexural Modulus 175°C (347°F) 178 Mpsi 0.52 0.71 0.67 0.61
Shear Strength 23°C (73°F) D 732 kpsi 14.7 15.6 12.7 13.0
Shear Strength 50%RH 23°C (73°F) D 732 kpsi 12.9 13.3 10.7 11.0
Compressive Strength 23°C (73°F) D 695 kpsi 26.9 28.1 21.4 26.0
Poisson’s Ratio 23°C (73°F) 0.41 0.41 0.39 0.41
Izod Impact, Notched 23°C (73°F) D 256 ft-lb/in 1.5 2.1 1.6 1.5
Izod Impact, Notched 50%RH 23°C (73°F) D 256 ft-lb/in 1.1 1.9 1.3 1.5
Izod Impact, Unnotched 23°C (73°F) D 4812 ft-lb/in 14 21 15 19
Izod Impact, Notched 23°C (73°F) 180/1A ft-lb/in2 4.2 4.9 4.3 4.6
Izod Impact, Unnotched 23°C (73°F) 180/1U ft-lb/in2 23 29 30 28
Charpy Impact 23°C (73°F) 179/1eA ft-lb/in2 4.5 4.9 4.4 5.1
Charpy Impact, Unnotched 23°C (73°F) 179/1eU ft-lb/in2 35 44 28 32
Rockwell Hardness 23°C (73°F) D 785 R 125 125 125 124

Typical Property Tables 2-4 SOLVAY Advanced Polymers, L.L.C.

Table 2-4
Glass-Reinforced Grades - Mechanical Properties - SI units
Method A-1133 A-1145 A-6135 AS-4133
Property Temperature ASTM ISO Units HS HS HN HS
Tensile Strength 23°C (73°F) D 638 MPa 221 259 202 200
Tensile Strength 50%RH* 23°C (73°F) D 638 MPa 193 228 178 172
Tensile Strength 23°C (73°F) 527 MPa 233 263 211 211
Tensile Strength 100°C (212°F) 527 MPa 148 173 121 125
Tensile Strength 150°C (302°F) 527 MPa 80 85 93 87
Tensile Strength 175°C (347°F) 527 MPa 72 76 82 79
Tensile Elongation 23°C (73°F) D 638 % 2.5 2.6 1.9 2.5
Tensile Elongation 50%RH 23°C (73°F) D 638 % 2.1 2.1 2.1 2.2
Tensile Elongation 23°C (73°F) 527 % 2.5 2.7 2.0 2.6
Tensile Elongation 100°C (212°F) 527 % 2.9 2.5 4.3 4.3
Tensile Elongation 150°C (302°F) 527 % 8.7 7.2 4.9 6.6
Tensile Elongation 175°C (347°F) 527 % 8.5 6.5 4.7 6.6
Tensile Modulus 23°C (73°F) D 638 GPa 13.1 17.2 13.8 11.7
Tensile Modulus 50%RH 23°C (73°F) D 638 GPa 13.1 17.2 12.2 11.7
Tensile Modulus 23°C (73°F) 527 GPa 13.4 16.8 11.5 12.6
Tensile Modulus 100°C (212°F) 527 GPa 10.8 11.2 7.3 6.8
Tensile Modulus 150°C (302°F) 527 GPa 6.7 8.0 6.3 5.3
Tensile Modulus 175°C (347°F) 527 GPa 4.3 5.4 5.3 4.8
Flexural Strength 23°C (73°F) D 790 MPa 317 363 310 290
Flexural Strength 50%RH 23°C (73°F) D 790 MPa 254 294 249 241
Flexural Strength 23°C (73°F) 178 MPa 319 377 300 296
Flexural Strength 100°C (212°F) 178 MPa 227 267 171 176
Flexural Strength 150°C (302°F) 178 MPa 93 111 123 111
Flexural Strength 175°C (347°F) 178 MPa 80 95 112 100
Flexural Modulus 23°C (73°F) D 790 GPa 11.4 13.8 11.4 11.0
Flexural Modulus 50%RH 23°C (73°F) D 790 GPa 11.4 13.8 10.9 11.0
Flexural Modulus 23°C (73°F) 178 GPa 11.6 15.9 11.4 10.4
Flexural Modulus 100°C (212°F) 178 GPa 9.8 13.0 6.6 7.2
Flexural Modulus 150°C (302°F) 178 GPa 4.0 5.4 4.9 4.6
Flexural Modulus 175°C (347°F) 178 GPa 3.6 4.9 4.6 4.2
Shear Strength 23°C (73°F) D 732 MPa 101 108 88 90
Shear Strength 50%RH 23°C (73°F) D 732 MPa 89 92 74 76
Compressive Strength 23°C (73°F) D 695 MPa 185 194 148 179
Poisson’s Ratio 23°C (73°F) 0.41 0.41 0.39 0.41
Izod Impact, Notched 23°C (73°F) D 256 J/m 80 110 85 80
Izod Impact, Notched 50%RH 23°C (73°F) D 256 J/m 60 100 70 70
Izod Impact, Unnotched 23°C (73°F) D 4812 J/m 770 1105 780 1030
Izod Impact, Notched 23°C (73°F) 180/1A kJ/m2 8.8 10.3 9.1 9.7
Izod Impact, Unnotched 23°C (73°F)) 180/1U kJ/m2 49 61 62 59
Charpy Impact 23°C (73°F) 179/1eA kJ/m2 9.5 10.3 9.2 10.7
Charpy Impact, Unnotched 23°C (73°F) 179/1eU kJ/m2 73 93 60 68
Rockwell Hardness 23°C (73°F) D785 R scale 125 125 125 124

Amodel PPA Design Guide 2-5 Typical Property Tables

Table 2-5
Glass-Reinforced Grades - Thermal, Electrical, and General Properties
Method A-1133 A-1145 A-6135 AS-4133
Property ASTM ISO Units HS HS HN HS
Thermal
Deflection Temperature Under Load, 264 psi D 648 °F 545 549 556 572
°C 285 287 291 300

Deflection Temperature Under Load, 1.8 MPa 75AF °F 536 538 550 561
°C 280 281 288 294

Vicat Softening Temperature D 1525 306 °F 577 580 573 597

°C 303 304 301 314

Melting Point D 3418 11357-3 °F 595 590 590 620

°C 313 310 310 327

Flammability, 1/8" (3.2 mm) bar UL -94 HB HB HB HB

Electrical
Dielectric Strength at 1/8” (3.2 mm) D 149 V/mil 533 584 * 510
kV/mm 21 23 * 21
Dielectric Strength at 1/16” (1.6 mm) D 149 V/mil 813 * * 813
kV/mm 32 * * 32

Volume Resistivity D 257 ohm-cm 1x1016 1x1016 * 1x1016

Surface Resistivity D 257 ohms 1x1015 * * 1x1015
Comparative Tracking Index D 3638 volts 550 550 * >600

Dielectric Constant at 60 Hz D 150 4.4 4.6 * 3.8

Dielectric Constant at 100 Hz D 150 5.1 * * 4.6
Dielectric Constant at 106 Hz D 150 4.2 4.4 * 3.6
Dielectric Constant at 109 Hz D 150 3.7 * * 3.6

Dissipation Factor at 60 Hz D 150 0.005 0.005 * 0.004

Dissipation Factor at 106 Hz D 150 0.017 0.016 * 0.012
Dissipation Factor at 109 Hz D 150 0.016 * * 0.013
General
Specific Gravity D 792 1183A 1.48 1.59 1.45 1.45
Moisture Absorption, 24 hours D 570 62 % 0.2 0.1 0.3 0.3

Mold Shrinkage, Flow Direction D 955 294-4 % 0.4 0.2 0.6 0.5
Mold Shrinkage, Transverse Direction D 955 294-4 % 0.8 0.6 0.9 1.0

Typical Property Tables 2-6 SOLVAY Advanced Polymers, L.L.C.

Table 2-6
Toughened Grades - Mechanical Properties - US units
Method AT-1002 ET-1000
Property Temperature ASTM ISO Units HS HS
Tensile Strength 23°C (73°F) D 638 kpsi 12.1 10.0
Tensile Strength 50%RH* 23°C (73°F) D 638 kpsi 11.1 9.1
Tensile Stress at Yield 23°C (73°F) 527 kpsi 10.9 10.2
Tensile Stress at Break 23°C (73°F) 527 kpsi 9.9 8.7
Tensile Stress at Yield 100°C (212°F) 527 kpsi 5.6 4.9
Tensile Stress at Break 100°C (212°F) 527 kpsi
Tensile Elongation at Yield 23°C (73°F) D 638 % 5.0 6.0
Tensile Elongation at Break 23°C (73°F) D 638 % 10-12 20.0
Tensile Elongation at Break 50%RH 23°C (73°F) D 638 % 30.0 18
Tensile Strain at Yield 23°C (73°F) 527 % 5.0 5.0
Tensile Strain at Break 23°C (73°F) 527 % 10.0 7.0
Tensile Strain at Yield 100°C (212°F) 527 % 3.7 4.3
Tensile Strain at Break 100°C (212°F) 527 % >95 >95
Tensile Modulus 23°C (73°F) D 638 kpsi 400 350
Tensile Modulus 50%RH 23°C (73°F) D 638 kpsi 400 350
Tensile Modulus 23°C (73°F) 527 kpsi 400 350
Tensile Modulus 100°C (212°F) 527 kpsi 305 290
Flexural Strength 23°C (73°F) D 790 kpsi 14.9 15.8
Flexural Strength 50%RH 23°C (73°F) D 790 kpsi 10.6 12.4
Flexural Strength 23°C (73°F) 178 kpsi 11.5 10.2
Flexural Strength 100°C (212°F) 178 kpsi 7.2 6.4
Flexural Modulus 23°C (73°F) D 790 kpsi 320 330
Flexural Modulus 50%RH 23°C (73°F) D 790 kpsi 330 310
Flexural Modulus 23°C (73°F) 178 kpsi 330 260
Flexural Modulus 100°C (212°F) 178 kpsi 250 190
Shear Strength 23°C (73°F) D 732 kpsi 9.3 8.5
Shear Strength 50%RH 23°C (73°F) D 732 kpsi 8.3
Poisson’s Ratio 23°C (73°F) 0.38 0.39
Izod Impact, Notched 23°C (73°F) D 256 ft-lb/in 2.4 17.0
Izod Impact, Notched 50%RH 23°C (73°F) D 256 ft-lb/in 2.6 20.0
Izod Impact, Unnotched 23°C (73°F) D 4812 ft-lb/in no break no break
Izod Impact, Notched 23°C (73°F) 180/1A ft-lb/in2 6.0 34.9
Izod Impact, Unnotched 23°C (73°F) 180/1U ft-lb/in2 84 no break
Charpy Impact 23°C (73°F) 179/1eA ft-lb/in2 6.4 36.9
Charpy Impact, Unnotched 23°C (73°F) 179/1eU ft-lb/in2 no break no break
Rockwell Hardness 23°C (73°F) D785 R 119 120

Amodel PPA Design Guide 2-7 Typical Property Tables

Table 2-7.
Toughened Grades - Mechanical Properties - SI Units
Method AT-1002 ET-1000
Property Temperature ASTM ISO Units HS HS
Tensile Strength 23°C (73°F) D 638 MPa 83 69
Tensile Strength 50%RH* 23°C (73°F) D 638 MPa 76 63
Tensile Stress at Yield 23°C (73°F) 527 MPa 75 70
Tensile Stress at Break 23°C (73°F) 527 MPa 68 60
Tensile Stress at Yield 100°C (212°F) 527 MPa 39 34
Tensile Stress at Break 100°C (212°F) 527 MPa
Tensile Elongation at Yield 23°C (73°F) D 638 % 5.0 6.0
Tensile Elongation at Break 23°C (73°F) D 638 % 10-12 20.0
Tensile Elongation at Break 50%RH 23°C (73°F) D 638 % 30.0 18.0
Tensile Strain at Yield 23°C (73°F) 527 % 5.0 5.0
Tensile Strain at Break 23°C (73°F) 527 % 10.0 7.0
Tensile Strain at Yield 100°C (212°F) 527 % 3.7 4.3
Tensile Strain at Break 100°C (212°F) 527 % >95 >95
Tensile Modulus 23°C (73°F) D 638 GPa 2.8 2.4
Tensile Modulus 50%RH 23°C (73°F) D 638 GPa 2.8 2.4
Tensile Modulus 23°C (73°F) 527 GPa 2.8 2.4
Tensile Modulus 100°C (212°F) 527 GPa 2.1 2.0
Flexural Strength 23°C (73°F) D 790 MPa 103 109
Flexural Strength 50%RH 23°C (73°F) D 790 MPa 73 85
Flexural Strength 23°C (73°F) 178 MPa 80 70
Flexural Strength 100°C (212°F) 178 MPa 50 44
Flexural Modulus 23°C (73°F) D 790 GPa 2.2 2.3
Flexural Modulus 50%RH 23°C (73°F) D 790 GPa 2.3 2.2
Flexural Modulus 23°C (73°F) 178 GPa 2.3 1.8
Flexural Modulus 100°C (212°F) 178 GPa 1.8 1.3
Shear Strength 23°C (73°F) D 732 MPa 64 59
Shear Strength 50%RH 23°C (73°F) D 732 MPa 57
Poisson’s Ratio 23°C (73°F) 0.38 0.39
Izod Impact, Notched 23°C (73°F) D 256 J/m 130 905
Izod Impact, Notched 50%RH 23°C (73°F) D 256 J/m 140 1065
Izod Impact, Unnotched 23°C (73°F) D 4812 J/m no break no break
Izod Impact, Notched 23°C (73°F) 180/1A kJ/m2 13 74
Izod Impact, Unnotched 23°C (73°F) 180/1U kJ/m2 177 no break
Charpy Impact 23°C (73°F) 179/1eA kJ/m2 14 78
Charpy Impact, Unnotched 23°C (73°F) 179/1eU kJ/m2 no break no break
Rockwell Hardness 23°C (73°F) D 785 119 120

Typical Property Tables 2-8 SOLVAY Advanced Polymers, L.L.C.

Table 2-8
Toughened Grades - Thermal, Electrical, and General Properties
Method
Property ASTM ISO Units AT-1002 HS ET-1000 HS
Thermal
Deflection Temperature Under Load, 264 psi D 648 °F 250 248
°C 121 120

Deflection Temperature Under Load, 1.8 MPa 75AF °F 244 228

°C 118 109

Vicat Softening Temperature D 1525 306 °F 547 542

°C 286 283

Melting Point D 3418 11357-3 °F 599 590

°C 315 310

Flammability, 1/8" (3.2 mm) bar UL -94 HB HB

Electrical
Dielectric Strength at 1/8” (3.2 mm) D 149 V/mil 431 *
kV/mm 17 *

Volume Resistivity D 257 ohm-cm 1x1016 *

Surface Resistivity D 257 ohm 8x1013
Comparative Tracking Index D 3638 volts >600 *

Dielectric Constant at 60 Hz D 150 3.3 *

Dielectric Constant at 106 Hz D 150 3.3 *

Dissipation Factor at 60 Hz D 150 0.004 *

Dissipation Factor at 106 Hz D 150 0.016 *

General
Specific Gravity D 792 1183A 1.13 1.13
Moisture Absorption, 24 hours D 570 62 % 0.5 0.7

Mold Shrinkage, Flow Direction D 955 294-4 % 2.0 1.5

Mold Shrinkage, Transverse Direction D 955 294-4 % 2.1 1.5

Amodel PPA Design Guide 2-9 Typical Property Tables

Table 2-9
Toughened Glass-Reinforced and Flame Retardant Grades - Mechanical Properties - US units
Method AFA-6133
Property Temperature ASTM ISO Units AT-1116 HS AT-6115 HS V0 Z
Tensile Strength 23°C (73°F) D 638 kpsi 23.3 17.7 28.8
Tensile Strength 50%RH 23°C (73°F) D 638 kpsi 19.0 13.9 24.1
Tensile Strength 23°C (73°F) 527 kpsi 23.2 16.5 27.0
Tensile Strength 100°C (212°F) 527 kpsi 9.5 9.9 16.5
Tensile Strength 150°C (302°F) 527 kpsi 10.9
Tensile Strength 175°C (347°F) 527 kpsi 9.2
Tensile Elongation 23°C (73°F) D 638 % 3.8 3.4 1.7
Tensile Elongation 50%RH 23°C (73°F) D 638 % 2.8 5.3 1.7
Tensile Elongation 23°C (73°F) 527 % 3.7 3.9 1.6
Tensile Elongation 100°C (212°F) 527 % 4.2 7.7 2.4
Tensile Elongation 150°C (302°F) 527 % 5.1
Tensile Elongation 175°C (347°F) 527 % 4.9
Tensile Modulus 23°C (73°F) D 638 Mpsi 0.94 0.78 2.33
Tensile Modulus 50%RH 23°C (73°F) D 638 Mpsi 1.03 0.97 1.99
Tensile Modulus 23°C (73°F) 527 Mpsi 1.00 0.78 2.10
Tensile Modulus 100°C (212°F) 527 Mpsi 0.97 0.45 1.33
Tensile Modulus 150°C (302°F) 527 Mpsi 0.86
Tensile Modulus 175°C (347°F) 527 Mpsi 0.74
Flexural Strength 23°C (73°F) D 790 kpsi 32.8 24.0 32.5
Flexural Strength 50%RH 23°C (73°F) D 790 kpsi 29.1 16.7 33.2
Flexural Strength 23°C (73°F) 178 kpsi 28.6 24.7 37.6
Flexural Strength 100°C (212°F) 178 kpsi 20.5 9.7 23.3
Flexural Strength 150°C (302°F) 178 kpsi 14.6
Flexural Strength 175°C (347°F) 178 kpsi 12.7
Flexural Modulus 23°C (73°F) D 790 Mpsi 0.87 0.64 1.90
Flexural Modulus 50%RH 23°C (73°F) D 790 Mpsi 0.90 0.50 1.93
Flexural Modulus 23°C (73°F) 178 Mpsi 0.97 0.62 1.83
Flexural Modulus 100°C (212°F) 178 Mpsi 0.72 0.34 1.17
Flexural Modulus 150°C (302°F) 178 Mpsi 0.72
Flexural Modulus 175°C (347°F) 178 Mpsi 0.67
Shear Strength 23°C (73°F) D 732 kpsi 10.1 8.2 11.6
Shear Strength 50%RH 23°C (73°F) D 732 kpsi 9.5 6.4 9.0
Compressive Strength 23°C (73°F) D 695 kpsi 18.0 14.5 21.1
Poisson’s Ratio 23°C (73°F) 0.40 0.39 0.37
Izod Impact, Notched 23°C (73°F) D 256 ft-lb/in 1.8 1.7 1.6
Izod Impact, Notched 50%RH 23°C (73°F) D 256 ft-lb/in 0.9 1.5 1.5
Izod Impact, Unnotched 23°C (73°F) D 4812 ft-lb/in 18 16 13
Izod Impact, Notched 23°C (73°F) 180/1A ft-lb/in2 3.8 5.5 3.9
Izod Impact, Unnotched 23°C (73°F) 180/1U ft-lb/in2 25 26 21
Charpy Impact 23°C (73°F) 179/1eA ft-lb/in2 4.3 5.2 6.6
Charpy Impact, Unnotched 23°C (73°F) 179/1eU ft-lb/in2 41 36 22
Rockwell Hardness 23°C (73°F) D785 R scale 124 116 125

Typical Property Tables 2-10 SOLVAY Advanced Polymers, L.L.C.

Table 2-10
Toughened Glass-Reinforced and Flame Retardant Grades - Mechanical Properties - SI units
Method AFA-6133
Property Temperature ASTM ISO Units AT-1116 HS AT-6115 HS V0 Z
Tensile Strength 23°C (73°F) D 638 MPa 161 122 199
Tensile Strength 50%RH* 23°C (73°F) D 638 MPa 131 96 166
Tensile Strength 23°C (73°F) 527 MPa 160 114 186
Tensile Strength 100°C (212°F) 527 MPa 66 68 114
Tensile Strength 150°C (302°F) 527 MPa 75
Tensile Strength 175°C (347°F) 527 MPa 63
Tensile Elongation 23°C (73°F) D 638 % 3.8 3.4 1.7
Tensile Elongation 50%RH 23°C (73°F) D 638 % 2.8 5.3 1.7
Tensile Elongation 23°C (73°F) 527 % 3.7 3.9 1.6
Tensile Elongation 100°C (212°F) 527 % 4.2 7.7 2.4
Tensile Elongation 150°C (302°F) 527 % 5.1
Tensile Elongation 175°C (347°F) 527 % 4.9
Tensile Modulus 23°C (73°F) D 638 GPa 6.5 5.4 16.1
Tensile Modulus 50%RH 23°C (73°F) D 638 GPa 7.1 6.7 13.7
Tensile Modulus 23°C (73°F) 527 GPa 6.9 5.4 14.5
Tensile Modulus 100°C (212°F) 527 GPa 6.7 3.1 9.2
Tensile Modulus 150°C (302°F) 527 GPa 5.9
Tensile Modulus 175°C (347°F) 527 GPa 5.1
Flexural Strength 23°C (73°F) D 790 MPa 226 165 224
Flexural Strength 50%RH 23°C (73°F) D 790 MPa 201 115 229
Flexural Strength 23°C (73°F) 178 MPa 197 170 259
Flexural Strength 100°C (212°F) 178 MPa 141 67 161
Flexural Strength 150°C (302°F) 178 MPa 101
Flexural Strength 175°C (347°F) 178 MPa 88
Flexural Modulus 23°C (73°F) D 790 GPa 6.0 4.4 13.1
Flexural Modulus 50%RH 23°C (73°F) D 790 GPa 6.2 3.4 13.3
Flexural Modulus 23°C (73°F) 178 GPa 6.7 4.3 12.6
Flexural Modulus 100°C (212°F) 178 GPa 5.0 2.4 8.1
Flexural Modulus 150°C (302°F) 178 GPa 5.0
Flexural Modulus 175°C (347°F) 178 GPa 4.6
Shear Strength 23°C (73°F) D 732 MPa 70 56 80
Shear Strength 50%RH 23°C (73°F) D 732 MPa 66 44 62
Compressive Strength 23°C (73°F) D 695 MPa 124 100 145
Poisson’s Ratio 23°C (73°F) 0.40 0.39 0.37
Izod Impact, Notched 23°C (73°F) D 256 J/m 95 90 85
Izod Impact, Notched 50%RH 23°C (73°F) D 256 J/m 45 80 80
Izod Impact, Unnotched 23°C (73°F) D 4812 J/m 945 825 710
Izod Impact, Notched 23°C (73°F) 180/1A kJ/m2 8.1 11.6 8
Izod Impact, Unnotched 23°C (73°F) 180/1U kJ/m2 53 54 44
Charpy Impact 23°C (73°F) 179/1eA kJ/m2 9.1 11.0 14.0
Charpy Impact, Unnotched 23°C (73°F) 179/1eU kJ/m2 85 75 47
Rockwell Hardness 23°C (73°F) D 785 R scale 124 116 125

Amodel PPA Design Guide 2-11 Typical Property Tables

Table 2-11
Toughened Glass-Reinforced and Flame Retardant Grades - Thermal, Electrical, and General Properties
Method AFA-6133
Property ASTM ISO Units AT-1116 HS AT-6115 HS V0 Z
Thermal
Deflection Temperature Under Load, 264 psi D 648 °F 489 519 531
°C 254 271 277

Deflection Temperature Under Load, 1.8 MPa 75AF °F 497 509 540
°C 258 265 282

Vicat Softening Temperature D 1525 306 °F 563 565 556

°C 295 296 291

Melting Point D 3418 11357-3 °F 590 585 590

°C 310 307 310

Flammability, 1/8" (3.2 mm) bar UL -94 HB HB V-0

Electrical
Dielectric Strength at 1/8” (3.2 mm) D 149 V/mil * 533 609
kV/mm * 21 24
Dielectric Strength at 1/16” (1.6 mm) D 149 V/mil 711 686
kV/mm 28 27

Volume Resistivity D 257 ohm-cm * 1x1016 1x1016

Surface Resistivity D 257 ohm 1x1015 1x1015
Comparative Tracking Index D 3638 volts * * *

Dielectric Constant at 60 Hz D 150 * * *

Dielectric Constant at 100 Hz D 150 * 4.0 4.8
Dielectric Constant at 106 Hz D 150 * 3.3 4.1
Dielectric Constant at 109 Hz D 150 * 3.1 3.7

Dissipation Factor at 60 Hz D 150 * * *

Dissipation Factor at 100 Hz D 150 * * *
Dissipation Factor at 106 Hz D 150 * 0.013 0.011
Dissipation Factor at 109 Hz D 150 * 0.011 *
General
Specific Gravity D 792 1183A 1.28 1.22 1.68
Moisture Absorption, 24 hours D 570 62 % 0.2 0.2 0.2

Mold Shrinkage, Flow Direction D 955 294-4 % 0.6 1.0 0.3

Mold Shrinkage, Transverse Direction D 955 294-4 % 0.6 1.1 0.6

Typical Property Tables 2-12 SOLVAY Advanced Polymers, L.L.C.

