Amodel

Amodel® PPA
Design Guide

SPECIALTY
POLYMERS
 Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Thermal Properties . . . . . . . . . . . . . . . . . . . . . . . . 42

Heat Distortion Temperature – HDT . . . . . . . . . . . . . 42
Amodel® Polyphthalamide (PPA) . . . . . . . . . . . . . . 3 Deflection Temperature Values for
Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Amodel® Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Crystallinity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Coefficient of Linear Thermal Expansion . . . . . . . . . . 43
Moisture Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . 45
Specific Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Thermal Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thermogravimetric analysis (TGA) . . . . . . . . . . . . 47
Amodel® Resin Property Tables . . . . . . . . . . . . . . . 6 Relative thermal index (UL) . . . . . . . . . . . . . . . . . . 48
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Glow wire testing . . . . . . . . . . . . . . . . . . . . . . . . . 49
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Smoke density test (NBS) . . . . . . . . . . . . . . . . . . . 50
Horizontal burning test . . . . . . . . . . . . . . . . . . . . . 50
50W (20 mm) Vertical burn test . . . . . . . . . . . . . . 50
Property Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 500 W Vertical burning test . . . . . . . . . . . . . . . . . 51
Typical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical Properties . . . . . . . . . . . . . . . . . . . . . . . 51
Accelerated Moisture Conditioning . . . . . . . . . . . . 8 Dielectric Breakdown Voltage and Strength -
ASTM D149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . 21 Volume Resistivity - ASTM D257 . . . . . . . . . . . . . . . . 52
Short-Term Mechanical Properties . . . . . . . . . . . . . . 21 Surface Resistivity - ASTM D257 . . . . . . . . . . . . . . . 52
Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Dielectric Constant - ASTM D150 . . . . . . . . . . . . . . . 52
Test methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Dissipation Factor - ASTM D150 . . . . . . . . . . . . . . . .53
Tensile property comparison . . . . . . . . . . . . . . . . 22 UL 746A Short-Term Properties . . . . . . . . . . . . . . . . 53
Tensile properties for GR PPA vs. temperature . . 23 High-Voltage, Low-Current, Dry Arc Resistance –
Tensile properties of A-1000 GR grades at ASTM D495 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
elevated temperatures . . . . . . . . . . . . . . . . . . . . . 24 Comparative Tracking Index (CTI) – ASTM D3638 . . . 54
Test methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hot Wire Ignition (HWI) - ASTM D3874 . . . . . . . . . . . 54
Flexural property comparison . . . . . . . . . . . . . . . . 25 High-Current Arc Ignition (HAI) . . . . . . . . . . . . . . . . . 55
Flexural properties at elevated temperatures . . . . 26 High-Voltage Arc Resistance to Ignition . . . . . . . . . . 55
Shear Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 UL Relative Thermal Indices . . . . . . . . . . . . . . . . . . . 55
Compressive Strength and Modulus . . . . . . . . . . . . . 28
Impact Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Environmental Resistance . . . . . . . . . . . . . . . . . . . 56
Izod (Cantilevered Beam) Impact . . . . . . . . . . . . . . . 29 Chemical Resistance . . . . . . . . . . . . . . . . . . . . . . . . 56
Falling weight impact properties . . . . . . . . . . . . . . 31 Chemical Compatibility . . . . . . . . . . . . . . . . . . . . . 60
Poisson’s Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Gamma Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Long-term Mechanical Properties . . . . . . . . . . . . . . . 32
Creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Design Information . . . . . . . . . . . . . . . . . . . . . . 61
Tensile creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Isochronous stress/strain curves . . . . . . . . . . . . . 35 Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . 62
Tensile creep rupture . . . . . . . . . . . . . . . . . . . . . . 35 Using Classical Stress/Strain Equations . . . . . . . 65
Flexural creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Limitations of Design Calculations . . . . . . . . . . . . . . . 65
Compressive creep . . . . . . . . . . . . . . . . . . . . . . . 36 Deflection Calculations . . . . . . . . . . . . . . . . . . . . . . . 65
Fatigue Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Stress Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fatigue strength of Amodel® resin . . . . . . . . . . . . 37 Reinforcing Fiber Orientation Considerations . . . . . . .65
Moisture Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Designing for Equivalent Part Stiffness . . . . . . . . . . . 66
Significance of moisture absorption . . . . . . . . . . . 38 Changing section thickness . . . . . . . . . . . . . . . . . 66
Moisture absorption and glass transition Adding ribs to maintain stiffness . . . . . . . . . . . . . . 66
temperature (Tg) . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Designing for Sustained Load . . . . . . . . . . . . . . . . . . 67
Absorption amount . . . . . . . . . . . . . . . . . . . . . . . 39 Calculating deflection . . . . . . . . . . . . . . . . . . . . . . 67
Effect of moisture on strength and stiffness . . . . . 40 Calculating allowable stress - creep rupture . . . . . 68
Dimensional change due to moisture . . . . . . . . . . 40
Considering Stress Concentrations . . . . . . . . . . . 69
Considering Thermal Stresses . . . . . . . . . . . . . . . 69
Loss of Bolt Tightness Due to Creep . . . . . . . . . . . . 70
Designing for Assembly . . . . . . . . . . . . . . . . . . . . . 71
Interference or Press Fits . . . . . . . . . . . . . . . . . . . . . 71