Table 2-12
Mineral and Mineral/Glass Filled Grades - Mechanical Properties - US units
Method A-1240 A-1565 AS-1566
Property Temperature ASTM ISO Units L HS HS
Tensile Strength 23°C (73°F) D 638 kpsi 15.0 19.0 30.0
Tensile Strength 50%RH* 23°C (73°F) D 638 kpsi 13.5 17.9 25.4
Tensile Strength 23°C (73°F) 527 kpsi 15.1 20.0 29.0
Tensile Strength 100°C (212°F) 527 kpsi 10.1 13.3 18.4
Tensile Strength 150°C (302°F) 527 kpsi 4.2 6.7 7.6
Tensile Strength 175°C (347°F) 527 kpsi 3.5 4.7 6.3
Tensile Elongation 23°C (73°F) D 638 % 1.6 1.2 1.7
Tensile Elongation 50%RH 23°C (73°F) D 638 % 1.2 1.2 1.8
Tensile Elongation 23°C (73°F) 527 % 1.6 1.0 1.4
Tensile Elongation 100°C (212°F) 527 % 1.9 1.3 1.5
Tensile Elongation 150°C (302°F) 527 % 9.1 2.4 3.4
Tensile Elongation 175°C (347°F) 527 % 7.3 1.8 3.1
Tensile Modulus 23°C (73°F) D 638 Mpsi 1.30 3.00 2.90
Tensile Modulus 50%RH 23°C (73°F) D 638 Mpsi 1.20 3.02 3.03
Tensile Modulus 23°C (73°F) 527 Mpsi 1.45 2.86 3.26
Tensile Modulus 100°C (212°F) 527 Mpsi 0.81 2.23 2.49
Tensile Modulus 150°C (302°F) 527 Mpsi 0.16 0.83 1.06
Tensile Modulus 175°C (347°F) 527 Mpsi 0.13 0.74 0.90
Flexural Strength 23°C (73°F) D 790 kpsi 30.0 30.5 42.0
Flexural Strength 50%RH 23°C (73°F) D 790 kpsi 25.6 28.4 38.1
Flexural Strength 23°C (73°F) 178 kpsi 24.9 30.6 41.2
Flexural Strength 100°C (212°F) 178 kpsi 17.6 23.6 29.7
Flexural Strength 150°C (302°F) 178 kpsi 4.0 10.1 13.9
Flexural Strength 175°C (347°F) 178 kpsi 3.2 8.1 11.0
Flexural Modulus 23°C (73°F) D 790 Mpsi 1.10 2.60 2.70
Flexural Modulus 50%RH 23°C (73°F) D 790 Mpsi 1.00 2.61 2.88
Flexural Modulus 23°C (73°F) 178 Mpsi 1.00 2.43 2.98
Flexural Modulus 100°C (212°F) 178 Mpsi 0.87 2.28 2.44
Flexural Modulus 150°C (302°F) 178 Mpsi 0.16 0.81 1.06
Flexural Modulus 175°C (347°F) 178 Mpsi 0.13 0.72 0.93
Shear Strength 23°C (73°F) D 732 kpsi 13.9 10.3 11.6
Shear Strength 50%RH 23°C (73°F) D 732 kpsi 13.5 7.2 9.1
Compressive Strength 23°C (73°F) D 695 kpsi 26.8 27.4 25.3
Poisson’s Ratio 23°C (73°F) 0.29 0.31 0.35
Izod Impact, Notched 23°C (73°F) D 256 ft-lb/in 0.9 0.7 1.2
Izod Impact, Notched 50%RH 23°C (73°F) D 256 ft-lb/in 0.6 0.6 1.0
Izod Impact, Unnotched 23°C (73°F) D 4812 ft-lb/in 7 7 13
Izod Impact, Notched 23°C (73°F) 180/1A ft-lb/in2 2.2 1.6 3.1
Izod Impact, Unnotched 23°C (73°F) 180/1U ft-lb/in2 11 11 21
Charpy Impact 23°C (73°F) 179/1eA ft-lb/in2 1.9 1.5 2.9
Charpy Impact, Unnotched 23°C (73°F) 179/1eU ft-lb/in2 14 12 16
Rockwell Hardness 23°C (73°F) D 785 R scale 125 124 122

Amodel PPA Design Guide 2-13 Typical Property Tables

Table 2-13
Mineral and Mineral/Glass Filled Grades - Mechanical Properties - SI units
Method A-1240 A-1565 AS-1566
Property Temperature ASTM ISO Units L HS HS
Tensile Strength 23°C (73°F) D 638 MPa 103 131 207
Tensile Strength 50%RH* 23°C (73°F) D 638 MPa 93 123 175
Tensile Strength 23°C (73°F) 527 MPa 104 138 200
Tensile Strength 100°C (212°F) 527 MPa 70 92 127
Tensile Strength 150°C (302°F) 527 MPa 29 46 53
Tensile Strength 175°C (347°F) 527 MPa 24 32 44
Tensile Elongation 23°C (73°F) D 638 % 1.6 1.2 1.7
Tensile Elongation 50%RH 23°C (73°F) D 638 % 1.2 1.2 1.8
Tensile Elongation 23°C (73°F) 527 % 1.6 1.0 1.4
Tensile Elongation 100°C (212°F) 527 % 1.9 1.3 1.5
Tensile Elongation 150°C (302°F) 527 % 9.1 2.4 3.4
Tensile Elongation 175°C (347°F) 527 % 7.3 1.8 3.1
Tensile Modulus 23°C (73°F) D 638 GPa 9.0 20.7 20.0
Tensile Modulus 50%RH 23°C (73°F) D 638 GPa 8.3 20.8 20.9
Tensile Modulus 23°C (73°F) 527 GPa 10.1 20.0 22.8
Tensile Modulus 100°C (212°F) 527 GPa 5.6 15.4 17.2
Tensile Modulus 150°C (302°F) 527 GPa 1.1 5.7 7.3
Tensile Modulus 175°C (347°F) 527 GPa 0.9 5.1 6.2
Flexural Strength 23°C (73°F) D 790 MPa 207 210 290
Flexural Strength 50%RH 23°C (73°F) D 790 MPa 177 196 263
Flexural Strength 23°C (73°F) 178 MPa 172 211 284
Flexural Strength 100°C (212°F) 178 MPa 121 162 205
Flexural Strength 150°C (302°F) 178 MPa 27 70 96
Flexural Strength 175°C (347°F) 178 MPa 22 56 76
Flexural Modulus 23°C (73°F) D 790 GPa 7.6 17.9 18.6
Flexural Modulus 50%RH 23°C (73°F) D 790 GPa 6.9 18.0 19.8
Flexural Modulus 23°C (73°F) 178 GPa 7.0 17.0 20.8
Flexural Modulus 100°C (212°F) 178 GPa 6.0 15.7 16.8
Flexural Modulus 150°C (302°F) 178 GPa 1.1 5.6 7.3
Flexural Modulus 175°C (347°F) 178 GPa 0.9 5.0 6.4
Shear Strength 23°C (73°F) D 732 MPa 96 71 80
Shear Strength 50%RH 23°C (73°F) D 732 MPa 93 50 63
Compressive Strength 23°C (73°F) D 695 MPa 185 189 174
Poisson’s Ratio 23°C (73°F) 0.29 0.31 0.35
Izod Impact, Notched 23°C (73°F) D 256 J/m 50 35 65
Izod Impact, Notched 50%RH 23°C (73°F) D 256 J/m 30 30 55
Izod Impact, Unnotched 23°C (73°F) D 4812 J/m 345 395 700
Izod Impact, Notched 23°C (73°F) 180/1A kJ/m2 4.7 3.4 6.6
Izod Impact, Unnotched 23°C (73°F) 180/1U kJ/m2 24 23 44
Charpy Impact 23°C (73°F) 179/1eA kJ/m2 4.1 3.1 6.2
Charpy Impact, Unnotched 23°C (73°F) 179/1eU kJ/m2 29 25 34
Rockwell Hardness 23°C (73°F) D 785 R 125 124 122

Typical Property Tables 2-14 SOLVAY Advanced Polymers, L.L.C.

Table 2-14
Mineral and Mineral/Glass Filled Grades - Thermal, Electrical, and General Properties
Method A-1240 A-1565 AS-1566
Property ASTM ISO Units L HS HS
Thermal
Deflection Temperature Under Load, 264 psi D 648 °F 355 520 532
°C 179 271 278

Deflection Temperature Under Load, 1.8 MPa 75AF °F 346 520 536
°C 174 271 280

Vicat Softening Temperature D 1525 306 °F 575 565 569

°C 302 296 298

Melting Point D 3418 11357-3 °F 590 592 592

°C 310 311 311

Flammability, 1/8" (3.2 mm) bar UL -94 HB HB HB

Electrical
Dielectric Strength at 1/16” (1.6 mm) D 149 V/mil * * 737
kV/mm * * 29

Volume Resistivity D 257 ohm-cm 9x1015 4x1014 1x1016

Surface Resistivity D 257 ohm * * 1x1015
Comparative Tracking Index D 3638 volts 550 >600 *

Dielectric Constant at 60 Hz D 150 * * *

Dielectric Constant at 100 Hz D 150 4.2 * 5.7
Dielectric Constant at 106 Hz D 150 4.0 * 4.7

Dissipation Factor at 60 Hz D 150 * * *

Dissipation Factor at 100 Hz D 150 0.006 * *
Dissipation Factor at 106 Hz D 150 0.017 * 0.011
General
Specific Gravity D 792 1183A 1.54 1.90 1.84
Moisture Absorption, 24 hours D 570 62 % 0.1 0.1 0.1

Mold Shrinkage, Flow Direction D 955 294-4 % 1.0 0.3 0.3

Mold Shrinkage, Transverse Direction D 955 294-4 % 1.0 0.5 0.5

Amodel PPA Design Guide 2-15 Typical Property Tables

 Tensile Properties
Mechanical Properties Test Methods
The mechanical properties of a material are of fundamental There are two widely accepted methods of testing tensile
importance to engineers when designing a part. The properties, ASTM method D 638 and ISO method 527. These
designer must match the mechanical properties of various test methods measure the same property, but slightly differ-
candidate materials to the performance requirements of ent test specimens and test procedures are used. If the
each application in order to determine which material is same material is tested using both procedures, the results
suitable for a given part design. Conversely, the designer will be similar but not the same. Therefore, only values
can use the material property values to achieve an optimum obtained using the same method should be compared. In
part design. this document, whenever a tensile property value is given,
To assist the designer, the material properties listed in this the test method is also given, and in many cases values by
manual have been grouped into short-term or instantaneous both methods are provided.
and long-term or time-dependent properties. The short-term Regardless of which test method is used, tensile properties
properties generally measure strength at failure while the are determined by clamping each end of a test specimen in
long-term properties show how the material properties are the jaws of a testing machine that applies a unidirectional
affected by temperature, continuous loading, or chemical axial force to the specimens at a specified rate The force
exposure as a function of time. required to separate the jaws divided by the minimum
cross-sectional area of the test specimen is defined as the
Short-term Mechanical Properties tensile stress. The test specimen will elongate as a result of
the stress being applied. The amount of elongation divided
Short-term mechanical properties typically include tensile by the original length of the test specimen is the strain.
strength and modulus, flexural strength and modulus, sev-
eral impact tests, compressive strength, shear strength, and When the applied stress is plotted against the resulting
surface hardness. These properties are usually reported at strain, a curve similar to that shown in Figure 3-1 for
room temperature, and other temperatures as appropriate. Amodel ET-1000 HS resin is obtained.
Since some polymers absorb atmospheric moisture which
may affect the properties, the moisture content may also be
Figure 3-1
specified, often using the Relative Humidity (RH) convention.
Typical Stress/Strain Curve for Amodel ET-1000
The data sheets provided by the material suppliers typically
list short-term properties, and their primary utility is for
comparing similar materials. When using data sheets to
compare materials, it is very important to insure that the
same test methods have been used and that the data is
reported in similar units
The utility of short-term mechanical properties in design is
limited. Typically, the properties are measured using molded
test specimens that have been specifically designed to yield
reproducible results, under carefully controlled environmen-
tal conditions, using specified loading rates. These mea-
surements often provide the highest value obtainable for any
property and material.
When parts are fabricated by a molding process they will
likely contain a number of features such as stress concen-
trations, weld lines, corners or other aspects that may This is known as a “Stress - Strain” curve and is very useful
reduce strength. The strength of a material in an actual in determining the short term behavior of a material when a
component may also be reduced, or in some cases load is applied. The curve of a ductile metal would have a
enhanced, by reinforcing fiber orientation, relative degree of similar shape.
crystallinity, or thermal history (annealing). In addition, PB
short-term properties do not provide any insight regarding
time-related effects or the influence of chemical
environments.

3– 1 Solvay Advanced Polymers, L.L.C.

Figure 3-2 shows a typical stress/strain curve for a the proportional limit, some conventions have been
non-ductile material, Amodel A-1933 PPA. Strain at failure is developed to standardize the measurements and reduce the
much lower than that of the unreinforced grade. The addi- variability in test results. One method uses the slope of a
tion of glass-fiber reinforcement improves the strength and line drawn tangent to the curve. Another method utilizes the
stiffness but reduces the elongation or strain at failure. slope of a secant drawn through the origin and some arbi-
trarily designated strain level, usually 1%. The tangent
method has been removed from the ISO test method and
Figure 3-2 replaced with a slope calculation based on specified strain
Typical Stress/Strain Curve for Amodel A-1933 values of 0.0005 and 0.0025. Alternatively, computerized
machines can use the least squares method to calculate the
slope over the same strain region.
The tangent method was used for the tensile data run by
ASTM D 638 presented in this brochure.
Ductile polymers undergo yield prior to rupture. At this point,
the material undergoes additional elongation without an
increase in stress. The stress level at which yield occurs is
often referred to as tensile strength at yield or tensile stress
at yield. The elongation achieved at this point is called the
elongation at yield or yield strain or tensile strain at yield. As
the test proceeds, the specimen continues to elongate until
rupture occurs. The stress level at this point is called tensile
strength at break or ultimate tensile strength or tensile
stress at break. Tensile strength is defined as the greater of
measured stresses which could be either the stress at yield
The initial portion of the stress/strain curve is also of special or the stress at rupture.
interest because its slope relates to the stiffness or modulus
of the material as shown in Figure 3-3 . Tensile Property Comparison
Amodel A-1133 HS resin has higher tensile strength at room
This figure shows that the strain is directly proportional to
temperature than 33% GR polyamide (PA) 66, 30% GR
stress up to a certain amount of stress. This region is known
polyphenylene sulfide (PPS), and 30% GR polyetherimide
as the “Hookean” or elastic region. The maximum stress
(PEI), as shown in Figure 3-4. Even after moisture condition-
level that results in a proportional amount of strain is known
ing, the Amodel PPA is stronger than the other resins.
as the proportional limit.
The tensile or elastic modulus is the slope of the
stress/strain curve when a specimen is subjected to a ten- Figure 3-4
sile loading. Since the stress/strain plot is non-linear above Tensile Strength of 30-33% GR Resins

Figure 3-3
Secant and Tangent Methods for Estimating Modulus

The tensile modulus of 33% GR Amodel PPA is compared to

the same resins in Figure 3-5. The Amodel resin has a
higher modulus as molded and shows no decline when
Amodel PPA Design Guide 3– 2 Short-term Mechanical Properties
moisture conditioned, while the PA 66 exhibits a reduction of Figure 3-7
over 20 percent.
Tensile Strength of 33% GR PPA vs. Temperature

Figure 3-5
Tensile Modulus of 30-33% GR Resins

Figure 3-8
Tensile Modulus of 33% GR PPA vs. Temperature
This same comparison for tensile elongation is shown in
Figure 3-6. The tensile elongation of the resins is low due to
the glass-fiber reinforcement. Moisture conditioning the
PA 66 results in an increase in elongation due to the reduc-
tion in Tg.

Figure 3-6
Tensile Elongation of 30-33% GR Resins

Figure 3-9
Tensile Elongation of 33% GR PPA vs. Temperature

Tensile Properties for GR PPA vs. Temperature

Figures 3-7 through 3-9 show the tensile properties of GR
grades of Amodel PPA based upon A-1000, A-4000, and
A-6000 base resins from RT to 175°C (347°F). Amodel
A-1133 HS has the highest strength and stiffness at room
temperature, but A-4133 L and A-6135 HN have better
strength and stiffness above 150°C (302°F).

Tensile Properties 3– 3 Solvay Advanced Polymers, L.L.C.

 Figure 3-12
Tensile Properties of A-1000 GR Grades at Elevated
Tensile Elongation of GR A-1000 PPA Grades vs.
Temperatures
Temperature
Figures 3-10 through 3-12 shows the tensile properties of
three glass-reinforced grades of Amodel PPA, based on the
A-1000 base resin containing 33%, 45% and 60%
glass-fiber over the temperature range of RT to 175°C
(347°F). The tensile strength and modulus increase with
glass fiber content, which is typical of semi-crystalline ther-
moplastics. Both strength and modulus decrease as temper-
atures rise. Elongation increases with increasing tempera-
ture. As a semi-crystalline material, Amodel resins show a
slow but steady loss in mechanical properties from ambient
temperature up to the glass transition temperature (Tg). At
the Tg, there is a more significant loss over a narrow tem-
perature range, followed by another gradual decline. This
behavior is typical of all semi-crystalline thermoplastics.

Figure 3-10 Figure 3-13

Tensile Strength of GR A-1000 PPA Grades vs. Temperature Tensile Strength of Mineral/Glass PPA Grades vs.
Temperature

Figure 3-11 Figure 3-14

Tensile Modulus of GR A-1000 PPA Grades vs. Temperature Tensile Modulus of Mineral/Glass PPA Grades vs.
Temperature

Amodel PPA Design Guide 3– 4 Short-term Mechanical Properties

 Flexural Properties
Flexural Property Comparison
Like tensile strength and modulus, the flexural strength and
The flexural strength of 33% GR Amodel PPA is compared to
modulus of a plastic material can be increased by adding
that of comparable PPS, PEI, and PA 66 materials in Figure
glass fibers into the plastic resin. Treatment of the glass
3-15. Amodel PPA’s strength is superior to the other resins,
fibers can produce a strong chemical bond between the
and although it declines somewhat with moisture condition-
plastic and the glass that enhances both tensile and flexural
ing it is still higher than most of the other materials as
properties over a wide range of environmental conditions. As
molded.
the amount of glass fiber reinforcement is increased in the
plastic, both the flexural strength and modulus increase. This comparison for flexural modulus is shown in Figure
3-16. The flexural modulus of the Amodel resin shown is
Test methods quite high and it is not affected by moisture conditioning.
Flexural properties of thermoplastic materials are deter- The modulus of the PA 66 material declines significantly
mined in accordance with either ASTM D 790 or ISO 178. with moisture conditioning.
ASTM D 790 includes a three point loading test, Method I
and a four point loading test, Method II. In this document,
whenever D 790 is referenced, Method 1 was used. ISO
178, Plastics - Determination of Flexural Properties, speci-
fies three point loading.
The two test methods differ in test specimen dimensions,
apparatus specifications, maximum deflection, and calcula- Figure 3-15
tion details. The three point loading refers to the specimen
Flexural Strength of 30-33% GR Resins
being supported at two points separated by a specified span
and a vertical load applied to the top of the test specimen at
a point midway between the supports. The test specimen
deforms or bends as a result of the load. The specimen is
deflected until rupture occurs or the maximum fiber strain is
reached. The flexural strength is defined as the maximum
fiber stress at the moment of rupture or maximum strain.
The maximum strain specified by the ISO 178 method is 3.5
%, while ASTM D 790 specifies 5%.
When the flexural properties of one material are determined
by both methods, the results obtained by the ASTM are dif-
ferent from those obtained using the ISO method. Data by
both methods are shown in the property tables. When com-
paring materials, ensure that the data being compared was
obtained using the same test method and test condition.
The flexural modulus of elasticity is the ratio, within the Figure 3-16
elastic limit, of the stress in the outermost fiber of the object Flexural Modulus of 30-33% GR Resins
being stressed to corresponding strain. As in tensile testing,
the modulus is calculated from the slope of the load deflec-
tion curve in the linear “Hookean” region.
Flexural testing provides information about the relative
strength and stiffness of materials when subjected to bend-
ing loads. The material with the higher flexural strength can
endure higher bending loads without fracture. Parts pro-
duced from a material with a higher flexural modulus will
deflect less when subjected to a bending load than parts
made of a lower modulus material.
Glass fibers and mineral additives increase the flexural
strength and modulus of Amodel PPA compared to the
unfilled resin. The resultant higher modulus may be desir-
able in many applications.

Tensile Properties 3– 5 Solvay Advanced Polymers, L.L.C.

 Figure 3-19
Flexural Properties at Elevated Temperatures
Flex Strength of GR A-1000 PPA Grades vs. Temperature
Figures 3-17 and 3-18 shows the flexural properties of
three glass-reinforced Amodel grades based on A-1000,
A-4000, A-6000 base resins from room temperature up to
175°C. The grade based on A-1000 has higher strength
and stiffness and room temperature, but the grades based
on A-4000 and A-6000 are better at temperatures above
125°C.
Figures 3-19 and 3-20 present the flexural properties of
Amodel PPA resins based on A-1000 containing different
glass reinforcement levels. As expected, the higher glass
content grades have the higher strength and stiffness
across the temperature range.

Figure 3-17 Figure 3-20

Flex Strength of GR PPA Resins vs. Temperature Flex Modulus of GR A-1000 PPA Grades vs. Temperature

Figure 3-18 Figure 3-21

Flex Modulus of GR PPA Resins vs. Temperature Flex Strength Of Min/Glass PPA Resins vs. Temperature

Amodel PPA Design Guide 3– 6 Short-term Mechanical Properties

 out a circular disc. The maximum stress is reported as the
Figure 3-22 shear strength, and is calculated by dividing the load
required to shear the specimen by the sheared area, which
Flex Modulus of Mineral/Glass PPA Resins vs. Temperature is calculated by multiplying the circumference of the hole by
the thickness of the plaque.
Figure 3-23 compares the shear strength of Amodel PPA to
PA 66, PPS, and PEI. The shear strength of Amodel PPA is
comparable to that of PA 66 and PEI and superior to that of
PPS.

Shear Properties
Shear strength is the resistance to yield or fracture of two
planes moving relative to one another in the direction of
load. Shear strength can also be defined as the maximum
load required to shear the specimen being tested in such a
manner that the moving plane has completely cleared the
stationary plane. Shear strength values are important in
designing structural components because in actual applica-
tions the maximum stress on a component is often a shear
stress.
Shear strength was determined in accordance with ASTM
D 732. In this test, a plaque molded from the material to be
tested is placed on a plate with a circular hole in it. A circu-
lar punch whose diameter is slightly smaller than the hole in
the plate is pushed through the molded plaque, punching

Figure 3-23
Shear Strength of 30-33% GR Resins

Flexural Properties 3– 7 Solvay Advanced Polymers, L.L.C.

Compressive Strength and Modulus Figure 3-26

Compressive strength and modulus are measured in accor- Compressive Modulus A-1000 Resins vs. Temperature
dance with ASTM D 695. The test specimen is molded from
the material to be tested and then placed between parallel
plates. These plates then exert a compressive force on the
specimen, while the force and the distance between the
parallel plates is monitored. The compressive strain is given
by the change in the distance between the plates. The
stress at failure, calculated by dividing the force by the
cross-sectional area, is the compressive strength, and the
slope of the stress/strain curve is the compressive modulus.

Figure 3-24
Compressive Strength of 30-33% GR Resins

Figure 3-25
Compressive Strength of A-1000 Resins vs. Temperature

Amodel PPA Design Guide 3– 8 Short-term Mechanical Properties

Impact Strength Figure 3-27
Because polymers are viscoelastic, their properties depend Izod Impact test specimen
upon the rate at which a load is applied. When the loading
rate is rapid, the part is said to be subjected to impact load-
ing. If a plastic part is to survive an impact without damage,
it must be able to absorb the kinetic energy transferred by
the collision.
The ability of a plastic part to absorb energy is a function of
its shape, size, thickness, and the type of plastic used to
make the part. The impact resistance testing methods most
frequently used may not adequately provide the designer
with information that can be used analytically. These tests
are most useful for determining relative impact resistance
and comparing the notch sensitivities of materials. While the
results may not adequately predict practical toughness in
actual applications, they will serve to offer comparisons
between materials.

Izod (Cantilevered Beam) Impact Data using both methods are included in this document. The
dimensions for the test specimens used are given in Table
Izod impact can be determined using ASTM D 256, Impact
3-1.
Resistance of Plastics and Electrical Insulating Materials, or
ISO 180, Plastics – Determination of Izod Impact Strength. In Izod Impact Property Comparison
both of these tests, a test specimen, as illustrated in Figure
3-27, with a notch of specified radius cut in its edge is Figure 3-28 shows a comparison of the notched Izod impact
struck by a swinging pendulum. After the impact, the pen- strength of 33% glass-fiber reinforced Amodel PPA to
dulum continues to swing, but with less energy due to the glass-fiber reinforced grades of PA66, PPS, and PEI. The
collision. The methods differ in the dimensions of the test glass-fiber reinforcement adds strength to these materials
specimen and in the way the results are calculated. When but reduces elongation and all of these materials have low
using ASTM D 256, the energy lost is divided by the width of Izod values. PA66 shows an increase in impact strength
the specimen remaining after notching, and the units are when moisture conditioned.
either Joules per meter (J/m) or foot-pounds per inch
(ft-lb/in). When using ISO 180, the amount of energy lost is
multiplied by 1,000 and divided by the product of the Figure 3-28
remaining width and the specimen thickness, and the units
Izod Impact Strength of 30-33% GR Resins, ASTM D 256
are either kiloJoules per square meter (kJ/m2) or
foot-pounds per square inch (ft-lb/in2).
Izod impact can also be run on un-notched specimens. The
applicable test methods are ASTM D 4812 or ISO 180U. The
major difference between these methods and the notched
methods is that the full width of the specimen is used in the
calculation.

Table 3-1
Izod Test Specimen Dimensions
ISO 180 ASTM D 256
Dimension mm in. mm in.
Length 80.00 3.150 63.50 2.500
Width 10.00 0.394 12.70 0.500
Thickness 4.00 0.157 3.20 0.125
Notch Radius 0.25 0.010 0.25 0.010

Compressive Strength and Modulus 3– 9 Solvay Advanced Polymers, L.L.C.

Figure 3-29 shows the Izod impact strength of a toughened Figure 3-31
grade of Amodel PPA, ET-1000 HS, and that of high impact
Low Temperature Izod of Amodel PPA Grades
grades of PA66 and PA6, as well as polycarbonate(PC) and a
polycarbonate-polyester (PC/PBT) blend. The Amodel grade
has impact strength comparable or better than the other
materials. Figure 3-30 shows that this grade is not as sensi-
tive to notch radius as most amorphous polymers are.
Figure 3-31 shows that ET-1000 HS has good Izod impact at
temperatures lower than room temperature, but Amodel
AT-1001 L has superior impact resistance at temperatures
as low as -40°C.

Charpy (Supported Beam) Impact

Charpy is similar to Izod because a test specimen is struck
by a falling pendulum and the energy the break the speci-
men measured. The primary difference is that in the Charpy
test the specimen is supported at both ends and struck in
the middle, as shown in Figure 3-32. The test methods used
were ISO 179/1eA and 179/1eU.

Figure 3-29 Figure 3-32

Izod Impact of Amodel ET-1000 Compared to PA and PC Charpy Impact Test Specimen

Figure 3-30 Figure 3-33

Notch Radius Sensitivity of ET-1000 HS and PC Notched Charpy Impact Strength of 30-33% GR Resins

Amodel PPA Design Guide 3– 10 Short-term Mechanical Properties

 Poisson’s Ratio
Falling Weight Impact Properties
Poisson’s ratio is a measure of the strain characteristics
ASTM D 3763, High-Speed Puncture Properties of Plastics
imposed on a material transverse to the applied load.
Using Load and Displacement Sensors, was used to mea-
sure the practical toughness of Amodel polyphthalamide Poisson’s ratio is the ratio of lateral strain to longitudinal
resins. strain within the proportional limit. To illustrate, consider a
cylindrical bar subjected to tensile stress, the length (L)
In this test, an injection molded specimen is clamped down
increases and simultaneously its diameter (D) decreases.
over a 76-mm (3-inch) diameter hole and a weighted
plunger is dropped from a predetermined height to give it a In this case, Poisson’s ratio () would be calculated by:
predetermined impact velocity. The plunger assembly con- −ΔD
sists of a 12.7-mm (0.500-inch) diameter steel rod with a
υ= D
hemispherical end. The plunger assembly is attached to a
ΔL
load cell which measures the energy needed to cause a
sample to fail. L
Most plastic materials have a Poisson’s ratio between 0.3
Specimens can fail in either a brittle or a ductile mode. In a and 0.5.
ductile failure mode, the specimen is permanently deformed
to the shape of the plunger, but remains in one piece after Table 3-4 gives the Poisson’s ratios for various Amodel for-
the penetration by the plunger. In a brittle failure mode, the mulations at 23°C (73°F),”dry, as molded”.
specimen does not have sufficient ductility to be deformed
without failure, and therefore breaks into two or more pieces Table 3-4
when impacted by the plunger. Poisson’s Ratio for Amodel Products
This method is preferred to ASTM D 3029, because although
Amodel PPA Grade Poisson’s ratio, υ
the impact values obtained are similar in nature to the “stair
step” falling weight impact test, the instrumented test ET-1000 HS 0.40
results are obtained via a computerized data reduction tech-
nique and fewer samples are required. A-1115 HS 0.41

AS-1133 HS 0.41
Table 3-3
AS-1145 HS 0.41
Penetration Impact (ASTM D3763) of Impact Modified PPA
A-1230 L 0.31
Max Load, Total Energy,
Grade and Condition N lb J ft-lb A-1240 L 0.29
AT-1001 L DAM 4900 1100 54 40
A-1340 HS 0.38

AT-1002 HS DAM 4400 1000 54 40 A-1440 HS 0.40

AT-1002 HS 50% RH 4000 900 47 35 A-1540 HS 0.38

AT-5001 DAM 4400 1000 54 40

AT-5001 50% RH 4000 900 50 37

ET-1000 HS DAM 4670 1050 54 40

ET-1001 L DAM 5600 1260 64 47

Impact Strength 3– 11 Solvay Advanced Polymers, L.L.C.

Long-term Mechanical Properties
In order for any engineered component fabricated from a
polymeric resin to perform within specified parameters
throughout its intended design life, the design engineer
must consider the long term effects of a number of factors.
A variety of stress loads as well as property changes due to
environmental factors must be taken into consideration. To
assess the time related effects of stress on the behavior of
polymeric materials, creep and fatigue properties are mea-
sured. A wide variety of environmental factors can also
affect the performance of an engineered component and
this subject is discussed in detail in the section entitled
“Environmental Resistance” starting on page 7-1. However,
certain environmental factors are so pervasive that it was
deemed appropriate to consider them in this section. These
are the effects of moisture absorption and long-term expo-
sure to high ambient temperatures.
This section will present data generated to assist the design
engineer with the analysis of design life requirements. The
data in this section includes:
* Creep modulus in tension, flexure, and compression
modes;
* Tensile creep rupture;
* Fatigue endurance;
* Property changes due to moisture absorption;
* Dimensional changes due to moisture absorption; and
* Property changes due to long-term exposure to elevated
temperatures.
The long term property data presented in this manual has
been generated to show trends and property loss for a num-
ber of Amodel PPA grades under a variety of representative
conditions. Due to the time required to generate the data,
not all grades or sets of conditions can be included. The
data are intended to show trends as a function of filler/rein-
forcement systems so that the designer may make edu-
cated decisions.
In some instances, attempts to generate data on long term
properties utilize “accelerated” test conditions to speed data
acquisition. Caution should be taken when evaluating data
generated in this manner as it is often non-linear. This is
especially true when measuring property loss as a function
of elevated temperature and/or chemical exposure. Thermal
“thresholds” such as the glass transition temperature (Tg)
and ultimately, the melting point are the main contributors to
this non-linear behavior.

Amodel PPA Design Guide 4– 1

Creep The normal progression of creep occurs in these three
stages:
When a material is subjected to stress, an immediate strain
occurs. For small strains, this strain is proportional to the 1. A rapid initial deformation.
stress and calculable from the appropriate modulus. If the 2. Continued deformation at a slow and constant rate.
application of stress continues for an extended period of
time, additional strain may be observed. This behavior is 3. Yield followed by rupture for ductile materials, or rupture
referred to as creep and the additional strain as creep for non-ductile materials.
strain. The significance of data from creep tests is that they can be
While creep is observed in metals, the phenomenon is more used to calculate the time dependent creep strain and creep
significant with plastics. Their lower modulus means that at modulus for use in stress calculations and to determine the
the same stress level, the magnitude of the strain is larger safe stress levels for specific time and temperature condi-
and a higher proportion of ultimate strain. In general, the tions. If the creep tests are conducted until failure occurs at
closer the initial strain is to the ultimate strain, the more various stress levels, a creep rupture curve can be
likely it is that creep is significant. produced.
The reality of creep must be factored into a design to insure Another aspect of creep may further complicate the analy-
long term satisfactory performance. The initial task is to sis: Under a given stress, creep will occur at the expected
determine if the creep will have a significant effect on the rate based on the apparent modulus. However, depending
dimensions or function of the part. If the stress levels are on how the stress is applied, the initial creep can result in
low enough so that any dimensional change will be insignifi- stress relaxation. For example, if a plastic part is clamped
cant, creep may be ignored. However, if the stress levels are with a bolt torqued to achieve a compressive stress on the
such that creep will result in unacceptable deformation, an plastic. As creep strain occurs, the compressive stress will
alternative design must be considered. This may include drop, resulting in less creep. The compressive stress will
investigating a material with a higher creep modulus, or drop until an equilibrium is established at a lower stress
incorporation of an alternate design such as a metallic insert level. A “single point” analysis would indicate that torque
to serve as the load bearing member. Additional discussion retention would drop to a failure level, while, in reality, an
can be found in the Design section. acceptable equilibrium is reached before failure levels
occur.
In general, glass and mineral/glass reinforced grades creep
less than the unreinforced grades. The time required to Further discussion of the influence of creep on part design,
observe measurable creep will also be shorter for the including examples, can be found on page 8-9 .
unreinforced grades. Apparent or creep modulus will
decrease at elevated temperatures with a corresponding
increase in creep. At temperatures above the glass transi-
tion temperature (Tg), the apparent modulus of the
unreinforced grades is so low that even relatively low loads
can result in significant creep, and therefore these
unreinforced grades are usually not recommended for use in
structural applications above these temperatures. Structural
applications that will be exposed to elevated temperatures
should be specified in the glass or mineral/glass reinforced
grades
Creep can occur in tension, compression, or flexural modes.
Therefore, to evaluate creep properties, strain is measured
as a function of time while a specimen is subjected to a
constant tensile, compressive or flexural load at specified
environmental conditions. The procedure followed is
described in ASTM D 2990, Standard Test Methods for Ten-
sile, Compressive, and Flexural Creep and Creep-Rupture of
Plastics. ISO Method 899, Plastics - Determination of Creep
Behaviour is similar, but because of differences in the test
specimen may not yield exactly the same results. The gen-
eral trends shown by either method should be comparable,
but material comparisons should only be done using data
generated by the same method.

4– 2 Solvay Advanced Polymers, L.L.C.

 Figure 4-2
Tensile Creep
Tensile creep was measured at three temperatures: 23°C Apparent Modulus at 23°C (73°F) and 34.5 MPa(5 kpsi)
(73°F); 125°C (257°F); and 175°C (347°F) and two stress
levels: 13.8 MPa (2000 psi) and 34.5 MPa (5000 psi). Test
specimens were 3.2 mm (0.125 inch) thick injection molded
ASTM D-638 Type I tensile bars. Samples were placed
under test in the “dry, as molded” condition. The samples
tested at the two elevated temperatures were placed in air
circulating ovens. Although the strain is measured, the
results are typically presented as the apparent modulus,
which is calculated by dividing the strain by the applied
stress. The apparent modulus is the value design engineers
use in their mechanical design calculations when designing
components that must perform when subjected to sustained
load.
The materials tested were A-1133 HS (33% glass-fiber),
A-1145 HS (45% glass-fiber), and A-1160 HSL (60%
glass-fiber). The results of the room temperature testing are Figure 4-3
shown in Figures 4-1 and 4-2. Apparent Modulus at 125°C(257°F) and 13.8 MPa(2 kpsi)
The results of the tensile creep testing at 125°C (257°F) are
shown in Figures 4-3 and 4-4, and at 175°C (347°F) in Fig-
ures 4-5 and 4-6.

Figure 4-1
Apparent Modulus at 23°C (73°F) and 13.8 MPa (2 kpsi)

Figure 4-4
Apparent Modulus at 125°C(257°F) and 34.5 MPa(5 kpsi)

Amodel PPA Design Guide 4– 3 Long-term Mechanical Properties

Figure 4-5 Figure 4-7
Apparent Modulus at 175°C(347°F) and 13.8 MPa(2 kpsi) Isochronous Stress-Strain of A-1133 HS PPA

Figure 4-6 Figure 4-8

Apparent Modulus at 175°C(347°F) and 34.5 MPa(5 kpsi) Isochronous Stress-Strain of A-1145 HS PPA

Isochronous Stress/Strain Curves

Another format for presenting creep data is through the use Figure 4-9
of isochronous (equal time) stress versus strain curves. To Isochronous Stress-Strain of A-1160 HSL PPA
prepare an isochronous curve, plot the stresses and the
resultant strains for a single time interval and draw a
smooth curve through the points. Repeat this process for
each time interval.
This method has the advantage of providing a concise sum-
mary of a large amount of data. The apparent modulus at
any point can be calculated by dividing the stress by the
indicated strain. (Please note that the figures show strain
expressed in percent; actual strain is the plotted value
divided by 100.)
The isochronous stress/strain curves for Amodel A-1133 HS
resin at 23°C, 125°C, and 175°C are shown in Figure 4-7.
Figure 4-8 shows the same information for Amodel A-1145
HS and Figure 4-9 shows the data for Amodel A-1160 HSL.

Creep 4– 4 Solvay Advanced Polymers, L.L.C.

As expected, the more glass reinforcement in the com- Creep resistance can be predicted to a large extent by the
pound, the better the creep resistance. relationship of the service temperature to the material’s
glass transition temperature. Typically, creep resistance is
Tensile Creep Rupture good at service temperatures much lower than Tg, and
Creep rupture is defined as a failure or rupture that occurs becomes poorer as service temperature approaches Tg.
as a result of a sustained load. Because the stress level at Therefore, it is not surprising that Amodel resins have creep
which rupture occurs due to sustained load is lower than resistance superior to many traditional semi-crystalline ther-
the short-term strength, creep rupture can be the limiting moplastics. For example, Amodel A-1000 resin has a glass
design property. transition temperature of 123°C (253°F) as determined by
Differential Scanning Calorimetry (ASTM D 3418). The corre-
The objective of tensile creep rupture testing is to determine
sponding Tg for PA 66 is 65°C (149°F). At all temperatures
the time required for a sustained load to produce a rupture.
up to its Tg, Amodel resins do have superior creep
A plot of stress versus the time to rupture is commonly
resistance.
known as a “creep rupture envelope”. Because the strength
of a material varies with temperature, a “creep rupture Figure 4-11 compares the apparent flexural modulus of
envelope” can be generated for each temperature of Amodel AS-1133 HS and A-1240 L resins to a 33% glass
concern. reinforced PA 66. While the AS-1133 HS resin is clearly
superior to the glass reinforced PA, even the mineral filled
Creep rupture envelopes were developed in accordance with
ASTM D 2990. Tensile specimens were 3.2 mm (0.125 inch)
thick injection molded ASTM D 638 Type I tensile bars. The
environments were the same as in the tensile creep testing Figure 4-11
above. The samples were loaded in tension using pneumati-
cally actuated bellows to maintain indicated stress levels. Apparent Flex Modulus at 69 Mpa (10 kpsi) at 23°C (73°F)

Figure 4-10
Tensile Creep Rupture - AS-1133 HS

Figure 4-12
Apparent Flex Modulus at 14 Mpa (2 kpsi) at 83°C (181°F)

The tensile creep rupture envelopes for Amodel AS-1133 HS

resin are shown in Figure 4-10 at 65, 100, and 150°C.

Flexural Creep
Flexural creep was determined according to ASTM D 2990
using the three-point bending mode with a 50.8 mm (2 inch)
span. Test specimens were 127 x 12.7 x 3.2 mm (5.0 x 0.5
x 0.125 inch) injection molded bars placed on test “dry, as
molded”. The environment was maintained at 50% relative
humidity and 23°C (73°F). Stress levels were predetermined
from flexural strength versus temperature curves and cho-
sen to be 25-35% of the ultimate strength of the material at
the test temperature.

Amodel PPA Design Guide 4– 5 Long-term Mechanical Properties

grade – Amodel A-1240 resin – has an effectively higher reciprocating or rotating devices where loading is cyclic, and
creep modulus after 1000 hours under load. mechanical devices such as gears where the cyclic load is a
function of position.
Figure 4-12 compares the apparent flexural modulus of
Amodel ET-1000 resin with that of unreinforced and impact This phenomenon is well known in metals. Metallurgists
modified grades of PA66 at 83°C (181°F) and 14 MPa (2 have defined the term “Fatigue Endurance Limit” to repre-
kpsi). sent the maximum cyclical stress that a material can be
subjected to without failure. Normally, this stress level corre-
Compressive Creep sponds to the highest stress level that does not cause failure
Compressive creep was determined according to ASTM in 10 million (107) cycles.
D 2990. Test specimens were 12.7 x 12.7 x 25.4 mm (0.5 x While the term “Fatigue Endurance Limit” is sometimes
0.5 x 1.0 inch) injection molded bars. The ends of the bars used in design discussions involving plastic materials, the
were machined until they were parallel to each other within response of plastics to cyclic stress is more complex than
0.025 mm (0.001 inch) and perpendicular to the axis. Dis- the response of metals, and the term is not strictly applica-
placement was monitored with bonded strain gauges. As in ble. Fatigue data is typically presented by plotting stress
the flexural creep experiments, the stress levels were cho- versus number of cycles at rupture. A smooth curve is cal-
sen to be less than 35% of the compressive strength at the culated that represents the best fit to the data. For compo-
temperature of the test. nent design purposes, this S - N (stress - number of cycles)
Figure 4-13 shows the compressive creep moduli of Amodel curve provides strength values appropriate for the compo-
AS-1133 HS resin at 23°, 100°, and 150°C (73°, 212°, and nents required life.
302°F). These moduli are lower than the flexural creep When designing a component that will be subjected to cyclic
moduli given in Figure 4-11. This is due to less fiber orienta- loading, the establishment of fatigue strength requirements
tion in the direction of the induced strain. is desirable. However, analysis of the fatigue strength
requirements is complicated by a large number of factors
that may influence them. Some of these factors are: the
Figure 4-13
shape of the component; stress concentration factors; the
Apparent Compressive Modulus of AS-1133 HS rate of load application; any temperature change caused by
load application; type of stress induced by load , that is, ten-
sile, compressive, or shear, etc.; environmental factors, such
as, chemicals, radiation, ambient temperature; residual
stresses; the duty cycle; and the desired component life.

Fatigue Strength of Amodel resin

When measuring and/or comparing the fatigue strength of
plastic materials, it is critical to specify the mode (tensile,

Figure 4-14
Flex Fatigue of GR Resins at 23°C (73°F) and 32 Hz

In most applications where Amodel resin will be loaded in a

compressive manner, the load will be applied in the direc-
tion transverse to flow direction and consequently the fiber
orientation. Therefore, the apparent moduli presented here
are representative of the material’s performance in typical
applications.
Fatigue Resistance
When a material is stressed cyclically, failure or rupture will
occur at stress levels much lower than its short-term ulti-
mate strength. Examples of cyclic stress would include com-
ponents subjected to severe vibration, components of

Creep 4– 6 Solvay Advanced Polymers, L.L.C.

compressive, or flexural), the frequency, and the stress can be machined from available stock shapes and subject to
profile. performance testing under the requirements of the applica-
tion. Stock shapes are usually available as extruded slabs or
Figure 4-15 rods and generally exhibit slightly lower mechanical proper-
ties than the injection molded part. Additionally, the machin-
Flex Fatigue of AS-1145 Resin at Elevated Temperature ing operations usually induce stresses that would not nor-
mally be present in an injection molded part. As a result of
this, a successful prototype test imparts an extremely high
confidence level in the reliability of the design.

The fatigue strength of Amodel resins was determined in

accordance with ASTM test method D 671. This method
uses a cantilever beam configuration with a constant deflec-
tion. The results shown in Figure 4-14 were generated at a
frequency of 32 Hz. Failure was defined when the stress
level decayed to 90% of its initial value. The Amodel resins
resist higher cyclic loads longer than PA66.
Figure 4-15 gives the fatigue behavior of Amodel AS-1145
HS resin at 110° and 170°C (230° and 338°F). As expected,
raising the temperature reduces the amount of cyclic stress
that can be endured.
A good example of an application involving cyclical stress is
a gear. As the driving gear causes the driven gear to rotate,
each tooth is subject to stress. This is then followed by a
period of time at low or zero stress. In designing a gear
tooth, the appropriate strength criteria is the fatigue endur-
ance limit of the material at the operating conditions of the
gear.
After all of the calculations have been made, the part design
can be modified to best utilize the properties of the selected
material. Conversely, the material grade can be modified to
best suit the application requirements. An extremely useful
tool to verify a design is to perform Finite Element Analysis
(FEA). In FEA, the part is electronically modeled and a com-
puter program is used to simulate the anticipated loads and
stresses. The resulting strain levels can be evaluated and, if
necessary, part design or material changes can be made. It
is much easier to make changes to the FEA model than to a
fabricated part or tooling.
Even after calculations and FEA’s have been performed, the
best way of evaluating a material for a component subject to
dynamic stresses is actual prototype testing. Prototype parts

Amodel PPA Design Guide 4– 7 Long-term Mechanical Properties

Moisture Effects constant specimen weight is obtained, typically for several
days. As would be expected, this accelerated procedure has
As with most thermoplastic resins, parts made from Amodel
some side effects which influence the test values. In the
resins can absorb moisture from the atmosphere. This
accelerated procedure, the test specimens are annealed and
absorption is a physical, not a chemical change and is
stress relieved, which may actually cause in an improve-
therefore reversible, in that parts can be “dried out” under
ment in the property test results. Conversely, exposure to
proper conditions. Amodel polyphthalamide resins have sig-
boiling water can cause some hydrolysis of the polymer,
nificant amounts of aromatic character in the polymeric
yielding a loss in properties. Additionally, exposure to the
“backbone” and this causes them to absorb much less
boiling salt solution has been shown to degrade the bond
moisture than aliphatic polyamides such as PA 66 and PA 6.
between the polymer and a reinforcing media, such as fiber-
As a result, the dimensions, strength, and stiffness of
glass, resulting in a loss of mechanical properties such as
Amodel parts will be significantly less affected by the
tensile, flexural and impact. Nonetheless, the effect of
absorption of moisture than traditional aliphatic PA parts.
absorbed moisture on Amodel resins is minimal.
Since moisture is ubiquitous, knowledge of the effects of
moisture on the properties of a material is critical to the Moisture Absorption and Glass Transition
design engineer trying to meet end use requirements. Temperature (Tg)
Significance of Moisture Absorption Perhaps much more significant than the effect of moisture
absorption on room temperature properties is the effect of
When a polymer absorbs atmospheric moisture, a number of
moisture absorption on the Glass Transition Temperature
changes may occur. Obviously, the part weight will increase
(Tg) of a polymer. By definition, the Tg of a polymer is the
and this weight increase is typically used to measure the
temperature above which, the crystalline region of the poly-
amount of moisture absorbed. Additionally, there may be
mer matrix is no longer dominant over the amorphous
some dimensional changes, generally an increase; parts will
region. Above the Tg, the amorphous region is dominant and
become larger. The presence of reinforcing fillers such as
there is a noticeable loss in mechanical properties as seen
fiberglass may result in anisotropic dimensional change due
in the discussion on mechanical properties vs. temperature.
to the fact that the fibers align themselves in the direction of
In unreinforced grades, this is very significant in that the
polymer flow as the resin fills the tool. Similar to mold
properties drop to levels which are essentially useless from
shrinkage values, dimensional changes due to moisture
a mechanical design perspective. In the reinforced grades,
absorption are often reported in flow and transverse
while the properties above Tg are still useful from a design
directions.
perspective, the loss of mechanical properties is significant
Mechanical properties may also be affected by moisture enough to make major design considerations.
absorption. Generally, a slight decrease in physical proper-
The effect of absorbed moisture on semi-crystalline poly-
ties such as tensile and flexural strength are seen. The
mers is to lower the glass transition temperature. The sever-
respective moduli also decrease slightly. Impact strength
ity of reduction is dependent on the specific polymer and the
values tend to increase slightly since the presence of mois-
amount of moisture absorbed.
ture can tend to plasticize the polymer. Since water is a con-
ductor, absorbed moisture can have a negative effect on the This phenomenon becomes of significant concern when
dielectric properties of a molded part. designing with a polymer that has a Tg near or below 100°C
(212°F). For example, a polymer with a Tg of 80°C (Dry as
Manufacturers of polymers that absorb moisture usually
molded) might exhibit a Tg of only 60°C after absorbing
publish two sets of data, one listing test results on test
moisture. The designer must consider the significant loss in
specimens that have no absorbed moisture, commonly
properties above 60°C due to the reduction in Tg when
referred to as “Dry – As Molded” (DAM), and a second set of
making decisions. Polymers with even lower dry Tg’s can
data that is generated on test specimens that have been
have a Tg reduction to at or near room temperature with
allowed to come to an equilibrium weight in a 50% Relative
moisture absorption. This can create a significant design
Humidity environment, known as “50% RH”. Polymers like
consideration.
PA 6 and PA 66 absorb moisture relatively quickly and reach
equilibrium in a 50% Relative Humidity environment quickly. Alternatively, consider the Amodel A-1000 series polymers,
Providing 50% RH data for these materials is fairly easy and which have a dry Tg of 123°C. Absorption of moisture at
extremely relevant to design, as will be understood in the room temperature can reduce this Tg to 84°C and have a
subsequent discussion. On the other hand, polymers like slight reduction in “room temperature” properties. However,
Amodel PPA absorb moisture very slowly and can take years since moisture absorption is a reversible phenomenon
to reach an equilibrium at 50% RH. In order to provide 50% (moisture absorption is a physical, not a chemical reaction),
RH data, a method was developed to accelerate the condi- at temperatures above 100°C, the polymer actually dries
tioning of test specimens. This involves boiling the test out, returning the Tg to the original 123°C value. Therefore,
specimens in an aqueous solution of potassium acetate until the Tg reduction due to moisture absorption is essentially

Fatigue Resistance 4– 8 Solvay Advanced Polymers, L.L.C.

insignificant for Amodel resins. The following data are pre- Figure 4-17
sented for consideration in applications in which moisture
Effect of Moisture on Tensile Strength of GR Resins
absorption is expected at ambient temperatures and a slight
loss of properties may be anticipated. Since the polymer
“desorbs” moisture and regains dry properties on exposure
to temperatures above 100°C, moisturized test data above
100°C is irrelevant for Amodel resins, but quite important for
polymers that have a Tg near or below 100°C.

Absorption Amount
As has been mentioned, water absorption is a reversible
process. At each specified relative humidity and tempera-
ture, a resin will absorb moisture until an equilibrium is
established. At equilibrium, a polymer absorbs moisture at
the same rate it releases moisture, achieving a constant
weight. Since the polymer, not the filler or reinforcement
additives absorb the moisture, the amount of water
absorbed is proportional to the amount of polymer present
in each grade, the more highly filled grades will have lower
absorption than the unfilled grades. Figure 4-16 compares Figure 4-18
the increase in weight due to moisture absorption of
Amodel AS-1133 HS to that of 33% glass reinforced PA 66 Effect of Moisture on Flex Modulus of GR Resins
at room temperature and specified relative humidities. The
33% glass reinforced PA 66 absorbs significantly more
moisture than Amodel AS-1133 HS resin. The amount of
time required for Amodel resins to reach equilibrium is also
significantly longer than PA 66.

Figure 4-16
Moisture Absorption of GR Resins

Figure 4-18 compares the flexural modulus of Amodel

AS-1133 HS resin to that of a 33% glass reinforced PA 66 at
73°F (23°C) and various moisture contents. The modulus of
the Amodel resin is higher as molded and remains relatively
constant. The modulus of the PA resin drops rapidly with
increasing moisture level and temperature due to the fact
that the Tg of PA 66 is below 100°C and decreases further
with moisture absorption.

Effect of Moisture on Strength and Stiffness Dimensional Change due to Moisture

Figure 4-17 compares the tensile strength of Amodel To evaluate the effect of moisture absorption on part dimen-
AS-1133 HS resin to that of 33% glass reinforced PA 66 at sions, plaques 102 x 102 x 3.6 mm (4 x 4 x 0.125 inch)
73°F (23°C) and specified moisture content. The tensile were molded, measured, and then placed into environments
strength of the Amodel resin is superior to that of the PA at room temperature, 23°C (73°F), and either 50% or 100%
“dry, as molded” and the difference increases with higher relative humidity. Periodically the plaques were removed
moisture levels. and measured. The direction of flow during the molding pro-
cess was noted and data for both the flow direction and
transverse to flow was reported. The dimensional change
Amodel PPA Design Guide 4– 9 Long-term Mechanical Properties
was calculated by subtracting the initial length from the final Figure 4-20 shows the same results for Amodel A-1340
length, dividing the result by the original length, and multi- PPA, a 40% mineral filled grade. Not only is the magnitude
plying the result by 100 to express the change in percent. of the dimensional change smaller, but the difference
between flow and transverse direction is almost negligible.
Figure 4-19 shows the results of this testing for Amodel
AS-1133 resin. Even at 100% relative humidity, the dimen- Dimensional Change Compared to PA 66
sions continue to change for a considerable length of time.
These graphs show that after one year, the rate of change Figure 4-21 compares the dimensional change due to mois-
has greatly diminished but the dimensions are still chang- ture absorption of Amodel AS-1133 HS resin with that of
ing. Dimensions in the flow direction change less than the 33% glass reinforced PA 66 at 100% RH. To ensure a valid
transverse direction, most likely due to alignment of the comparison, both resins were molded under conditions that
reinforcement fiber in the flow direction. The magnitude of promote maximum crystallinity. In the case of the Amodel
the dimensional change is relatively small (less than 0.6%), resin, a mold temperature of 135°C (275°F) was used. For
but could be important is applications requiring extremely the PA 66, the mold temperature was 93°C (200°F). Plaques
tight dimensional tolerances and stability. with at thickness of 3.2 mm (0.125 inch) were exposed to
100% RH at room temperature.
Amodel resin absorbs moisture much more slowly than PA
66, because the diffusion coefficient at room temperature of
Figure 4-19 water in PA 66 is approximately five times larger than that
Dimensional Change of 33% GR PPA of Amodel resins. Therefore, for these plaques, PA 66
reaches equilibrium in approximately four months while
Amodel AS-1133 HS resin requires over two years.

Figure 4-21
Dimensional Comparison of GR PA66 to GR PPA at 100% RH

Figure 4-20
Dimensional Change of 40% Mineral Filled PPA

Moisture Effects 4– 10 Solvay Advanced Polymers, L.L.C.

 above the glass transition temperature, or about 160°C
Thermal Properties (320°F) for Amodel PPA.
In general, the thermal properties characterize the way a in In general, annealing reduces the variability in deflection
material responds to changing temperatures, both in the temperature measurements, in addition to raising the value
short and long term . Thermal properties include the effects slightly. Figure 5-1 shows the effects of mold temperature
of temperature on: and annealing on deflection temperature at 1.8 MPa (264
• 1. Strength and stiffness,
psi) for Amodel AS-1133 HS resin. As can be seen, mold
temperature and/or annealing effects can cause the deflec-
• 2. Dimensions, tion temperature to vary by as much as 17°C (30°F). The
deflection temperature data in this manual were generated
• 3. Chemical changes in the polymer itself due to ther-
on specimens annealed at 160°C (320°F) for 2 hours.
mal or oxidative degradation,
• 4. Softening, melting, or distortion, and Figure 5-1

• 5. Morphology. Mold Temperature and Annealing Effects on HDT of Amodel

AS-1133 HS
The properties of the material in the molten state are dis-
cussed in the Amodel PPA Processing literature. The behav-
ior of the material while burning is discussed in the section
on combustion properties.
Heat Deflection Temperature - HDT
The tests most commonly used by the plastics industry to
measure short-term thermal capability are ASTM D 648,
Standard Test Method for Deflection Temperature of Plastics
Under Flexural Load and ISO 75. Plastics - Determination of
Temperature of Deflection under Load. These tests are com-
monly referred to as Heat Distortion Temperature or HDT or
Deflection Temperature under Load (DTUL). Both tests are
similar in that the test specimen is supported at two points
while a load is applied to the center. The temperature is
increased at a constant rate until the specimen deflects a
specified amount as indicated by a dial micrometer. Deflection Temperature is a modulus at temperature mea-
Although details such as specimen geometry, deflection surement. Classical stress/strain analysis indicates that the
endpoint, specimen orientation, and distance between the ASTM D 648 test actually measures the temperature at
supports are different for these methods, the desired stress which the flexural modulus is 240 MPa (35,000 psi) when
levels for both methods includes a loading of 1.8 MPa (264 the applied stress is 0.45 MPa (66 psi), or 965 MPa
psi) and 0.45 MPa (66 psi). When comparing data from mul- (140,000 psi) when the applied stress is 1.8 MPa (264 psi).
tiple sources, it is important to verify that the same test Because the test method directs that the indicator be
method was used for all the data being compared. In the re-zeroed after five minutes, any creep strain that occurs in
product property tables starting on page 2-3, data collected the first five minutes is effectively subtracted from the end-
using both methods is listed. Examination of the data will point strain lowering the actual modulus at the end point of
reveal a considerable amount of difference between the val- the test. The initial modulus can be related to the creep
ues for some grades. strain.
Certain test parameters can have a significant influence In summary, deflection temperature does not measure ther-
upon the results obtained in this test. The designer should mal capability, it simply provides one point on the modulus
be certain that data from multiple sources are comparable. versus temperature curve.
The most common and critical error is to compare the In general, HDT can only be used as a general indicator of
results from testing performed at 1.8 MPa (264 psi) with short-term thermal capability. It is useful for comparing sim-
results obtained from testing at 0.45 MPa (66 psi). All ilar materials but can be misleading if, for example, an
Amodel resins are tested at 1.8 MPa, unless otherwise amorphous material is compared to a semi-crystalline
specified. The other test parameters that should be consid- material. It doesn’t provide any information about long-term
ered are specimen thickness and thermal history. The test thermal stability. The actual loads and performance require-
may be performed as molded or after heat treating or ments will dictate the suitability of the material. Many
“annealing” for several hours at a temperature slightly semi-crystalline resins can be used in applications that
Amodel PPA Design Guide 5– 1
experience temperatures higher than their deflection tem- Figure 5-2
perature value.
HDT of 30-33% GR Resins
Deflection Temperature Values for Amodel Resins
Deflection temperature values by both ASTM D 648 and ISO
75Af for 19 representative grades of Amodel PPA are shown
in the Tables starting on page 2-3.
Figure 5-2 compares the deflection temperature at 1.8 MPa
(264 psi) of Amodel AS-1133 HS resin with a 33% glass
fiber reinforced PA 66, a 30% glass fiber reinforced
polyphenylene sulfide, and a 30% glass fiber reinforced
polyetherimide. Amodel resin offers a 75°C HDT advantage
relative to PEI, a 42°C advantage relative to PA66, and a
22°C advantage relative to PPS.
Coefficient of Linear Thermal Expansion
The dimensions of most materials increase with increasing
temperature. The coefficient of linear thermal expansion (α)
is the ratio of the change in length to the change in lower thermal expansion coefficient than the polymers, the
temperature. coefficient of expansion are generally lower in the flow
direction than the transverse direction.
If the coefficient α is known, the change in length of an uni-
form straight bar raised to a temperature Tf can be calcu- The values shown in Table 5-1 should allow the design
lated from: engineer to estimate the magnitude of the thermal stresses
in parts molded from Amodel resins due to thermal
Δ L = α L (T F − T 0 ) expansion.
where:
Δ L = change in length
L = original length
α = coefficient of linear thermal expansion
T F = final temperature
T 0 = original temperature

The coefficient of linear thermal expansion (α), as measured

by ASTM E 831, of several Amodel grades and some com-
mon metals is given in Table 5-1 . This method provides an
average value for the expansion coefficient over a tempera-
ture range.
The thermal expansion behavior of metals is uniform over
the temperature range of concern. As shown in Table 5-1 ,
the thermal expansion coefficients of the polymer materials
are a function of the temperature range used for the mea-
surement. In general, the polymer materials expand slightly
more above their glass transition temperature than they do
below it and the behavior in the vicinity of the Tg is also
somewhat non-linear. However, over large temperature
ranges, the variations are usually insignificant and excellent
prediction of dimensional properties can be obtained using
the values provided in the table. Also, the addition of glass
fiber and other reinforcing additives results in the thermal
expansion becoming directional. Since fibers tend to
become oriented in the flow direction, and since glass has a

Heat Deflection Temperature - HDT 5– 2 Solvay Advanced Polymers, L.L.C.

Table 5-1
Coefficients of Linear Thermal Expansion
Values are 10-6 L/L per degree where L is Length

Temperature 0 - 50°C (32 - 122°F) 50 - 100°C (122 - 212°F) 100 - 150°C (212 - 302°F) 150 - 200°C (302 - 392°F)
Direction FD* TD** FD* TD** FD* TD** FD* TD**
Units /°C /°F /°C /°F /°C /°F /°C /°F /°C /°F /°C /°F /°C /°F /°C /°F
Glass-Reinforced Grades
A-1133 HS 24 13 50 28 24 13 60 33 27 15 99 55 27 15 130 72
A-1145 HS 22 12 49 27 21 12 58 32 27 15 88 49 15 8 122 68
A-1160 HSL 18 10 40 22 18 10 49 27 12 7 89 49 9 5 106 59
A-4133 L 22 12 66 37 20 11 88 49 17 9 119 66 5 3 152 84
A-6135 HN 23 13 59 33 21 12 63 35 16 9 96 53 15 8 109 61
AS-4133 HS 20 11 64 36 20 11 87 48 20 11 114 63 9 5 126 70
Toughened Grades
AT-1002 HS 70 39 84 47 85 47 101 56 145 81 126 70 112 62 153 85
ET-1000HS 68 38 80 44 85 47 81 45 147 82 97 54 142 79 113 63
ET-1001 L 71 39 69 38 94 52 80 44 167 93 88 49 170 94 118 66
AT-5001 93 52 106 59 136 76 144 80 184 102 184 102 153 85 142 79
Toughened Glass-Reinforced Grades
AT-1116 HS 20 11 72 40 23 13 77 43 16 9 116 64 16 9 133 74
AT-6115 HS 23 13 83 46 21 12 97 54 34 19 116 64 26 14 121 67
Flame Retardant Grades
AFA-6133 V0 Z 18 10 56 31 16 9 72 40 11 6 93 52 3 2 120 67
FR-4133 21 12 56 31 18 10 73 41 10 6 102 57 5 3 113 63
Mineral and Mineral/Glass Filled Grades
A-1240 L 26 14 68 38 19 11 91 51 18 10 117 65 15 8 121 67
A-1340 HS 34 19 50 28 42 23 60 33 51 28 103 57 19 11 103 57
A-1565 HS 20 11 34 19 20 11 39 22 20 11 72 40 14 8 89 49
AS-1566 HS 17 9 36 20 17 9 44 24 17 9 59 33 16 9 85 47
AP-9240NL 54 30 48 27 87 48 61 34 110 61 81 45 87 48 110 61
Common Metals
Zinc Alloy 27 15 27 15 27 15 27 15 27 15 27 15 27 15 27 15
Aluminum Alloy A-360 21 12 21 12 21 12 21 12 21 12 21 12 23 13 23 13
Stainless Steel 17 9 17 9 17 9 17 9 17 9 17 9 18 10 18 10
Carbon Steel 11 6 11 6 11 6 11 6 11 6 11 6 12 7 12 7
* FD = Flow Direction ** TD = Tranverse Direction or Perendicular to Flow Direction.

Amodel PPA Design Guide 5– 3 Thermal Properties

Thermal Conductivity Figure 5-3
Thermal conductivity is the rate at which heat energy will Thermal Conductivity of Glass Reinforced AMODEL PPA
flow through a material. This property is important in appli-
cations where the polymeric material is used as a thermal
insulator, or where heat dissipation is of concern.
The measurement of thermal conductivity was performed in
accordance with ASTM F 433. The test is conducted by
placing a sample between plates controlled at different tem-
peratures and monitoring the heat flow through the sample.
The thermal conductivity was determined at three average
temperatures, 40°C (104°F), 100°C (212°F), and 150°C
(302°F), by setting the hot plate about 7°C (12°F) above the
average and setting the cold plate about 7°C (12°F) below
the average temperature.
The thermal conductivity of various grades of Amodel resin
was measured at each of the stated temperatures and the
results are presented in Table 5-2. Higher thermal conduc-
tivity values indicate greater heat flow, while lower values
indicate better thermal insulating characteristics.
Figure 5-3 shows that the thermal conductivity increases
with glass content and temperature.

Table 5-2
Thermal Conductivity of Amodel PPA Resins
Average Temperature, °C (°F )
40 (104 ) 100 (212) 150 (302)

W Btu in W Btu in W Btu in

Amodel Grade Additive Amount, % mK hr ft2 ° F mK hr ft2 ° F mK hr ft2 ° F
A-1115 HS glass 15 0.289 2.00 0.307 2.13 0.324 2.25

AS-1133 HS glass 33 0.341 2.37 0.360 2.50 0.376 2.61

AS-1145 HS glass 45 0.372 2.58 0.393 2.73 0.409 2.84

A-1240 L mineral 40 0.377 2.62 0.388 2.69 0.399 2.77

A-1340 HS mineral/glass 25/15 0.422 2.93 0.430 2.98 0.436 3.02

A-1440 HS mineral 40 0.461 3.20 0.462 3.20 0.464 3.22

Coefficient of Linear Thermal Expansion 5– 4 Solvay Advanced Polymers, L.L.C.

Specific Heat Figure 5-6
Specific heat is defined as the amount of heat required to Amodel A-5000 - Specific Heat vs. Temperature
change the temperature of a unit mass one degree. Figures
5-4 through 5-7 show the specific heat as a function of
temperature for the Amodel base resins. Notice that the
specific heat changes significantly at the melting point. This
behavior is typical of semi-crystalline thermoplastics.
This information can be used by process engineers to calcu-
late the heat input needed to process Amodel resins on
equipment such as extruders or injection molding machines.

Figure 5-4 Figure 5-7

Amodel A-1000 PPA - Specific Heat vs. Temperature Amodel A-6000 - Specific Heat vs. Temperature

Figure 5-5
Amodel A-4000 - Specific Heat vs. Temperature

Amodel PPA Design Guide 5– 5 Thermal Properties

Thermal Stability aging times before loss of impact resistance occurs than
the PA66 resin.
The general term, thermal stability, is used to describe the
ability of a material to resist loss of properties due to heat. Thermal aging tests like this are used to compare plastic
Various methods are used to evaluate this tendency. In the materials and to estimate their service life. The service life
next section, we will discuss several of these methods, of a material at a particular end use temperature will be
including thermogravimetric analysis, and long-term heat largely dependent upon the requirements of the application
aging. and should be judged on the basis of its heat aging data and
actual or simulated end use testing.
Thermogravimetric Analysis (TGA)
Thermogravimetric analysis is performed by increasing the Relative Thermal Index (UL)
temperature of a small sample of the test material at a con- A primary function of Underwriters Laboratories Inc is to
stant rate while monitoring its weight. The atmosphere is assist in the assessment of the risk of fire associated with
controlled and the test can be performed using air or an electrical devices. Because insulating materials may deteri-
inert atmosphere, such as nitrogen. Figure 5-8 shows the orate over time some method of evaluating this tendency
weight loss of Amodel A-1000 resin as a function of temper- and providing guidance to designers and users of electrical
ature in air at a heating rate of 10°C/min (18°F/min). The devices was required. Underwriters Laboratories (UL) has
graph shows that Amodel PPA resins are thermally stable developed a method and rating system for this purpose. This
beyond the recommended upper processing temperature method is UL Standard 746B, Polymeric Materials,
limit of 350°C (662°F). Long-Term Property Evaluation. A similar method is ASTM
D 3045, Standard Practice for Heat Aging of Plastics Without
Thermal Aging Load.
Nearly all polymeric materials exhibit some loss of perfor- Based on the results of aging tests as described in the pre-
mance properties after long-term exposure to elevated tem- vious section, Underwriters Laboratories assigns a rating
peratures. While some polymers are more stable than oth- called the “Relative Thermal Index” to insulating materials.
ers, the property loss is typically a function of both exposure Because all material properties do not decay at the same
time and temperature. Because the property losses result rate, a material may have different Relative Thermal Indices
from both oxidative attack and thermal degradation, the for electrical properties, mechanical properties without
term “thermal oxidative stability” is frequently used. impact, and mechanical properties with impact.
Thermal oxidative stability limits the acceptable long-term The Relative Thermal Index or RTI is determined by a statis-
use temperature of some polymers. To evaluate these tical analysis of thermal aging data for the properties being
long-term effects on the properties of Amodel evaluated. The RTI predicts the aging temperature that a
polyphthalamide, molded test specimens of Amodel resins material can endure for 100,000 hours and still retain at
were placed in circulating air ovens at several elevated tem- least fifty percent of the initial property or properties being
peratures. Specimens were removed from the oven at regu- measured.
lar intervals, then tested at room temperature for tensile
strength and impact resistance. Because the rate of decay is greater for thinner specimens,
UL gives RTI ratings for each thickness tested.
Typically, these aging tests are run until the property being
monitored has been reduced to one-half its starting value. To obtain a UL RTI rating, a long-term heat aging program is
The aging tests are conducted at several aging tempera- performed. Sets of test specimens molded from the material
tures and an “Arrhenius Plot” is prepared. An “Arrhenius to be tested are put into ovens at preset temperatures. Peri-
plot” plots the heat aging time required to reduce a property odically specimens are removed and tested. The results for
to one-half of its starting value, sometimes referred to as its each aging temperature are plotted on a time versus prop-
half-life, against the reciprocal of the aging temperature in erty graph, until the property being measured has declined
degrees Kelvin. The advantage of analyzing the data in this to 50 percent or less of its initial value. This combination of
manner is that the plot is theoretically a straight line and, time and aging temperature can be referred to as the
therefore, easily extrapolated. “half-life” for that property, material, and thickness.
Figure 5-9 shows the plot of tensile strength half lives of The half-lives (time to 50% or less) for a particular property,
Amodel AS-1133 HS resin and GR PA66 versus the aging which were experimentally determined at four aging tem-
temperature. Amodel PPA maintains its tensile strength lon- peratures, are plotted against the reciprocal of the absolute
ger than PA66 does. aging temperature. The points should establish a straight
line which can be extrapolated to predict the half-life of the
Figure 5-10 shows the thermal aging curves for notched material for the particular property at other temperatures.
Izod half lives of Amodel AS-1133 HS resin and GR PA66 This is called an “Arrhenius plot”.
versus aging temperature. Amodel PPA also requires longer

Specific Heat 5– 6 Solvay Advanced Polymers, L.L.C.

To estimate the RTI for the material, the best fit straight line
is drawn through the four half-life points for tensile strength
and extended to 100,000 hours. The temperature at which
this line crosses the 100,000 hours line is an estimate of the
RTI for the material. If only three half-life points are avail-
able, such as when the data for the fourth temperature is
still under test, then a provisional RTI can be granted. The
RTI assigned by UL may be somewhat lower as statistical
methods are used to compensate for experimental
variability.
Testing of Amodel resins for the establishment of UL Rela-
tive Thermal Indices is a continuing long-term activity. The
UL ratings of some Amodel resins when this manual was
printed is shown in Table 5-3. Because this testing is ongo-
ing, the Underwriters’ Laboratories website
([Link] should be con-
sulted for the latest RTI’s.

Figure 5-8 Figure 5-9

Thermogravimetric Analysis of A-1000 in Air Thermal Aging Comparison - Tensile Strength

Figure 5-10
Thermal Aging Comparison - Izod Impact

Amodel PPA Design Guide 5– 7 Thermal Properties

Table 5-3
Relative Thermal Indices of Amodel PPA Grades
Relative Thermal Index (RTI), °C
Mechanical
Grade Color Thickness, mm Electrical with Impact w/o Impact
AF-1133 V0 ALL 0.75 50 50 50
1.5 140 130 130
3.0 140 130 130
AF-1145 V0 NC, RD, BK 0.75 50 50 50
1.5 140 115 120
3.0 140 130 140
AF-4133 V0 ALL 0.75 130 115 115
1.5 140 130 130
3.0 140 130 130
BK 0.75 130 115 115
1.0 130 115 115
AFA-4133 V0 (*) ALL 0.75 130 130 130
1.5 130 130 130
3.0 130 130 130
AFA-6133 V0 (*) ALL 0.75 130 130 130
1.5 130 130 130
3.0 130 130 130
AFA-6145 V0 (*) ALL 0.75 140 — 130
1.5 140 — 130
3.0 140 140 140

Combustion Properties The test can be applied at one or more recommended tem-
peratures and at any wall thickness needed. Recommended
This section describes the resistance of Amodel resins to
temperatures are 550°C (1022°F), 650°C (1202°F), 750°C
burning and ignition, and the smoke density characteristics
(1382°F), 850°C (1562°F), and 960°C (1760°F). Thickness
of the material once it has been ignited. Described below
is usually mandated by the design or the requirements of
are glow wire test results, classifications according to UL 94
the device. It is most difficult to resist ignition at the high
and ASTM smoke density test results.
glow wire temperature and thinner wall sections.
Glow Wire Testing
The ability to support and sustain ignition in plastic materi- Table 5-4
als may be characterized by the standardized glow wire UL Definitions of GWIT and GWIF
test. This test simulates conditions present when an
exposed, current carrying conductor contacts an insulating IEC Glow-Wire Ignitability Temperature (GWIT)
material during faulty or overloaded operation. The test In accordance with IEC 695-2-1/3, is expressed as the tempera-
method followed is referenced in IEC 695-2-1/3. ture (in degrees C), which is 25 degrees C hotter than the maxi-
The glow wire test apparatus consists of a loop of heavy mum temperature of the tip of the glow wire which does not cause
gauge nickel-chromium resistance wire, a thermocouple, ignition of the material during three subsequent tests.
and a sample mounting bracket. IEC Glow-Wire Flammability Temperature (GWFI)
During the test, an electrical current is passed through a In accordance with IEC 695-2-1/2, is expressed as the highest
nickel-chromium loop in order to obtain a predetermined temperature (in degrees C) at which, during three subsequent
temperature. The sample is then brought in contact with the tests, flaming or glowing of the test specimen extinguish within 30
wire for 30 seconds. The test is passed if after withdrawal, seconds after removal of the glow wire without ignition of the indi-
the sample displays no flame or glowing, or if so, it is cator by burning drips or particles.
self-extinguishing after 30 seconds.
Thermal Stability 5– 8 Solvay Advanced Polymers, L.L.C.
The UL definitions for the parameters usually reported are
shown in Table 5-4.
Amodel resins have passed glow wire testing as shown in
Table 5-5.

Table 5-5
Glow Wire Results
GWIT GWFI
Amodel Grade °C °F °C °F
A(AS)-1133 HS 725 1337 725 1337
AT-6115 HS 750 1382 800 1472
AT-6130 725 1337 750 1382
AS-1566 HS 775 1427 800 1472
A-1340 HS 825 1517 800 1472
AS-4133 HS 750 1382 750 1382
AFA-6133 V0 Z 960 1760 960 1760
FR-4133 960 1760 960 1760
All samples tested at 0.8 mm (0.031 in.) thickness

Smoke Density Test (NBS)

When a material burns, smoke is generated. The quantity
and density of the generated smoke is important in many
applications. ASTM E 662, Standard Test Method for Spe-
cific Optical Density of Smoke Generated by Solid Materials,
provides a standard technique for evaluating relative smoke
density. This test was originally developed by the National
Bureau of Standards (NBS), and is often referred to as the
NBS Smoke Density test. The data in Table 5-6 was gener-
ated in both flaming and non-flaming modes. A six tube
burner is used to apply a row of flamelets across the lower
edge of the specimen. A photometric system aimed verti-
cally is used to measure light transmittance as the smoke
accumulates. The specific optical density (Ds) is calculated
from the light transmittance. The maximum optical density
is called Dm.

Table 5-6
Smoke Density
Amodel
Grade Ds @ 4 min Dm Dm Corr.
Flaming Mode
AS-1133 HS 565 510 469
AF-1133 V0 711 773 756

Non-Flaming Mode
AS-1133 HS 3 162 162
AF-1133 V0 12 386 382

Amodel PPA Design Guide 5– 9 Thermal Properties

 this manner. Table 5-7 lists the criteria by which a material
Vertical Flammability per UL 94 is classified in this test.
The UL 94 flammability standard established by Underwrit- In the 20 MM Vertical Burning Test, Amodel resins AF-1115
ers’ Laboratories is a system by which plastic materials can V0, AF-1133 V0, and AF-1145 V0 have been recognized by
be classified with respect to their ability to withstand com- UL with a 94V-0 rating at specimen thicknesses down to
bustion. The flammability rating given to a plastic material is 0.032 inch (0.8 mm) in black and natural colors.
dependent upon the response of the material to heat and
flame under controlled laboratory conditions and serves as a
preliminary indicator of its acceptability with respect to Table 5-7
flammability for a particular application. The actual response
to heat and flame of a thermoplastic depends on other fac- UL Criteria for Classifying Materials V-0, V-1, or V-2
tors such as the size, form, and end-use of the product Criteria Conditions 94V-0 94V-1 94V-2
using the material. Additionally, characteristics in end-use
Afterflame time for each individual ≤ 10s ≤ 30s ≤ 30s
application such as ease of ignition, burning rate, flame specimen,
spread, fuel contribution, intensity of burning, and products (t1 or t2)
of combustion will affect the combustion response of the Total afterflame time for any ≤ 50s ≤ 250s ≤ 250s
material. condition set (t1 + t2 for the 5
specimens)
Three primary test methods comprise the UL 94 standard. Afterflame plus afterglow time for ≤ 30s ≤ 60s ≤ 60s
They are the Horizontal Burning Test, the 20 MM Vertical each individual specimen after the
Burning Test, and the 500 MW Vertical Burning Test. second flame application (t2 + t3)
Afterflame or afterglow of any No No No
Horizontal Burning Test specimen up to the holding clamp
For a 94HB classification rating, injection molded test speci- Cotton indicator ignited by flaming No No Yes
mens are limited to a 125 mm (5.0 inch) length, 13 mm (0.5 particles or drops
inch) width and the minimum thickness for which the rating
is desired. The samples are clamped in a horizontal position
with a 20 mm blue flame applied to the unclamped edge of 500 W Vertical Burning Test
the specimen at a 45 degree angle for 30 seconds or so as
soon as the combustion front reaches a premarked line 25 A material which passes the flammability requirements
mm from the edge of the bar. After the flame is removed, established by the 500 W Vertical Burning Test earns either
the rate of burn for the combustion front to travel from the a 94-5VA or 94-5VB rating. This particular test is the most
25 mm line to a premarked 100 mm line is calculated. At severe of the three described. The dimensions of the molded
least three specimens are tested in this manner. A plastic bars used in this test are identical to those used for the 20
obtains a 94HB rating by not exceeding a burn rate of 40 MM Vertical Burning Test. Additionally, plaques are required
mm/min for specimens having a thickness greater than 3 that measure 150 mm (5.9 in.) by 150 mm (5.9 in.) by the
mm or 75 mm/min for bars less than 3 mm thick. The rating minimum and maximum thicknesses required for the appli-
is also extended to products that do not support combustion cation. The bars are clamped in a vertical position with a
to the 100 mm reference mark. 125 mm high flame applied five times for five seconds each
time with a five second interval between each application.
Amodel AS-1133 HS resin has obtained a 94HB rating in the The plaques are clamped in a horizontal, flat position with a
Horizontal Burning Test, at thicknesses down to 0.8 mm in a 125 mm high flame applied to the bottom surface at a 20
black color. degree angle using the same burn times described for the
20 MM Vertical Burn Test bars. Table 5-8 lists the criteria that must be met to obtain a
94-5VA or 94-5VB rating.
Materials can be classified 94V-0, 94V-1, or 94V-2 on the
basis of results obtained from the combustion of samples
Table 5-8
clamped in a vertical position. The 20 MM Vertical Burn Test
is more aggressive than the 94HB test and is done on sam- UL Criteria for Classifying Materials 5VA or 5VB
ples that measure 125 mm in length, 13 mm in width, and Criteria Conditions 94-5VA 94-5VB
the minimum thickness at which the rating is desired (typi-
Afterflame time plus afterglow time after fifth ≤ 60s ≤ 60s
cally 0.8 mm or 1.57 mm). The samples are clamped in a flame application for each individual bar
vertical position with a 20 mm high blue flame applied to specimen
the lower edge of the clamped specimen. The flame is Cotton indicator ignited by flaming particles or No No
applied for 10 seconds and removed. When the specimen drops from any bar specimen
stops burning, the flame is reapplied for an additional 10 Burn-through (hole) of any plaque specimen No Yes
seconds and then removed. A total of five bars are tested in
Combustion Properties 5– 10 Solvay Advanced Polymers, L.L.C.
Table 5-9 lists the current UL-94 ratings of some Amodel
resins. Because ratings may change and additional products
rated please consult the Underwriters’ Laboratories website
for the latest information.

Table 5-9
UL94 Ratings of Amodel PPA Grades
Thickness,
Grade Color mm UL 94 Rating
AF-1133 V0 ALL 0.75 V-0
1.5 V-0
3.0 V-0

AF-1145 V0 NC, RD, BK 0.75 V-0

1.5 V-0
3.0 V-0

AF-4133 V0 ALL 0.75 V-0

1.5 V-0
3.0 V-0
BK 0.75 5VB
1.0 5VA

AFA-4133 V0 Z ALL 0.75 V-0

1.5 V-0
3.0 V-0

AFA-6133 V0 Z ALL 0.75 V-0

1.5 V-0
3.0 V-0

AFA-6145 V0 Z ALL 0.75 V-0

1.5 V-0
3.0 V-0

FR-4133 NC, BK 0.8 V-0

1.6 V-0
3.0 V-0

FR-6133 NC, BK 0.75 V-0

1.5 V-0
3.0 V-0

FR-6145 NC, BK 0.8 V-0

1.6 V-0

Amodel PPA Design Guide 5– 11 Thermal Properties

 subjected to 500 volts DC for 1 minute, and the current
Electrical Properties through the material is measured. Materials with higher vol-
Many applications for thermoplastic resins depend upon ume resistivity are more effective at electrically isolating
their ability to function as electrical insulators. A wide vari- components.
ety of tests have been developed to measure specific UL 746A specifies that the test be run on two sets of speci-
aspects of material performance in electrical applications. A mens: one set conditioned for 48 hours at 73°F (23°C) and
brief description of some of the more common tests follows: 50% relative humidity; and the other conditioned for 96
hours at 95°F (35°C) and 90% relative humidity.
Dielectric Breakdown Voltage and Strength - ASTM
D 149 Volume resistivity is particularly sensitive to temperature
changes as well as changes in humidity. Data on different
Dielectric strength is a measure of the ability of a material to materials are comparable only for equivalent moisture con-
resist high voltage without dielectric breakdown. It is mea- tent and temperatures. Materials with resistivities above 108
sured by placing a specimen between two electrodes and ohm-cm are considered insulators, while those with values
increasing the applied voltage until dielectric breakdown of 103 to 108 ohm-cm are partial conductors.
occurs. The dielectric strength is reported at the highest
voltage prior to failure. Of the various methods included in Surface Resistivity - ASTM D 257
ASTM D 149, UL 746A specifies the short-time test using a
The surface resistivity of a material is the electrical resis-
uniform rate of voltage increase of 500 volts per second.
tance between two electrodes on the surface of the speci-
Although the results are reported in units of kV/mm men. The material is subjected to 500 volts DC for 1 minute,
(volts/mil), the dielectric strength is a function of thickness, and the current along the surface of the material is mea-
moisture content, and temperature. Therefore, data on dif- sured. Although some finite thickness of material is actually
ferent materials are comparable only for equivalent sample carrying the current, this thickness is not measurable, there-
thickness, moisture content, and test temperature. fore, this property is an approximate measure. Surface
resistivity is affected by surface contamination and is not
Table 6-1 shows the dielectric strengths of several Amodel
considered a basic material property. UL specifies the same
grades. The dielectric strength of samples conditioned to
specimen conditioning used for volume resistivity. Data from
50% RH are the same as the dry as molded samples.
this test are best used to compare materials for use in appli-
Volume Resistivity - ASTM D 257 cations where surface leakage is a concern.
The volume resistivity of a material is defined as the electri- Table 6-2
cal resistance of a unit cube of material. The material is Volume and Surface Resistivity of Amodel Resins
Volume Surface
Table 6-1 Resistivity, Resistivity,
Grade Cond.* ohm-cm ohm
Dielectric Strength of Selected Amodel Grades A-1133 HS dry 1 x 1016 1 x 1015
Thickness A-1133 HS 50%RH 2 x 1015
3.2 mm (1/8”) 1.6 mm (1/16”) A-1145 HS dry 1 x 1016
Grade Cond.* kV/mm V/mil kV/mm V/mil A-1145 HS 50%RH 2 x 1015
A-1133 HS dry 21 533 32 813 AS-4133 HS dry 1 x 1016 1 x 1015
A-1133 HS 50%RH 21 533 AS-4133 HS 50%RH 5 x 1014
A-1145 HS dry 23 584 AT-1002 HS dry 1 x 1016 8 x 1013
A-1145 HS 50%RH 23 584 AT-1002 HS 50%RH 7 x 1014 2 x 1013
AS-4133 HS dry 21 533 32 813 AT-5001 dry 4 x 1015 4 x 1015
AS-4133 HS 50%RH 21 533 AT-5001 50%RH 2 x 1015 2 x 1015
AT-1002 HS dry 17 432 AT-6115 HS dry 1 x 1016 1 x 1015
AT-1002 HS 50%RH 17 432 AFA-6133 V0 Z dry 1 x 1016 1 x 1015
AT-5001 dry 17 432 FR-4133 dry 1 x 1016 1 x 1015
AT-5001 50%RH 17 432 A-1240 L dry 9 x 1015
AT-6115 HS dry 28 711 A-1240 L 50%RH 2 x 1015
AFA-6133 V0 Z dry 24 610 27 686 A-1340 HS dry 1 x 1016
FR-4133 dry 20 508 29 737 A-1340 HS 50%RH 1 x 1016 1 x 1015
A-1340 HS dry 32 813 A-1565 HS dry 4 x 1014
AS-1566 HS dry 29 737 AS-1566 HS dry 1 x 1016 1 x 1015
*Condition, dry is dry as molded, 50%RH is moisture conditioned as *Condition, dry is dry as molded, 50%RH is moisture conditioned as
described on page 2-3. described on page 2-3.

Amodel PPA Design Guide 6– 1

Dielectric Constant - ASTM D 150 Table 6-4
The dielectric constant is defined as the ratio of the capaci- Dissipation Factor of Amodel Resins
tance of a condenser using the test material as the dielectric Frequency
to the capacitance of the same condenser with a vacuum
Grade Cond.* 60 Hz 100 Hz 106 Hz 10 Hz
9

replacing the dielectric. Insulating materials are used in two

A-1133 HS dry 0.005 0.017 0.016
very distinct ways. First, to support and insulate components
A-1133 HS 50%RH 0.009 0.022
from each other and the ground, and second, to function as
A-1145 HS dry 0.005 0.016
a capacitor dielectric. In the first case, it is desirable to have
A-1145 HS 50%RH 0.009 0.021
a low dielectric constant. In the second case, a high dielec-
AS-4133 HS dry 0.004 0.012 0.013
tric constant allows the capacitor to be physically smaller.
AS-4133 HS 50%RH 0.020 0.019
Dielectric constants have been found to change rapidly with
AT-1002 HS dry 0.004 0.016
increasing temperature or moisture contents, hence data on
AT-1002 HS 50%RH 0.018 0.035
different materials are comparable only at equivalent mois-
AT-5001 dry 0.004 0.016
ture content and temperature.
AT-5001 50%RH 0.012 0.027
AT-6115 HS dry 0.013 0.011
Table 6-3 AFA-6133 V0 Z dry 0.011
FR-4133 dry 0.014 0.010
Dielectric Constant of Amodel Resins
A-1240L dry 0.006 0.017
Frequency A-1240L 50%RH 0.007 0.019
Grade Cond.* 60 Hz 100 Hz 106 Hz 10 Hz
9
A-1340 HS dry 0.005 0.017
A-1133 HS dry 4.4 5.1 4.2 3.7 A-1340 HS 50%RH 0.008 0.017 0.014
A-1133 HS 50%RH 4.7 4.3 AS-1566 HS dry 0.011 0.011
A-1145 HS dry 4.6 4.4 *Condition, dry is dry as molded, 50%RH is moisture conditioned as
A-1145 HS 50%RH 4.9 4.5 described on page 2-3.
AS-4133 HS dry 3.8 4.6 3.6 3.6
AS-4133 HS 50%RH 4.3 3.4 UL 746A Short-Term Properties
AT-1002 HS dry 3.3 3.3
Certain electrical properties are included in the Underwrit-
AT-1002 HS 50%RH 3.8 3.8
ers’ Laboratories (UL) Standard 746A entitled Standard for
AT-5001 dry 3.2 3.2
Polymeric Materials Short-term Property Evaluations and
AT-5001 50%RH 3.6 3.6
these properties are reported by “Performance Level Cate-
AT-6115 HS dry 4.0 3.3 3.1
gory” (PLC). For each property, UL has specified test result
AFA-6133 V0 Z dry 4.8 4.1 3.7
ranges and corresponding Performance Level Categories.
FR-4133 dry 4.8 3.5 3.4
Desired or best performance is assigned to a PLC of 0,
A-1240L dry 4.2 4.0
therefore, the lower the PLC, the better the performance in
A-1240L 50%RH 4.4 4.0
that test.
A-1340 HS dry 4.5 4.3
A-1340 HS 50%RH 4.5 4.3 3.8
High-Voltage, Low-Current, Dry Arc Resistance -
AS-1566 HS dry 5.7 4.7 4.5
ASTM D 495
*Condition, dry is dry as molded, 50%RH is moisture conditioned as
described on page 2-3. This test measures the time, in seconds, that a 12,500 volt
arc can travel between two tungsten rod electrodes on the
surface of a material, following a specified test sequence of
Dissipation Factor - ASTM D 150 increasing severity, until a conductive path or track is
formed. This test is intended to approximate service condi-
Dissipation Factor (also referred to as loss tangent or tan
tions in alternating-current circuits operating at high voltage
delta) is a measure of the dielectric loss, or energy dissi-
with currents generally limited to less than 0.1 ampere.
pated, when alternating current loses energy to an insulator.
Table 6-5 shows the relationship between the arc resistance
In general, low dissipation factors are desirable because
and the UL assigned Performance Level Categories.
they correspond to a better dielectric material. Contamina-
tion, testing frequency, temperature, and humidity can affect
the dissipation factor.

6– 2 Solvay Advanced Polymers, L.L.C.

Table 6-5 Table 6-7
High-Voltage, Low-Current, Dry Arc Resistance High-Voltage Arc-Tracking-Rate
Performance Level Categories (PLC) Performance Level Categories

Value Range, sec. Value Range, mm/min

> < Assigned PLC > < Assigned PLC
420 0 0 10 0

360 420 1 10 25.4 1

300 360 2 25.4 80 2

240 300 3 80 150 3

180 240 4 150 4

120 180 5
60 120 6
0 60 7 Hot Wire Ignition (HWI) - ASTM D 3874
This test measures the relative resistance of plastic materi-
als to ignition by an electrically heated wire. A portion of a
Comparative Tracking Index (CTI) - ASTM D 3638 test specimen is wrapped with a heater wire under specified
The Comparative Tracking Index is defined as the voltage conditions and a current is passed through the wire at a lin-
that causes the formation of a permanent electrically con- ear power density of 6.5 0.26 W/mm (W/in.). The current
ductive carbon path when 50 drops of electrolyte are flow is maintained until ignition occurs, and the time to igni-
applied at a rate of 1 drop every 30 seconds. This test mea- tion is recorded.
sures the susceptibility of an insulating material to tracking. Under certain operational or malfunction conditions, compo-
Table 6-6 shows the relationship between the voltage nents become abnormally hot. If these overheated compo-
obtained and the PLC. nents are in intimate contact with the insulating materials,
the insulating material may ignite. The intention of this test
Table 6-6 is to determine relative resistance of insulating materials to
Comparative Tracking Index ignition under these conditions. Table 6-8 shows the hot
Performance Level Categories wire ignition times and the assigned PLC.
Value Range, volts Table 6-8
> < Assigned PLC Hot Wire Ignition Performance Level Categories
600 0
Value Range, sec
400 600 1
< > Assigned PLC
250 400 2
120 0
175 250 3
120 60 1
100 175 4
60 30 2
0 100 5
30 15 3
15 7 4
High-Voltage Arc-Tracking-Rate (HVTR)
7 0 5
This test measures the susceptibility of an insulating mate-
rial to form a visible carbonized conducting path (track) over
its surface when subjected to repeated high-voltage, High-Current Arc Ignition (HAI)
low-current arcing. The high-voltage arc-tracking-rate value This test measures the relative resistance of insulating
is the rate, in mm/minute, at which a conducting path is materials to ignition from arcing electrical sources. Under
produced on the surface of a material under standardized certain conditions, insulating materials may be in proximity
test conditions. This test simulates a malfunctioning to arcing. If the intensity and duration of the arcing are
high-voltage power supply with lower values indicating severe, the insulating material can ignite. This test mea-
better performance. sures the number of 240-volt 32.5-ampere arcs on the sur-
Table 6-7 shows the HVTR values and the corresponding face of a material required to cause ignition or a hole. The
PLC. distance between the electrodes in increased at a rate of

Amodel PPA Design Guide 6– 3 Electrical Properties

254 mm (10 in.) per second. The maximum number of arcs Table 6-11
to be used is 200. UL 746A Property PLC for Amodel PPA Grades
This test measures the performance of an insulating mate- Grade mm
(1)
HWI HAI HVTR CTI
rial in close proximity to arcing. A(AS)-1133 HS 0.80 0 0 4 0
Table 6-9 shows the relationship between the High-Current AT-6115 HS 0.80 0(2) 0 1 0
Arc Ignition value and the UL assigned Performance Level AT-6130 0.80 4 0 1 0
Categories. AS-1566 HS 0.80 — 0 0 0

Table 6-9 A-1340 HS 0.80 0(2) 0 1 1

AS-4133 HS 0.80 0(2) 0 1 0
High-Current Arc Ignition Performance Level Categories
AF-1133 V0 0.75 0 0 1 1
Value Range, sec
AF-1145 V0 0.75 0 — 1 1
< > Assigned PLC AFA-4133 V0 Z 0.75 0 0 1 1
120 0 AFA-6133 V0 Z 0.75 0 0 1 1
120 60 1 AFA-6145 V0 Z 0.75 0 1 — 1
60 30 2 FR-4133 0.80 0 0 2 0
30 15 3 FR-6133 0.75 0 0 2 0
15 7 4 FR-6145 0.80 0 0 1 0
7 0 5 (1) Minimum Thickness, mm
(2) This value measured at 1.5 mm thickness.

High-Voltage Arc Resistance to Ignition

This test measures the susceptibility of a material to resist
ignition or form a visible carbonized conducting path when
subjected to high-voltage, low-current arcing. The applica-
tion of the high-voltage arc is continued until ignition, a hole
is burned through the specimen, or 5 minutes. If ignition
occurs, the time to ignition is reported. If ignition does not
occur the value >300 is reported.
The relationship between the mean time to ignition and the
Performance Level Categories is given in Table 6-10.

Table 6-10
High Voltage Arc Resistance to Ignition Performance Level
Categories
HVAR - Mean Time to Ignition, sec
< > Assigned PLC
300 0
300 120 1
120 30 2
30 0 3

UL 746A Properties of Amodel Resins

Selected UL 746A properties for selected Amodel grades are
shown in Table 6-11. The grades selected are the ones most
often used for electrically insulating applications.

UL Relative Thermal Indices

The UL Relative Thermal Indices are the result of thermal
aging tests and, therefore, appear in the Thermal Stability
section on page 5-8.

UL 746A Short-Term Properties 6– 4 Solvay Advanced Polymers, L.L.C.

 The screening evaluation using aqueous solutions at ele-
Environmental vated temperatures showed a loss in tensile strength for all
three of the resins tested. This phenomenon is common to
Resistance all glass reinforced thermoplastics. The loss of tensile
strength for Amodel AS-1133 HS resin in deionized water at
As previously mentioned, the performance of polymeric 200°F (93°C) is initially rapid due to loss of interfacial adhe-
materials may be reduced by environmental factors. This sion between the glass fibers and the resin matrix, and then
section discusses the effects of environmental factors, such slows to a gradual rate reflecting hydrolytic attack. Aqueous
as chemical exposure, conditions likely to promote hydroly- solutions of antifreeze or zinc chloride produce a similar
sis, exposure to gamma and/or ultraviolet radiation, on the effect. PA 66 is severely attacked by the zinc chloride solu-
performance of Amodel resins. When appropriate, the tion. PET is severely attacked by the antifreeze solution and
effects of these environmental factors on the performance of even badly hydrolyzed by distilled water at elevated
competitive resins is included for comparison. temperatures.
Table 7-1
Chemical Resistance Key to Chemical Resistance Ratings
Amodel resins are semi-crystalline polyphthalamides, and % reduction in
like other members of the semi-crystalline polyamide family, Symbol Rating tensile strength
they exhibit excellent chemical resistance to common
organic solvents. However, the chemical structure of Amodel E Excellent ≤ 10
resins is highly aromatic — imparting an even greater A Acceptable ≤ 50 but ≥ 10
degree of chemical resistance to an even broader range of
chemicals. U Unacceptable > 50

It is difficult to predict the exact effect of chemical exposure

on a polymeric component because the reagent, the con-
centration of the reagent, the exposure time, the tempera-
ture of the reagent, the temperature of the polymeric com-
ponent, and the stress on the component all affect the
extent of attack and any change in performance. While the
only reliable method for evaluating the effect of chemical
attack on the performance of a polymeric component is pro-
totype testing, screening tests are often performed to pro-
vide general guidance and compare materials.
Screening chemical resistance testing was performed by
immersing ASTM D 638 Type I tensile bars in various chem-
icals for 30 days at the indicated test temperatures. The
Amodel resin used was the 33% fiber glass reinforced grade
– Amodel AS-1133 HS. Data on 33% glass reinforced PA 66
and 30% glass reinforced polyethylene terephthalate (PET)
is provided for comparison.
The material performance was rated as shown in Table 1. In
addition to the performance rating, data on the percent
change in tensile strength, length, and weight are reported.
The chemicals used for the screening tests were classified
into three groups:
1. Organic solvents (Table 7-2),
2. Aqueous solutions (Table 7-3), and
3. Automotive fluids ( Table 7-4).

Amodel PPA Design Guide 7– 1 Environmental Resistance

Organic Chemicals

Table 7-2
Screening Chemical Resistance Tests — Organic Chemicals
30 day immersion at 23°C (73°F)
Tensile
Strength, % Change in Change in
Reagent Resin Rating Retained Length, % Weight, %
Acetone Amodel AS-1133 HS E 97 0.1 0.2
33% glass PA 66 E 99 0.2 0.2
30% glass PET A 72 0.3 3.2
Isopropanol Amodel AS-1133 HS E 99 0.0 0.2
33% glass PA 66 E 112 0.0 0.3
30% glass PET E 109 0.0 0.3
Methanol Amodel AS-1133 HS A 83 0.1 2.9
33% glass PA 66 A 68 0.5 5.6
30% glass PET E 96 0.1 0.5
Methylene Chloride Amodel AS-1133 HS E 94 0.0 1.1
33% glass PA 66 E 90 0.1 2.4
30% glass PET A 71 2.0 9.5
Methyl Ethyl Ketone Amodel AS-1133 HS E 103 0.0 0.1
33% glass PA 66 A 113 0.0 0.1
30% glass PET A 72 0.1 3.0
Toluene Amodel AS-1133 HS E 101 0.0 0.1
33% glass PA 66 E 109 0.1 0.2
30% glass PET E 91 0.1 1.6
1,1,1 trichloroethane Amodel AS-1133 HS E 99 0.0 0.2
33% glass PA 66 E 110 0.0 0.2
30% glass PET E 100 0.0 2.3
Trichloroethylene Amodel AS-1133 HS E 102 0.0 0.3
33% glass PA 66 E 97 0.0 0.4
Freon® 113 Amodel AS-1133 HS E 96 0.0 0.1
33% glass PA 66 E 99 0.0 0.2
n-Heptane Amodel AS-1133 HS E 104 0.0 0.1
33% glass PA 66 E 96 0.0 0.2
Freon is a registered trademark of E. I. duPont de Nemours and Company.

7– 2 Solvay Advanced Polymers, L.L.C.

Aqueous Chemicals

Table 7-3
Screening Chemical Resistance Tests — Aqueous Chemical Solutions
30 day immersion at indicated temperature
Tensile
Temperature Strength,
% Re- Change in Change in
Reagent Conc. °C °F Resin Rating tained Length, % Weight, %
Ammonium Hydroxide 10% 23 73 Amodel AS-1133 HS E 96 0.1 0.8
33% glass PA 66 A 61 0.2 4.5
30% glass PET E 95 0.2 0.4
Deionized Water 100% 93 200 Amodel AS-1133 HS A 69 0.2 3.4
33% glass PA 66 A 62 0.2 5.0
30% glass PET U 19 0.0 2.4
Sodium Chloride 10% 23 73 Amodel AS-1133 HS E 97 0.1 2.1
33% glass PA 66 A 67 0.2 3.3
30% glass PET E 98 0.0 0.3
Zinc Chloride 50% 93 200 Amodel AS-1133 HS A 66 0.1 4.8
33% glass PA 66 U 0 * *
30% glass PET A 54 -0.1 0.6
Sulfuric Acid 36% 23 73 Amodel AS-1133 HS E 92 0.0 1.8
33% glass PA 66 U 0 * *
30% glass PET E 94 0.0 0.3
Sodium Hydroxide 10% 23 73 Amodel AS-1133 HS E 93 0.0 1.6
33% glass PA 66 A 62 0.0 3.1
30% glass PET A 70 0.0 -4.2
Sodium Hypochlorite 5% 23 73 Amodel A-1133 HS E 94 0.0 1.4
33% glass PA 66 A 57 0.0 -1.5
30% glass PET E 94 0.0 0.4
* = Attacked

Amodel PPA Design Guide 7– 3 Chemical Resistance

Transportation Fluids

Table 7-4
Screening Chemical Resistance Tests — Transportation Fluids
30 day immersion at indicated temperature
Tensile
Temperature Strength ,
Change in Change in
Fluid °C °F Resin RATING % Retained Length, % Weight, %
50% Antifreeze Solution 104 220 Amodel AS-1133 HS A 77 0.2 5.6
33% glass A 54 0.3 8.3
30% glass PET U 0 * *
Brake Fluid 49 120 Amodel AS-1133 HS E 99 0.0 0.4
33% glass PA 66 E 105 -0.1 0.2
30% glass PET E 97 0.0 1.0
Diesel Fuel 23 73 Amodel AS-1133 HS E 98 0.0 0.1
33% glass PA 66 E 100 0.0 0.3
30% glass PET E 100 -0.1 0.0
Gasohol (10% Ethanol) 23 73 Amodel AS-1133 HS A 86 0.0 1.4
33% glass PA 66 A 65 0.1 3.5
30% glass PET E 93 -0.1 0.7
Hydraulic Fluid 49 120 Amodel AS-1133 HS E 92 0.0 0.3
33% glass PA 66 E 103 0.0 0.3
30% glass PET E 105 -0.1 0.1
JP-4 Jet Fuel 23 73 Amodel AS-1133 HS E 95 0.0 0.4
33% glass PA 66 E 100 0.0 0.3
30% glass PET E 100 0.0 0.1
Motor Oil 121 250 Amodel AS-1133 HS E 100 0.0 0.1
33% glass PA 66 E 106 0.0 -0.2
30% glass PET E 91 -0.1 -0.6
Power Steering Fluid 49 120 Amodel AS-1133 HS E 97 0.0 0.1
33% glass PA 66 E 106 0.0 0.2
30% glass PET E 108 0.0 0.0
Transmission Fluid 121 250 Amodel AS-1133 HS E 97 0.0 0.1
33% glass PA 66 E 105 -0.1 -0.2
30% glass PET A 64 0.1 -0.5
Unleaded Gasoline 23 73 Amodel AS-1133 HS E 96 0.1 0.0
33% glass PA 66 E 99 0.1 0.1
30% glass filled PET E 99 0.0 0.1

* = Attacked

7– 4 Solvay Advanced Polymers, L.L.C.

Chemical Compatibility
Chemical Compatibility
Table 5 can be used as a general guide to the chemical
resistance of Amodel resins. However, this data should be
used for screening only. As mentioned earlier, the perfor- Table 7-5
mance of Amodel resins under actual chemical exposure General Chemical Compatibility Guidelines for Amodel PPA
conditions will vary with differences in mechanical stress, Resins
concentration, time and/or temperature. It is recommended
that tests be conducted under conditions close to those Reagent Rating
anticipated in the actual application to get reliable perfor- Aliphatic Hydrocarbons E
mance information. Aromatic Hydrocarbons E
Oils E
Greases E
Chlorinated Hydrocarbons E
Methylene Chloride A
Chloro-Fluoro Carbons E
Ketones E
Esters E
Higher Alcohols E
Methanol A
Phenols U
Strong Acids A
Alkalis E

Amodel PPA Design Guide 7– 5 Chemical Resistance

Gamma Radiation
Amodel AS-1133 HS resin has excellent resistance to
gamma radiation. Tests on injection molded tensile bars
exposed to 5.0 megarads of gamma radiation indicate
essentially no significant affect on the mechanical properties
of Amodel AS-1133 HS resin. Results are given in Table 7-6

Table 7-6
Effect of Gamma Radiation on Amodel AS-1133 HS

% Retention of 5 mrad Exposure

Tensile Strength, psi 90

Tensile Elongation, % 100

Gamma Radiation 7– 6 Solvay Advanced Polymers, L.L.C.

 Table 8-1.
Design Information Design Benefits of Amodel Resin over Metals

In this section, basic design principles and general recom-

mendations are presented to assist the design engineer in Amodel Resin Benefit in Design
designing plastic components that meet the cost/perfor- Characteristics
mance requirements of their applications. Guidelines are
given on the effects of stresses caused by assembly, tem- Amodel resins are fabri- Ribs, bosses, or cored sec-
perature changes, environmental factors, and time as it cated by the injection tions can be readily
relates to creep. molding process, which incorporated.
Of the various materials available to a design engineer, ther- allows substantial design
moplastics offer the greatest variety, versatility and freedom freedom. Snap fits can be molded in,
of design. Plastics can be translucent or opaque, rigid or simplifying assembly.
flexible, hard or soft. Plastic materials are available that pro-
vide a wide range of chemical resistance, from chemically Eliminate many secondary
inert to selective solubility in certain environments. Broad operations such as drilling,
versatility is also available for other properties like strength, tapping, boring, deburring,
stiffness and impact resistance, lubricity and thermal capa- and grinding.
bility. Blends and alloys are possible that further increase
the material choices for a particular application. Metal inserts can be easily
At times, designing with plastics may appear more compli- used where necessary to
cated than with metals. But the diversity of products, con- optimize part strength.
version processes, and secondary operations (welding,
inserts, printing, painting, metallizing) available with plastics Features from several
gives the designer unprecedented freedom as shown in metal parts of an assembly
Table 8-1. may be combined into a
single part, simplifying
A designer may be tempted to make a plastic part that
assembly and reducing
merely duplicates the dimensions of a metal part without
cost.
taking advantage of the versatility of the plastic material or
the design freedom offered. This approach can lead to inef-
ficient designs or parts that are difficult to produce, or Amodel resins are Parts may be joined with
whose performance is less than optimal. thermoplastic. ultrasonic or vibration
welding rather than
The following sections discuss those areas of mechanical fasteners.
design and stress analysis that relate to designing with
plastics, comparing metal to plastics and discussing factors Color may be molded-in
that are specific to plastics alone. rather than added after-
ward as paint.

Amodel resins resist Parts will not rust, and

chemicals. resist corrosion.

Amodel PPA Design Guide 8– 1 Design Information

Mechanical Design
The use of classical stress and deflection equations provide
starting points for part design. Mechanical design calcula-
tions for Amodel resins will be similar to those used with
any engineering material. As with all plastics, however, the
analysis used must reflect the viscoelastic nature of the
material. In addition, the material properties can vary with
strain rate, temperature, and chemical environment or with
fiber orientation for fiber reinforced plastics. Therefore, the
analysis must be appropriate for all anticipated service
conditions.
For example, if the service condition involves enduring load
for a long period of time, then the apparent or creep
modulus should be used instead of the short-term elastic
modulus. Or if the loading is cyclical and long term, the
fatigue strength at the design life will be the limiting factor.
The initial step in any part design analysis is the determina-
tion of the loads the part will be subjected to, and calcula-
tion of the resultant stress and deformation or strain. The
loads may be externally applied or result from stresses due
to temperature changes or assembly.
An example of an externally applied load is the weight of
medical instruments on a sterilizer tray. Examples of assem-
bly loads are the loads on a housing flange when it is bolted
to an engine or the load on the hub of a pulley when a bear-
ing is pressed into it. Thermally induced stresses can arise
when the temperature of the assembly increases and the
dimensions of the plastic part change more or less than the
metal part to which it is attached.

Mechanical Design 8– 2 Solvay Advanced Polymers, L.L.C.

Table 8-2
Maximum Stress and Deflection Equations

Simply Supported Beam Cantilevered Beam (One End Fixed)

Concentrated Load at Center Concentrated Load at Free End

FL FL
σ= σ=
4Z Z
(at load) (at support)
FL 3
FL 3
Y= Y=
48 EI 3 EI
(at load) (at load)

Simply Supported Beam Cantilevered Beam (One End Fixed)

Uniformly Distributed Load Uniformly Distributed Load

FL FL
σ= σ=
8Z 2Z
(at center) (at support)
5FL 3
FL 3
Y= Y=
384 EI 8 EI
(at center) (at support)

Both Ends Fixed Both Ends Fixed

Concentrated Load at Center Uniformly Distributed Load

FL FL
σ= σ=
8Z 12 Z
(at supports) (at supports)
3
FL FL 3
Y= Y=
192 EI 384 EI
(at load) (at center)

Amodel PPA Design Guide 8– 3 Mechanical Design

Table 8-3
Area and Moment Equations for Selected Cross-Sections

8– 4 Solvay Advanced Polymers, L.L.C.

Using Classical Stress/Strain Equations Limitations of Design Calculations
To use the classical equations, the following simplifying The designs given by the application of the classical mechanical
assumptions are necessary: design equations are useful as starting points, but some critical
1. the part can be analyzed as one or more simple factors are simply not adequately considered by these analyses.
structures; The viscoelastic behavior of polymeric materials limits applica-
tion of some of the design equations to, for example, low deflec-
2. the material can be considered linearly elastic and tion cases. Often the calculation of maximum stress contains a
isotropic; number of simplifying assumptions which can diminish the cred-
3. the load is a single concentrated or distributed static ibility of the results, or the expected failure mode is buckling or
load gradually applied for a short time; and shear, where the appropriate property data is lacking.

4. the part has low residual or molded-in stresses. Also, the impact resistance of a design is directly related to its
ability to absorb impact energy without fracture. It is difficult to
While all of these assumptions may not be strictly valid for a predict the ability of a design to absorb energy. In addition, even
particular situation, the classical equations can provide a armed with the energy absorption requirements, practical tough-
starting point for analysis. The design engineer can then ness constants for engineering resins don’t exist. The results of
modify the analysis to take into consideration the effects of laboratory testing vary with the type and speed of the impact
the simplifying assumptions. test, even for fixed geometries. Therefore, the ability of the de-
A variety of parts can be analyzed using a beam bending sign to withstand impact must be checked by impact testing of
model. Table 8-2 lists the equations for maximum stress prototype parts.
and deflection for some selected beams. Similarly, fatigue test results will vary depending on the cyclic
The maximum stress (σ) occurs at the surface of the beam rate chosen for the test, the dynamics of the test, and the test
furthest from the neutral surface, and is given by: specimen used. Therefore, they should only be used as a rough
indication of a material’s ability to perform in a fatigue
Mc M application.
σ= =
I Z
where:
M = bending moment , N ⋅ m (inlb)
c = distance from neutral axis , m (in)
I = moment of inertia , m 4 (in 4 )
I
Z = = section modulus , m 3 (in 3 )
c

Table 8-3 gives the cross sectional area (A), the moment of
inertia (I), the distance from the neutral axis (c), and the
section modulus (Z) for some common cross sections.
For other crosssections and/or geometries, the design engi-
neer can consult stress analysis handbooks or employ finite
element analysis.

Amodel PPA Design Guide 8– 5 Mechanical Design

Deflection Calculations
To determine the deflection of a proposed part design using
classical equations, a modulus of elasticity value is required.
It is important that the appropriate value be used. The value
must represent the modulus of the material at or near the
temperature and humidity expected in the application. Room
and elevated temperature values can be found in the prop-
erty tables on pages 2-4 to -. If the load is sustained, then
the apparent or creep modulus should be used. Values are
given in the isochronous stress/strain curves, Figures 4-7
through 4-9 on page 4-4.

Stress calculations
After the designer has calculated the maximum stress,
those values are then compared to the appropriate material
property, i.e., tensile, compressive, or shear strength. The
comparison should be appropriate in terms of temperature
and humidity to the requirements of the application.
Reinforcing Fiber
Orientation Considerations
When designing with plastics, especially filled plastics, the
designer must be cognizant of the effects of the fillers and
reinforcing fibers on the mechanical properties of the plas-
tic. The processing of filled plastics tends to cause orienta-
tion of fibers or high-aspect-ratio fillers parallel to the direc-
tion of flow. Throughout this manual, properties have been
given both with and across flow direction whenever
practical.
Since the design of the part and the processing are interre-
lated, the designer should consider what portions of the part
are likely to be oriented and how the properties will be
affected. Shrinkage, strength, stiffness, and coefficient of
thermal expansion will differ depending on the aspect ratio
of the fiber (the ratio of its length to its diameter) and the
degree of fiber orientation. Perpendicular to the fiber orien-
tation, the fibers act more as fillers than as reinforcing
agents.
When molding polymers, there are instances where melt
fronts meet (commonly known as weld lines) such as when
the plastic melt flows around a core pin. However, the rein-
forcement in the plastic, if present, does not cross the weld
line. Thus the weld line does not have the strength of the
reinforced polymer and at times can even be less than the
matrix polymer itself. These factors must be taken into
account when designing parts with reinforced plastics.

Using Classical Stress/Strain Equations 8– 6 Solvay Advanced Polymers, L.L.C.

Designing for Equivalent Part Stiffness
Sometimes, a design engineer wants to replace a metal part
with one made of plastic, but still wants to retain the rigidity If the metal part were magnesium having a modulus of elas-
of the metal part. There are two fairly simple ways to main- ticity E of 44.8 GPa (6.5 Mpsi) and the thermoplastic chosen
tain the stiffness of a part when substituting one material to replace it was Amodel AS-1145 HS resin having a
with another material — even though the materials have modulus of elasticity of 13.8 GPa (2.0 Mpsi), we need to
different moduli of elasticity. increase the moment of inertia I of the plastic version by
increasing the part thickness or adding ribs.
In the first method, the cross sectional thickness is
increased to provide the stiffness. In the second, ribs are Substituting the E values in equation (1):
added to achieve greater stiffness. An example of each
approach follows.
(448. × 10 )I9
metal (
= 138 )
. × 10 9 I AMODEL

Changing Section Thickness . I metal = I AMODEL

325

In reviewing the deflection equations in Table 8-2, the From Table 8-3, the moment of inertia for rectangular sec-
deflection is always proportional to the load and length and tions is:
inversely proportional to the modulus of elasticity and bd 3
moment of inertia. I =
12
Selecting one case, for example, both ends fixed with a uni- where b is the width and d is the thickness of the section,
formly distributed load, the deflection is determined by: substituting into our equation to determine the required
FL3 thickness yields:
Y =
384EI 3
. d metal
325 = d AMODEL
3

Therefore, to equate the stiffness using two different materi- If d for the metal part is 2.54 mm (0.10 in.) then the thick-
als, the deflections are equated as follows: ness is Amodel resin is:
⎧ FL3 ⎫ ⎧ FL3 ⎫ . (254
d AMODEL = 3 325 . ) = 376
3
. mm ( 0148
. in. )
⎨ ⎬ =Y = ⎨ ⎬
⎩ 384EI ⎭ metal ⎩ 384EI ⎭ plastic
or 48 percent thicker than the magnesium part. However,
Since the load and length are to remain the same, the FL3 ribs can be used to effectively increase the moment of iner-
becomes a constant on both sides of the equation and what tia as discussed in the next section.
remains is:
(1)
{EI } metal = {EI } plastic
This, then, is the governing equation for equating part
stiffness.

Amodel PPA Design Guide 8– 7 Mechanical Design

Adding Ribs to Maintain Stiffness Therefore, the ribbed design will be 9.5 times stiffer than
the Amodel plate design or the original magnesium part that
In the last section, it was determined that if a metal part
was 2.5 mm (0.100 in.) thick.
were to be replaced with a part molded of Amodel AS-1145
HS resin, a part thickness of 3.7 mm (0.148 in.) would be The same rib having half the height would still produce a
required to equal the stiffness of a 2.5 mm (0.100 in.) thick part twice as stiff as the magnesium part. The ribbed design
magnesium part. shown requires placing a rib every 25 mm (1 in.) of section
width.
By incorporating ribs into the Amodel design, the wall thick-
ness and weight can be reduced very efficiently and yet be
as stiff as the magnesium part.
To demonstrate this, the moment of inertia (I) of the new rib
design can be equated with that of the 3.7 mm (0.148 in.)
thick plate design. Selecting the same material, Amodel
AS-1145 HS, the modulus of elasticity remains 13.8 GPa
(2.0 Mpsi) in both cases; therefore, if the moment of inertia
of the ribbed design is equal to the plate design, the parts
will have equivalent deflection and/or stiffness.
From Table 8-3, the I for a ribbed section is selected. By
assuming that the section width “b” is the same for both,
the Irib has to be equal or greater than the Iplate. Assigning a
section width “b“ = 25.4 mm (1.0 in.), the moment of inertia
of a ribbed construction that will satisfy that condition can
be calculated.
The moment of inertia for the plate design is:

bh 3 25.4 × (376
. )
3

I plate = = = 1125 . × 10 −4 in. 4 )

. mm 4 ( 270
12 12

By choosing the arbitrary rib design shown in Figure 8-1,

and working through the calculations, the moment of inertia
is found to be:
. × 10 −4 in. 4 )
I rib = 1379 mm 4 ( 3319

Figure 8-1
Adding Ribs to Increase Stiffness

Using Classical Stress/Strain Equations 8– 8 Solvay Advanced Polymers, L.L.C.

 Figure 8-2
Designing for Sustained Load
Up to this point, the stress strain calculations and examples Cantilever Beam, Bending load Example
have dealt with immediate stress/strain response and there-
fore short-term properties. If the part in question must sus-
tain loads for long periods of time or at elevated tempera-
tures, apparent (creep) modulus values must be used to
account for the additional strain and part deflection that may
occur. An example showing how the calculations are modi-
fied for sustained load follows.

Calculating Deflection
If a cantilever beam with a rectangular cross-section, as
shown in Figure 8-2, is loaded with a 10 kg (22.0 lb) force
at the free end, what is the deflection after 1,000 hours?
From Table 8-2 on page 8-3, the deflection of a cantilever
beam is given by:
FL3
Y =
3EI
where I, the moment of inertia, as shown in Table 8-3 is:
bd 3
I =
12
and E is the flexural modulus of the material.
Calculating the moment of inertia for this example gives:
(25)(6) 3
I = = 450 mm 4 ( 1081
. × 10 3 in. 4 )
12
The data sheet for Amodel A-1133 HS resin gives 11.6 GPa
(1.68 Mpsi) for the flexural modulus. Using this value and
the equation previously cited, the short-term room tempera-
ture deflection can be calculated by:
(10 kg × 9.8066)(.1 m) 3
Y =
( . × 10 9 Pa
3 116 )(45. × 10 −10
m4 )
Y = 6.3 mm (0.25 in. )
If the application requires that the load be sustained for a
long time, we would expect the deflection to be greater than
this because of creep. To calculate the deflection consider-
ing the creep, we would use the apparent modulus instead
of the short-term flexural modulus. The value of apparent
modulus shown for Amodel A-1133 HS resin at 1000 hours
in Figure is 7.58 GPa (1.10 Mpsi). Therefore the calculated
deflection is:
(10 kg × 9.8066)(.1 m) 3
Y =
(
3 7.58 × 10 9 Pa )(45. × 10 −10
m4 )
Y = 9.6 mm ( 038
. in. )
The deflection is about fifty percent greater when a sus-
tained load is considered.

Amodel PPA Design Guide 8– 9 Mechanical Design

 Figure 8-3
Calculating Allowable Stress - Creep Rupture
Tensile Creep Rupture - Amodel A-1133 HS Resin
If a load is sustained for a long time and if the load and/or
temperature are high enough, rupture of the part will even-
tually occur due to creep,
To estimate the combinations of time, temperature, and load
that will cause this type of failure, creep rupture tests are
conducted at various temperatures as shown in Figure 8-3.
This figure illustrates the actual time to failure for different
levels of stress so that a creep rupture envelope can be
obtained. From this envelope, the safety factor in time or
stress can be determined for that particular temperature.
For instance, if the application life is 1,000 hours at 65°C
(149°F) for a part molded from Amodel A-1133 HS resin, the
curve indicates that rupture will occur within that time
frame if the part is exposed to a stress level of approxi-
mately 158 MPa (23 kpsi).
If the part can be redesigned to reduce the stress to 124
MPa (18 kpsi), the predicted time to rupture is now well
beyond 10,000 hours. This automatically builds a safety fac-
tor into the design. Actual part testing is still recommended
to confirm these results.
For operating temperatures that are different from the tested
temperatures, information is usually extrapolated from
known creep rupture envelopes to approximate the enve-
lope for the temperature of interest.

Designing for Sustained Load 8– 10 Solvay Advanced Polymers, L.L.C.

Considering Stress Concentrations Figure 8-4
Classical mechanical design may result in a component Stress Concentration Factor at Inside Corners
design which fails prematurely or at a much lower stress
than predicted. This could arise due to stress concentration.
Stress concentrations may occur at sharp corners, around
holes, or other part features. Impact and fatigue situations
are especially sensitive to stress concentrations.
Minimizing sharp corners reduces stress concentrations and
results in parts with greater structural strength. To avoid
stress concentration problems, inside corner radii should be
equal to at least half of the nominal wall thickness. A fillet
radius of 0.4 mm (0.015 in.) should be considered
minimum.
Figure 8-4 shows the effect of inside corner radius on the
stress concentration factor. For example, if the nominal wall
thickness is 2 mm (0.080 in.) and an inside corner radius is
0.5 mm (0.020 in.), then the radius to thickness ratio is 0.25
and the stress concentration factor will be over two. A stress
of x will have the effect of over 2x on the part.
Outside corners should have a radius equal to the sum of
the radius of the inside corner and the wall thickness to
maintain a uniform wall thickness.

Amodel PPA Design Guide 8– 11 Mechanical Design

Considering Thermal Stresses and the increase in compressive stress on the plastic will
be:
When a plastic part attached to metal undergoes tempera-
ture changes, stresses may be induced that should be con- F
σ=
sidered by the designer in the development of the part Ap
design.
Figure 8-5 illustrates a typical plastic flange fastened by a
steel bolt to a steel frame. Because the thermal expansion of
the plastic is significantly greater than that of the steel, an
increase in temperature will produce an increase in com-
pressive stresses in the plastic and tension in the bolt. It is
the increase in compressive stress under the washer that Figure 8-5
must be considered if creep and loss of torque load on the
Thermal Stress Example
bolt is of concern.
For example, the change in length of a material when
exposed to a change in temperature is given by:
ΔL = L(T F − T 0 )α
where:
ΔL = change in length
L = original length
α = coefficient of thermal expansion
T F = final temperature
T0 = original temperature
Since the plastic is constrained, the unit elongation, combin-
ing both thermal expansion and strain, of both the steel bolt
and the plastic, will be as follows:
F F
α s (T F − T 0 ) + = α p (T F − T 0 ) −
AsE s ApE p

where:
A s = cross sectional area of the bolt
A p = cross sectional area of the washer
E s = modulus of steel
E p = modulus of plastic
α s = coefficient of thermal expansion of steel
α p = coefficient of thermal expansion of plastic
F = increase in the tensile force of the bolt
Solving for F

F =
(α p )
− α s (T F − T 0 )A s E s
AsE s
1+
ApE p

Considering Stress Concentrations 8– 12 Solvay Advanced Polymers, L.L.C.

 Figure 8-6
Loss of Bolt Tightness Due to Creep
Bolt Torque Retention
When threaded metal fasteners are used to retain or secure
plastic parts to an assembly, and the assembly is subjected Temperature, F

to changes in temperature, the difference between the ther- 7

50 75 100 125 150 175 200 225
60
mal expansion coefficients of the metal and the plastic can
6
cause problems. When a threaded fastener is tightened, the 50

fastener is elongated slightly and a compressive stress is 5

generated on the substrate. This compressive stress main- 40

Torque, in-lb
Torque, N-m
4
tains the tightness of the bolt.
30
3
When the assembly is heated, both the plastic part and the
metal fastener will expand. The plastic part, however, is 2
20

constrained by the metal fastener, and cannot expand. This A-1133 HS

10
1
results in increased compressive stresses in the plastic, and 33% GR PA66
30% GR PA46
a corresponding increased tendency for compressive creep 0 0
20 40 60 80 100 120
or stress relaxation to occur. The relaxation of the compres-
Temperature, C
sive stress will result in reduced torque retention in the
bolts.
To evaluate this tendency, 6.4 mm (0.250 in.) thick plaques
of Amodel A-1133 HS resin, 33% glass reinforced PA 66 and
30% glass reinforced PA 4,6 were bolted to a metal surface
with steel machine bolts tightened to 6.8 N-m (60 in-lb) of
torque with a torque wrench compressing the plastic plaque
under the bolt face. The temperature of the bolted assem-
blies was then raised to the indicated temperatures shown
in Figure 8-6, held for one hour, and then cooled to room
temperature. The torque required to loosen the bolts was
then measured.
Figure 8-6 compares the amount of torque retained versus
temperature. The coefficient of linear thermal expansion of
Amodel resin is lower than those of the other materials
tested, and therefore closer to that of the steel.
The smaller difference in thermal expansion results in lower
induced stress due to the compressive strain caused by the
thermal excursion in the constrained part. This translates to
lower creep and therefore better torque retention for such
bolted assemblies.

Amodel PPA Design Guide 8– 13 Mechanical Design

 If the shaft and hub are made from the same grade of
Designing for Assembly Amodel resin, then:
Interference or Press Fits Eh = Es = E
One of the most economical methods that can be used to and the interference is:
assemble two parts is a press fit. The joint is achieved by Sd ⎛ F + 1⎞
pressing or forcing the shaft into a hole whose diameter is I = Ds ⎜ ⎟
smaller than the diameter of the shaft. The difference in E ⎝ F ⎠
diameter between the hole and shaft is referred to as the If the hub is made from Amodel resin and the shaft is made
diametrical interference. The force maintaining the joint is from metal, then the interference is:
primarily a compressive stress on the shaft resulting from
the hoop stress in the hub created by the insertion of the S d Ds F + υh
I =
shaft. Depending upon the relative moduli of the shaft and F Eh
hub materials, the compressive stress in the shaft can also
contribute to maintaining the joint. The stress holding an When a press fit is used with dissimilar materials, the differ-
interference fit will exhibit relaxation over time in a manner ences in thermal expansion can increase or decrease the
that is analogous to creep, because the apparent modulus of interference between two mating parts. This could increase
the polymeric material decreases over time. or reduce the stress affecting joint strength.
A press fit can creep or stress relax over time. This could
Calculating the Allowable Interference cause a decrease in the retention force of the assembly.
The allowable interference between a shaft and a hub can Therefore, testing the assembly under its expected operat-
be determined by using the general equation: ing conditions is highly recommended.
S d D s ⎧F + υ h 1− υ s ⎫
I = ⎨ + ⎬
F ⎩ Eh Es ⎭

and the geometry factor is given by:

2
⎛D ⎞
1+ ⎜ s ⎟
⎝Dh ⎠
F = 2
⎛D ⎞
1− ⎜ s ⎟
⎝Dh ⎠

where:

I = Diametrical interference
S d = Working stress
D h = Outside diameter of the hub
D s = Diameter of the shaft
E h = Modulus of the hub material
E s = Modulus of the shaft material
υ h = Poisson's Ratio of the hub material
υ s = Poisson's Ratio of the shaft material
F = Geometry factor

Designing for Assembly 8– 14 Solvay Advanced Polymers, L.L.C.

Mechanical Fasteners Figure 8-7
Mechanical fasteners provide an economical method of join- Designing for Mechanical Fasteners
ing dissimilar materials together. Fasteners frequently used
with injection molded plastic parts include screws, bolts,
nuts, lock washers and lock nuts. When using metal
mechanical fasteners, good design practice should be used
to prevent the plastic parts being assembled from becoming
overstressed.
The most obvious procedure for preventing a highly stressed
assembly is to control the tightening of the mechanical fas-
teners with torque limiting drivers. When torque cannot be
controlled, as might be the case with field assembly, shoul-
der screws will limit compression on the plastic part. Other
alternatives may be to use flange-head screws, large wash-
ers or shoulder washers. Figure 8-7 presents some pre-
ferred designs when using mechanical fasteners.
Repeated assembling and disassembling should be avoided
when using self-tapping screws. If repeated assembly is
required, thread-forming screws are recommended.

Self-tapping Screws
A common type of mechanical fastener used with plastics is
a self-tapping screw. A self-tapping screw cuts or forms
threads as it is inserted into the plastic and eliminates the
need for molding internal threads or the secondary opera-
tion of tapping the thread form by machining. The major
types are thread-forming and thread-cutting.
The modulus of elasticity of the plastic material plays an
important role in deciding what type of self-tapping screw is
most suitable for the application. For plastic materials with a
modulus less than 3.0 GPa (440 kpsi), such as most
unreinforced resins, thread-forming screws are best since
the plastic is ductile enough to be deformed without crack-
ing or shearing. For glass and mineral filled grades,
Figure 8-8
thread-cutting screws are preferred.
Boss Design for Self-Tapping Screws
For optimum strip-out torque, the hole diameter of the boss
should be equal to the pitch diameter of the screw. The
outer diameter of the boss should be equal to two or three
times the hole diameter and the boss height should be more
than twice the thickness of the boss.
Figure 8-8 illustrates the basic boss design for use with
self-tapping screws.
To avoid stripping or high stress assemblies, torque con-
trolled drivers should be used on assembly lines.

Amodel PPA Design Guide 8– 15 Designing for Assembly

 When repeated assembly and disassembly are required or
Improving Torque Retention expected, threaded metal inserts should be used instead of
To minimize the loss of torque due to creep, reduce the self-tapping screws.
compressive stress under the screw head by:
• Increasing the screw head diameter
• Using a large-diameter flat washer
• Reducing the clamping torque
• Using a spring or spiral washer
• Using shoulder bolt to reduce stresses on plastic part
• Using a metal bushing.

Tightening Torque Figure 8-9

Figure 8-9 shows how torque changes as a function of Torque Developed During Screw Installation
screw penetration. Tightening torque must be high enough
to fully engage the screw threads and develop clamp load
but lower than the torque that would cause failure of the
threads, known as the stripping torque.
The tightening torque is the recommended installation
torque for a given application. It should be sufficiently high
so as to fully drive the screw and generate clamp load, yet
low enough to avoid stripping.
The optimum tightening torque value can be calculated from
the average driving torque and the average stripping torque
using the following equation.
1 ⎛3 1 ⎞
TT = ⎜ T D + TS ⎟
2 ⎝2 2 ⎠

Where
TT = Tightening Torque
T D = Average Driving Torque
TS = Average Stripping Torque

Some self-tapping screws have been designed specifically

for use with plastics and these have the advantage of hav-
ing a greater difference between driving and stripping
torque than the typical screws designed for metal. These
special fasteners can provide an additional safety factor for
automated assembly

Pull out force calculation

The strength of a joint can be characterized by the amount
of force required to pull-out a screw. The pull out force can
be estimated by using the following equation:
F = πSDL
where
F = Pull out force
S = Shear strength
D = pitch diameter
L = thread engagement length

Mechanical Fasteners 8– 16 Solvay Advanced Polymers, L.L.C.

Threaded Inserts
Threaded metal inserts can be used to provide permanent
metal threads in a plastic part; a wide variety of sizes and
types are available. Inserts are usually installed in molded
bosses whose internal diameter is designed for the insert.
The most commonly used metal inserts are either molded-in
or ultrasonically placed in the part as a secondary operation.
In the case of the molded-in insert, the insert is placed in
the mold and the plastic is injected around it. Stress will
develop when the plastic cools around the insert. To reduce
this stress, heat the inserts to the temperature of the mold.
The ultrasonic insert is pressed into the plastic by melting
the plastic with high frequency vibrations, generated by an
ultrasonic welding machine. The ultrasonic welding melts
material around the metal insert as it is being installed,
forming a bond between the insert and the plastic that is
usually strong and relatively free of stress.
Figure 8-10 depicts the recommended insert and boss
designs for use with Amodel PPA resin.

Figure 8-10
Boss Design for Ultrasonic Inserts

Amodel PPA Design Guide 8– 17 Designing for Assembly

 Straight Cantilever Beam Equation
Molded-in Threads
The relationship between maximum deflection and strain for
One of the benefits of using plastic materials instead of met-
a straight cantilevered beam was calculated as follows:
als is the ability to mold thread forms directly into the part.
From Table 8-2, the cantilever beam was chosen and the
This eliminates the secondary machining operations needed
drawing is repeated as Figure 8-12 . The maximum stress,
with metal parts to form the threads. molded-in threads can
is given by the following:
be either external or internal. In the case of internal threads,
some type of unscrewing or collapsible core is required. FL
σ=
External threads can be formed more easily if the parting Z
line of the mold is perpendicular to the thread.
Since this beam has a rectangular cross section,
Designing with Snap Fits bd 2
Z = and
The use of snap fits in plastics is very prevalent. All snap fit 6
designs require the plastic to flex like a cantilever spring as
bd 3
it moves past an interference that is designed on the mating I =
part. Once the flexible arm moves past the interference, it 12
returns to its normal unflexed, unstressed position. Usually a Therefore:
step or protrusion has been designed on the cantilever that
FLd
engages and locks into the mating part, creating a simple σ=
assembly method without additional parts. This is shown in 2I
Figure 8-11. The deflection of the beam, Y, is given by:
FL3
Y =
Figure 8-11 3EI
Cantilever Type Snap Fit Solving the deflection equation for F, the force needed to
deflect the beam can be calculated as follows:
3YEI
(1) F =
L3
The modulus of elasticity, E, is defined as:
σ σ
E = and therefore ε =
ε E
substituting that in the cantilever stress equation:
FLd
(2) ε=
2EI

Figure 8-12
Cantilever Beam - Concentrated Load at Free End

Each cantilever arm must deflect a distance “Y” in order to

be inserted. The key to proper snap design is to not exceed
the strain/stress limits of the material being used. A snap fit
design that has been used for a ductile, low modulus plastic
will probably not be suitable for a highly reinforced, very
rigid plastic.
For rigid materials, the length of the cantilever may be
increased or the interference deflection “Y” reduced. Adding
a “stop” can prevent over deflection of the cantilever during
assembly.

Mechanical Fasteners 8– 18 Solvay Advanced Polymers, L.L.C.

Using the relationship of equation (1) and substituting for F
in equation (2) the relationship between strain and deflec-
Figure 8-13
tion is derived:
Snap Fit Design Using Tapered Beam
3Yd
(3) ε=
2L2
This equation allows the designer to calculate the strain
required from the maximum deflection of a design. Table
8-4 summarizes maximum strain recommendations for sev-
eral grades of Amodel resins.
Once a suitable grade of Amodel resin has been selected,
the basic equations can be used to find the load, F, needed
to deflect the cantilever the required amount.
In a cantilever snap fit, the stress and strain are maximum
at the base of the cantilever and become proportionately
lower toward the tip where the load is applied. In fact the
stress and strain at any point can be calculated by substitut-
ing a different L, the distance from the load toward the fixed
end. Therefore, if the cantilever thickness was gradually
reduced from fixed end to tip, the beam will be able to
deflect more than in the fixed thickness cantilever without
incurring higher maximum stresses. In this way, the capabil- Figure 8-14
ity of the material can be maximized. Proportionality Constant (K) for Tapered Beam
Table 8-4
2.4
Strain Recommendations for Cantilever Snap-Fits
2.2
Amodel PPA Grade Maximum Strain, %
Proportionality Constant, K

2.0
ET-1000 HS 1.0
A-1230 L 0.5 1.8

AS-1133 HS 1.0
1.6

1.4

Tapered Cantilever Beam Equation

1.2
For the tapered design shown in Figure 8-13, hL is the thick-
1.0
ness at the free end. The value of the proportionality con- 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

stant, , for a tapered beam design can be found in Figure Ratio of h L to h o

8-14. The maximum strain can be calculated from equation
(4).
3Yh 0
(4) ε=
2L2 K
For example, if the beam thickness has been gradually
reduced to half its fixed end thickness; the ratio of hL to h0
would be 0.5 and K (from Figure 8-14) would be 1.6. There-
fore, the maximum strain and the corresponding stress
would be multiplied the reciprocal of K, 0.625. The strain
will be reduced by about 40% of the strain of a constant
thickness cantilever beam design with equal deflection.

Amodel PPA Design Guide 8– 19 Designing for Assembly

 Figure 8-15
Designing for Injection Molding
Wall Thickness Transition
Many of the applications for Amodel PPA resins will be man-
ufactured using the injection molding process. An engineer
who has designed a part to meet the performance require-
ments of the application must also take into account the fact
that there are elements in the part design that can influence
moldability. These factors include wall thickness and wall
thickness transitions, draft, ribs, bosses, and coring. The
effect of these factors on moldability should be considered
by the design engineer before a mold is built to make the
part.
Wall Thickness
In general, parts should be designed with the thinnest wall
that will have sufficient structural strength to support the
expected loads, keep deflection within design criteria limits,
have adequate flow, and meet flammability and impact
requirements. Parts designed in this manner will have the
lowest possible weight, and therefore the lowest material
cost, and the shortest molding cycle.
Wall Thickness Variation
Part designs that contain uniform wall thicknesses are ide-
ally suited for the injection molding process. They minimize
molded-in stress, reduce the potential for sink marks on the
surface of the part, and eliminate the potential for voids in a
molded part. However, structural, appearance, and draft
considerations may require varying wall thicknesses. When
changes in wall section thickness are necessary, the
designer should consider a gradual transition, such as the
tapered or gradual designs shown in Figure 8-15.
Sharp transitions may create problems in appearance and
dimensional stability, because they may result in differential
cooling and turbulent flow. A sharp transition may also result
in a stress concentration, which may adversely affect part
performance under loading or impact.

Designing for Injection Molding 8– 20 Solvay Advanced Polymers, L.L.C.

Draft Angle Figure 8-16

To aid in the release of the part from the mold, parts are Draft - Designing for Mold Release
usually designed with a taper. The taper creates a clearance
as soon as the mold begins to move, allowing the part to
break free from its mold cavity. The taper is commonly
referred to as draft, and the amount of taper as draft angle,
as shown in Figure 8-16.
Adequate draft angle should be provided to allow easy part
removal from the mold. Generally, the designer should allow
a draft angle of 0.5° to 1° per side for both inside and out-
side walls for Amodel resins. However, in some special
cases, smaller draft angles, as low as 1/8° to ¼°, have been
used with draw polish on the mold surface.
More draft should be used for deep draws or when cores
are used. Textured finishes increase draft requirements by a
minimum of 1° per side for each 0.001 inch (0.025 mm) of
texture depth.
Ribs
The stiffness of a part design can be increased with properly
designed and located ribs, without creating thick walls as
illustrated in the Design Section entitled “Using Ribs to
Maintain Stiffness” on page 8-8. Proper rib design will allow
for decreased wall thickness. This will save material and Figure 8-17
weight, and shorten molding cycles. It will also eliminate
thick walls, which can cause molding problems like sink Recommended Rib Design
marks on the surface of parts or voids on the inside of parts.
Ribs that are correctly positioned may also function as inter-
nal runners, assisting plastic melt flow during molding.
In general, the following guidelines should be used when
designing with ribs. The thickness at the rib base should be
no greater than 60% of the adjacent wall thickness. When
ribs are opposite appearance areas, the width should be
kept as thin as possible. If there are areas in the molded
part where structure is more important than appearance,
then ribs are often 75%, or even 100%, of the outside wall
thickness. Whenever possible, ribs should be smoothly con-
nected to other structural features such as side walls,
bosses, and mounting pads. If there are several ribs in a
part, they need not be constant in height or width, and are
often matched to the stress distribution in the part. All ribs
should have a minimum of ½° of draft per side and should
have a minimum radius of 0.8 mm (0.03 in.) at the base to
reduce stress concentrations and sink marks.
Figure 8-17 shows the recommended rib size relationships.

Amodel PPA Design Guide 8– 21 Designing for Injection Molding

Coring Figure 8-18
Proper design practice should include uniform wall thick- Boss Design - General Guidelines
ness throughout a part. Heavy sections in a part can extend
cycle time, cause sink marks on the part surface, cause
voids within the part and increase molded-in stresses.
Heavy sections should be cored to provide uniform wall
thickness. For simplicity and economy in injection molds,
cores should be parallel to the line of draw of the mold.
Cores placed in any other direction usually create the need
for some type of side action or manually loaded and
removed loose cores.
Cores which extend into the cavity will be subject to high
pressure. For blind cores (cores that are unsupported) that
have diameters greater than 1.5 mm (0.060 in.) the core
lengths should not exceed three times the diameter, while
blind cores with diameters less than 1.5 mm (0.060 in.)
should not exceed twice their diameter in length. These rec-
ommendations may be doubled for through cores (cores
that telescope into or shut off with the opposite side of the
mold). Draft should be added to all cores, and all tooling
draw polished for best ejection.
Bosses
Bosses are projections from the nominal wall of a part that
will eventually be used as mounting or fastening points. The
design of bosses is largely dependent upon their role in a
given part. Cored bosses can be used for press fits, self-tap-
ping screws, and ultrasonic inserts. Each of these will exert
stress on the wall of the boss.
As a general guideline, the outside diameter of a boss
should be twice the inside diameter of the hole, and the wall
thickness at the base of the boss should not exceed 60% of
the part wall thickness unless structural concerns override
appearance requirements. Figure 8-18 illustrates these
guidelines.
Additional forces imposed on bosses may tend to be trans-
mitted down the boss and into the nominal wall. For this
reason, a minimum radius of 25% of the wall thickness is
required at the base of the boss to provide strength and
reduce stress concentration. A boss can be further strength-
ened by using gusset-plate supports around the boss, or
attaching it to a nearby wall with a properly designed rib.
Bosses should be designed in the same manner as ribs.
Heavy sections should be avoided to prevent the occurrence
of sink marks on the surface and voids in the interior of the
part.

Ribs 8– 22 Solvay Advanced Polymers, L.L.C.

Undercuts Figure 8-19
Some design features, depending on orientation, can place Thermostat Housing Showing Beads
portions of the mold in the way of ejecting the part. These
features are called undercuts and can require special mold
configurations, such as slides or cams, to move prior to
ejection. In some cases, the material being molded will have
enough flexibility than the part can be pushed off the under-
cut without damage.
For example, the typical automotive thermostat housing, as
shown in Figure 8-19, has beads to provide for leak-proof
hose connections. To provide a smooth surface for the hose
connection, the designer has specified that the parting line
cannot be in this area. This results in an undercut at each
bead.
Under some circumstances, it may be possible to eject a
part with an undercut if the core can be pulled first and the
undercut ratio is 8 or less.
100 (Bead diameter ( A) - Tube OD (B) ) Figure 8-20
Undercut Ratio (R ) =
Tube ID (C) Undercut Diagram

If the part must be molded without side pulls and the under-
cut ratio calculated is greater than 8, the design should be
modified. One possible modification is to taper the tube
inside diameter effectively reducing the wall thickness
under the bead. For tubes with inside diameters less than
25 mm (1 in.), it may be necessary to modify the bead
geometry to get an undercut ratio of 8 or less.
The success of this approach is based upon removing the
part from the mold while the part is still hot and therefore
more flexible than it will be a room temperature.

Amodel PPA Design Guide 8– 23 Designing for Injection Molding

Secondary Operations Figure 9-1
Joint Design for Hot Plate Welding
Welding
Components produced from Amodel resins can be readily
joined using hot-plate, vibration, spin, or ultrasonic welding.
In this section, each welding method is described, and the
apparatus and the conditions that produced acceptable
welds with Amodel AS-1133 HS resin are discussed. These
conditions are the suggested starting points for determining
welding conditions for actual applications. Other Amodel
grades may require refinement of the noted process condi-
tions. In some instances, additional information will be pro-
vided, such as sensitivity to welding conditions, sample
geometry, or moisture content.
Because Amodel resins absorb moisture, tests were per-
formed on specimens conditioned to three different mois-
ture levels; 0%, 1.8% and 3.8% moisture. These moisture Best results were obtained using a hot plate temperature of
contents were selected to represent the moisture levels for 330°C (626°F), a clamping pressure of 207 KPa (30 psi).
parts molded from Amodel AS-1133 HS resin that had The optimum heating time for the test samples proved to be
reached equilibrium in air with relative humidity levels of 0, 40 seconds, with a holding time of 20 seconds. The strength
50, and 100% respectively. To simplify the discussion of of the bond produced was comparable to the strength of the
results, the term dry will be used for the dry, as molded material itself, i.e., the majority of the specimens failed at
specimens, normal for those containing 1.8 percent mois- points other than the joint during mechanical testing.
ture, and saturated for those containing 3.8 percent Test plaques occasionally stuck to the hot plate unless a sili-
moisture. cone mold release was applied and the hot plate was
In summary, acceptable welds can be achieved using all of allowed to reach thermal equilibrium. Tests showed that the
the welding techniques evaluated and described in this sec- use of mold release did not reduce the weld strength.
tion. Ultrasonic welding does require near-field energy appli- Absorbed moisture did not significantly affect weld strength
cation for strong welds. In general, absorbed moisture does at dry (0%) and normal (1.8%) levels, but it did reduce weld
not interfere with welding, but best results are obtained strength at the saturated (3.8%) condition.
using samples that contain normal amounts of moisture Vibrational Welding
(1.8%) or less.
In vibrational welding, friction is used to generate heat at
Hot Plate Welding the weld joint. One of the parts to be assembled is held sta-
In hot plate welding, the thermoplastic samples are pressed tionary while the mating part vibrates ~0.8 to 1.5 mm
against a heated element causing the contact surface to (0.030 to 0.060 in.) in a linear fashion at 100 to 400 Hz.
melt. The element is then removed and the samples are Vibrational welding is limited to flat parts, but has a rela-
forced together under pressure. This welding method typi- tively fast cycle time and a low tooling cost.
cally requires a longer cycle time than other methods, but it The machine used for these experiments was a Vinton
allows for the joining of parts that have a much larger sur- Hydroweld Vibration welding machine. This machine oper-
face area. With care, a strong and hermetic bond may be ates at a nominal frequency of 240 Hz. The specimens used
obtained using this method with Amodel resins. were 102 mm (4 in.) long, by 25 mm (1 in.) wide, by 6 mm
The hot plate welding machine used was a Bielomatic HV (0.25 in.) thick, and they were welded in a 25 by 13 mm (1
4806 welding machine manufactured in 1986 by Leuze by 0.5 in.) lap shear configuration as shown in Figure 9-2.
GMBH. The specimens used were bars 102 mm (4 in.) long, This method was very effective and welds as strong as the
25 mm (1 in.) wide, and 6 mm (0.250 in.) thick. The welding parent material were easily obtained. This technique proved
machine was set up to provide a nominal lap shear weld of relatively insensitive to welding conditions, giving good
13 by 25 mm (0.5 by 1 in.). A diagram of the weld joint is results at weld times as short as 0.60 seconds and pres-
shown in Figure 9-1. sures as low as 2.20 MPa (320 psig). Best results were
obtained using specimens containing a normal (1.8%)
amount of moisture.

9– 1 Solvay Advanced Polymers, L.L.C.

 Spin welded joints using Amodel PPA should incorporate a
Figure 9-2 design known as a shear joint like that shown in Figure 9-3.
Lap Shear Joint Configuration Details known as flash traps may be incorporated to chan-
nel the localized flow of the material to one side of the part
depending on requirements.
The spin welding machine used for these experiments was
a Mechasonic KLN Omega machine, model SPN-063. Typi-
cally the important parameters for this welding method are
angular speed, in revolutions per minute, normal force, and
welding time. Because this specific machine was an iner-
tia-type, the energy available for spinning the sample was
limited to that stored in the flywheel. Instead of adjustments
per se to speed, the energy stored in the flywheel was con-
trolled. More modern spin welding machines allow for the
control of speed, force, time, and in some cases, angular
location.
The specimens used for the spin weld testing were injection
molded cups with an interference joint design. Excellent
Spin Welding weld strength was obtained using this method.
The spin welding method uses frictional heat to join two Because the welding condition settings were machine-spe-
cylindrical or spherical mating parts. While one half is held cific, they are not generally useful in setting a starting point.
stationary in a nest fixture, the mating part is spun rapidly Rather, it was observed that as forge pressure and angular
against it. Friction at the interface raises the temperature of velocity were increased, weld strength increased up to a
the material until melting occurs. When the spinning action maximum and then decreased when an excessive amount
is stopped, the parts are held under pressure until cooled. of either pressure or velocity were applied. The values for
Obviously, this welding method is limited to parts with circu- these parameters are strictly dependent on the part geome-
lar geometry at the joint. The advantage obtained through try and therefore they are not noted here. The explanation of
spin welding is the increased dispersion of material at the the observed phenomena is that when a weld was made
joint compared to other techniques. This allows for the with too high a forge pressure, the spinning motion was
development of hermetic seals and reduces the tolerance stopped too rapidly and not enough polymer melted and
requirements on the joint geometry. flowed to create a sound joint. In the other extreme, a high
angular velocity and a low forge pressure, the top part
essentially sat on top of the bottom part and freely rotated
without being forced into the interference fit. Thus, to assure
a good joint, a welding condition must be found so both
melting and forging occurs.
Figure 9-3 Moisture content did not significantly affect weld strength.
Shear Joint Configuration
Ultrasonic Welding
In the ultrasonic welding of thermoplastic materials, high
frequency (10 to 40 KHz) mechanical vibrations are trans-
mitted through one of the mating parts to the joint interface
while the other half of the assembly is held stationary. The
combination of friction and an applied force causes the tem-
perature at the joint interface to increase to the melting
temperature of the material. Normal force is held after the
ultrasonic energy input is removed to achieve a mechanical
bond or weld.
Ultrasonic welding has the advantage of being very high
speed and is well suited to high volume production. Weld
consistency and quality are high using this method; even
hermetic seals may be obtained with close tolerance parts.

Amodel PPA Design Guide 9– 2 Welding

Figure 9-4 To prepare the test specimens for the Lord 305-1/-2, a cure
cycle of 30 minutes at 120°C (250°F) followed by condition-
Typical Energy-Directing Joint Configuration ing at room temperature for 72 hours was employed. The
cure cycle for the Lord 7500 A© adhesive was 10 minutes
at 90°C (200°F) followed by a 72-hour room temperature
conditioning step.
The bond strength for both materials was tested at low tem-
perature, room temperature, and an elevated temperature.
To evaluate the effect of humid aging, specimens were con-
ditioned for 14 days at 38°C (100°F) and 100% relative
humidity. Some specimens were tested immediately after
conditioning; others were tested 24 hours after conditioning.
Impact performance was determined with a side impact
tester according to GM specification #9751P. Lap shear val-
ues were measured on an Instron testing machine using a
pull rate of 13 mm/min (0.5 in./min) according to ASTM
D1002.
Aside from the ultrasonic weld equipment, a customized
horn must be employed for each assembly to focus the Figure 9-5
ultrasonic energy for the given part configuration. Lap Shear Bond Strength
An energy-directing joint design is recommended for use
with Amodel materials to ensure that there is localized melt-
ing at the joint. A typical joint design is shown in Figure 9-4.
The recommended interference using a shear joint design is
a minimum of 0.2 mm (0.008 in.).
The ultrasonic welding machine used for this testing was a
Branson Model 910 M microprocessor-controlled machine.
With this unit it is possible to adjust the amount of ultrasonic
energy that is applied to the sample. For testing, the output
from the booster was fed to near and far field horns. The
samples used were similar to the injection molded cup used
for the spin welding evaluation. Aluminum fixtures held the
parts in place and a butt weld joint configuration was
employed.
Welds produced using a near field horn [defined as 6 mm
(0.25 in.) or less measured from the horn to the weld joint] Figure 9-6
were excellent. Welds made using the far field horn position Side Impact Bond Strength
were weak (one-third of the strength achieved with near
field) and are probably not useful. The conditions that gave
acceptable weld strength were: weld energy of 750 J and
pressure of 4.3 MPa (617 psi).

Adhesive Bonding
Injection molded samples of Amodel A-1133 HS resin were
bonded with both an epoxy and a urethane adhesive. Both
adhesives were supplied by Lord Corporation. The epoxy
was a two part adhesive sold under the trade name Lord®
305-1/-2 and the urethane was a two part system known as
Lord® 7500 A©.

Ultrasonic Welding 9– 3 Solvay Advanced Polymers, L.L.C.

Table 9-1 Because of the need to vaporize the metal materials during
Suitable Automotive Primers this process, an elevated temperature may be expected in
the vacuum chamber. The rate at which parts may be
Supplier Primer Description coated is controlled by the thermal characteristics of the
BASF U04KD004 solvent, flexible substrate material. For this reason, Amodel resin, with its
U04AD041 solvent, rigid high heat deflection temperature, is an excellent candidate
U36AD001 water based material when metallization is required as comparatively
PPG RPP9870 solvent, high solids rapid cycle times may be obtained.
AHAP9470R solvent, one coat
Table 9-3
Red Spot AE146 solvent, lacquer
Suppliers of InkJet Printing Equipment
Siebert-Oxidermo UBP9604 solvent, high solids
BP2024 solvent Company Website
Sherwin-Williams E75BC2301 solvent Videojet Systems International, [Link]
Inc.
E75AC6 solvent
ID Technology [Link]

The results are shown in Figures 9-5 and 9-6. In general, Laser Marking
the epoxy adhesive performed slightly better than the ure-
It is possible to obtain a durable, high contrast mark on
thane. Acrylic adhesives are not recommended for use with
Amodel resins using commercially available laser marking
Amodel resins.
systems. Depending upon the wavelength and intensity of
the laser system used, the appearance of the mark can
Coatings and Surface Finishes range from a bleached surface to an engraved mark.
Vacuum Metallizing No one set of conditions can be specified for laser marking
Vacuum metallization involves the evaporation, and subse- all Amodel PPA resins. Operating parameters must be
quent condensation, of a metal onto a substrate in a vacuum adjusted depending upon the particular application and part
chamber. The metal used in most industrial applications is being marked.
aluminum. When the end use requirement is primarily deco- The manufacturers in Table 9-2 have equipment that should
rative, the substrate is usually processed with two organic be suitable for marking Amodel PPA resins.
coatings called the basecoat and the topcoat with the metal
layer deposited in between. The primary function of the Inkjet Printing
basecoat is to produce a smooth surface on molded plastic Inkjet printing can be used to provide a highly visible mark
parts so that the metal layer will have maximum luster. A on Amodel PPA resin substrates of any color. The durability
secondary function of the basecoat is to maximize adhesion of marks made using an inkjet system depends upon the
of the metal layer to the substrate. On substrates that tend environment to which the marked part will be exposed and
to outgas in a vacuum, the basecoat also provides a barrier the type of ink used to make the mark. In many cases the
layer. The function of the topcoat is to protect the metal durability of the mark will be satisfactory.
layer from physical, oxidative, or chemical deterioration.
Equipment needs vary depending upon the type of ink used,
Table 9-2 the speed at which the mark is made, and size of the
desired mark. A wide variety of equipment and inks are
Suppliers of Laser Marking Equipment commercially available. Two sources are shown in Table
Company Website 9-3.
Videojet Systems International,
Inc.
[Link] Painting
Aromat Corporation [Link] Several grades of Amodel PPA resin were evaluated for their
ID Technology [Link] compatibility with various automotive paint systems. Repre-
sentative glass-reinforced, mineral-reinforced, and min-
eral/glass-reinforced compounds were evaluated.
Basecoats that are compatible with Amodel resins include As with all plastic substrates, the primer system is critical.
#VB-4315, #VB-4774, and #VB-4836-1 from Pearl Paints, The test specimens were cleaned with isopropyl alcohol
[Link] Topcoats that are then coated with primers and cured as per the manufac-
compatible with Amodel resin include #VT 4316-2, also turer’s instructions. The plaques were tested for tape adhe-
from Pearl Paints. sion (GM9071P, method A) and cross-hatch adhesion

Amodel PPA Design Guide 9– 4 Adhesive Bonding

(GM9071P, method B) and gravelometer chip resistance
(GM9508P and SAEJ400) as coated and after conditioning
for 96 hours with water/fog/humidity per GM4465P specifi-
cation. Table 9-1 lists primers that meet or exceed all test
requirements and represent adequate coating performance
for most painted automotive applications.
Overmolding
A process developed by the Bryant Rubber Corporation
allows for the overmolding of Amodel materials with soft
touch silicone rubber. The silicone rubber materials are ideal
for the creation of sealing surfaces, tactile grips, and
sound/noise dampening details. While overmolding with sili-
cone rubber is not a new idea, these design details are typi-
cally characterized as having poor adhesion to the rigid sub-
strates even if primers, or priming processes, are employed.
The adhesion and peel strength achieved through the use of
Bryant’s Select Primerless Adhesion Polymer System
(SPAPS™ Technology) is uniquely better than anything that
has previously been achieved. In fact, cohesive failure of the
silicone rubber is typical of the SPAPS™ Technology
process.
Amodel resins are particularly well suited for use in con-
junction with SPAPS™ silicone rubbers due to their excel-
lent properties at high temperatures. This allows for reduced
cycle times for the silicone cure process, improving overall
economics. The silicone materials match the long-term
thermal stability of Amodel resin, more so than other
elastomeric materials, ensuring long-term performance in
difficult environments.
The SPAPS™ silicone rubbers are offered in the full range of
property options available in other common silicon rubbers.
The materials are naturally transparent and colorable using
liquid colorants during the molding process, with excellent
color fastness, even with prolonged ultraviolet light expo-
sure. They are available with durometer ratings of 10-85 on
the Shore A scale. Their chemical resistance is similar to
that of other silicone rubber materials. The unreactive char-
acter of the materials will allow for agency approvals, such
as NSF, FDA, and U.S.P., of the finished parts.
Further information regarding the overmolding process may
be obtained from the Bryant Rubber Corporation at
[Link]

Painting 9– 5 Solvay Advanced Polymers, L.L.C.

Index
A D
Adhesive Bonding 9-3 Deflection Calculations 8-6
AMODEL PPA base resins 1-1 Deflection Temperature 5-1
Amorphous 1-1 Design 8-1
Assembly Dielectric Constant 6-2
Designing for 8-14, 8-15, 8-17, 8-19 Dielectric strength 6-1
ASTM D 149 6-1 Dissipation Factor 6-2
ASTM D 257 6-1 Draft Angle 8-21
ASTM D 2990 4-5
ASTM D 3763 3-11 E
ASTM D 638 3-1 Elastic modulus 3-2
ASTM D 648 5-1 Electrical Properties 6-1, 6-3
ASTM D 671 4-7 Test Methods 6-1
ASTM D 256 3-9 Environmental Resistance 7-1
ASTM D 3045 5-6 Example Design
ASTM D 695 3-8 Equivalent Stiffness 8-7
ASTM D 732 3-7 Examples
ASTM D 790 3-5 Design 8-7
ASTM E 662 5-9
ASTM E 831 5-2 F
ASTM F 433 5-4
Fasteners
B Designing for Mechanical 8-15
Fatigue Resistance 4-6
Base resins 1-1 Fatigue Strength 4-6
Beam Bending Model 8-5 Fiber Orientation 8-2
Bolt Tightness Flammability
Design Example 8-13 UL 94 5-10
Bosses Flexural modulus 3-5
Use in Part Design 8-22 Flexural strength 3-5, 4-5, 4-8
Bryant Rubber 9-5
G
C
Glow Wire 5-8
Calculations Glow Wire Test 5-8
Press Fit 8-14
Charpy 3-10 H
Chemical Compatibility
General 7-5 High-Current Arc Ignition 6-4
Chemical Resistance 7-1, 7-3, 7-5 Heat Deflection Temperature 5-1
Aqueous Chemical Solutions 7-3 High-Voltage Arc Resistance to Ignition 6-4
Effect of Chemical Structure 7-1 High-Voltage Arc-Tracking-Rate 6-3
Organic Chemicals 7-2 High-Voltage, Low-Current, Dry Arc Resistance 6-2
Screening Tests 7-1 Horizontal Burning Test 5-10
Transportation Fluids 7-4 Hot Plate Welding 9-1
Chemistry 1-1 Hot Wire Ignition 6-3
Coefficient of linear thermal expansion 5-2 High-Voltage Arc-Tracking-Rate 6-3
Combustion Properties 5-8 Hot Wire Ignition 6-3
Comparative Tracking Index 6-3
Compressive strength 3-8 I
Coring IEC 695-2-1/3 5-8
Use in Part Design 8-22 Impact Resistance Testing 3-9
Creep Impact Strength 3-9
Compressive 4-6 Charpy 3-10
Flexural 4-5 Izod 3-9
Tensile 4-5 Inserts
Creep Design Threaded 8-17
Deflection Calculations 8-9 Ultrasonic 8-17
Creep- Sustained Load Interference Fits 8-14
Designing for 8-9 Introduction 1-1
Crystallinity 1-1 ISO 527 3-1
Comparative Tracking Index 6-3 ISO 178 3-5
ISO 179/1eA 3-10
ISO 180 3-9

10-1
Index-continued
Section Thickness
ISO 75 5-1 Influence on Stiffness 8-7
ISO 899 4-2 Semi-crystalline 1-1, 1-2
Isochronous 4-4 Shear strength 3-7
Izod impact 3-9 Silicone Rubber 9-5
Smoke Density 5-9
M Snap Fits
Marking Calculation Straight Beam 8-18
Laser 9-4 Calculation Tapered Beam 8-19
Material Strength in Design 8-6 Designing 8-18
Mechanical Design 8-2 Specific heat 5-5
Mechanical Properties Spin Welding 9-2
Long-term 4-1 Stress - Strain curve 3-1
Short Term 3-1 Stress Concentrations 8-11
Moisture Absorption 4-8 Stress Max Allowable 8-10
Moisture Effects 1-3, 4-8 Stress/Strain Calculations 8-5
Dimensions 4-9 Stress/strain curve 3-2
Strength and Stiffness 4-9 Surface Resistivity 6-1
Mold Release 8-21 Sustained Load
Designing for 8-21 Designing for 8-9
Molding
Designing for 8-20 T
Tensile modulus 3-2
N Tensile properties 3-1
Nomenclature 2-1 Tensile strength 3-2, 3-4, 4-9, 5-6, 7-1
Notched Izod Impact 3-9 TGA 5-6
Thermal aging 5-6
O Thermal conductivity 5-4
Overmolding 9-5 Thermal Expansion 5-2
Thermal properties 5-1
P Thermal stability 5-6
Thermal Stresses
PA66 3-9, 3-10, 4-6 Designing for 8-12
Painting 9-4 Thermogravimetric analysis 5-6
Poisson’s ratio 3-11 Threaded inserts 8-17
Polyamide 1-1 Threads
Polyphthalamide 1-1 Molded in 8-18
PPA base resins 1-1
PPA property tables 2-1 U
Press Fits 8-14
Printing UL 746A 6-1
Inkjet 9-4 UL 746B 5-6
Property Tables 2-1 UL 94 5-10
Horizontal Burning Test 5-10
R Vertical Burn Test 20MM 5-10
Vertical Burn Test 500 MW 5-10
Radiation Ultrasonic Welding 9-3
Gamma 7-6
Reinforcing Fiber Orientation V
Effect on Mechanical Performance 8-6
Relative Thermal Index 5-6 Vacuum Metalizing 9-4
Ribs Vertical Flammability 5-10
Influence on Stiffness 8-8 Volume Resistivity 6-1
Molding Recommendations 8-21 W
RTI 5-6
Wall Thickness 8-20
S Welding 9-1
Screw Hot Plate 9-1
Torque Retention 8-16 Spin 9-2
Screws Ultrasonic 9-2
Self-tapping 8-15 Vibrational 9-1
Secondary Operations 9-1 Wire 6-3

10-2
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Health and Safety Information

Material Safety Data Sheets (MSDS) for products of Solvay Advanced Polymers are available upon
request from your sales representative or by e-mailing us at advancedpolymers@[Link].
Always consult the appropriate MSDS before using any of our products.

To our actual knowledge, the information contained herein is accurate as of the date of this docu-
ment. However, neither Solvay Advanced Polymers, LLC nor any of its affiliates makes any warranty,
express or implied, or accepts any liability in connection with this information or its use. This infor-
mation is for use by technically skilled persons at their own discretion and risk and does not relate
to the use of this product in combination with any other substance or any other process. This is not
a license under any patent or other proprietary right. The user alone must finally determine suitability
of any information or material for any contemplated use, the manner of use and whether any
patents are infringed. This information gives typical properties only and is not to be used for spec-
ification purposes. Solvay Advanced Polymers, LLC reserves the right to make additions, deletions,
or modifications to the information at any time without prior notification.

Amodel is a registered trademark of Solvay Advanced Polymers, LLC

AM-50477 © 2002 Solvay Advanced Polymers, LLC. All rights reserved. D03/07

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