Amodel® PPA Design Guide / 1

 Calculating the Allowable Interference . . . . . . . . . . . . 71 Secondary Operations . . . . . . . . . . . . . . . . . . . 79
Mechanical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . 72
Self-tapping screws . . . . . . . . . . . . . . . . . . . . . . . 72 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Improving torque retention . . . . . . . . . . . . . . . . . . 72 Hot Plate Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . 73 Vibrational Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Pull out force calculation . . . . . . . . . . . . . . . . . . . 73 Spin Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Threaded inserts . . . . . . . . . . . . . . . . . . . . . . . . . 73 Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Molded-in threads . . . . . . . . . . . . . . . . . . . . . . . . 74 Adhesive Bonding . . . . . . . . . . . . . . . . . . . . . . . . . 81
Designing with snap fits . . . . . . . . . . . . . . . . . . . . 74
Straight cantilever beam equation . . . . . . . . . . . . 74 Coatings and Surface Finishes . . . . . . . . . . . . . . . 82
Tapered Cantilever Beam Equation . . . . . . . . . . . . . . 75 Vacuum Metallizing . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Laser Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Designing for Injection Molding . . . . . . . . . . . . . . 76 Inkjet Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wall Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Overmolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Wall Thickness Variation . . . . . . . . . . . . . . . . . . . . . . 76
Draft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Ribs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Coring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

2 \ Amodel® PPA Design Guide

 Introduction

Amodel® Polyphthalamide (PPA) The naming convention for polyamides uses the
number of carbon atoms in the monomers with the
Amodel® PPA resins were commercialized in 1991.
diamine component first. Thus, a polyamide made from
Polyphthalamide resin technology can produce a wide
hexamethylene diamine and adipic acid is called polyamide
range of polymers that includes both semi-crystalline
6,6 or nylon 6,6; the one made from hexamethylene
and amorphous resins. Since 1991, several base polymer
diamine and dodecanedioic acid would be nylon 6,12.
formulations have been commercialized to meet specific
industry needs. All of the commercial Amodel® products When an aromatic diacid is used instead of an aliphatic
are semi-crystalline. diacid, the nomenclature is modified to reflect the isomeric
form of the aromatic diacid, and the term polyphthalamide
The semi-crystalline grades of Amodel® PPA resins have
may be used to distinguish these polymers from those of
excellent mechanical properties, outstanding dimensional
solely aliphatic raw materials.
stability, exceptional elevated thermal performance, and
good processing characteristics. Amodel® resins bridge Polyamide 6,T produced by the condensation of
the cost/performance gap between the high-volume, hexamethylene diamine with terephthalic acid, has long
moderate-performance engineering resins, such as been recognized for its excellent dimensional stability, low
thermoplastic polyesters and aliphatic nylons, and the moisture absorption, high strength, and heat resistance.
low-volume, high-cost specialty thermoplastics, such The fundamental problem preventing its commercialization
as polyetheretherketone (PEEK). has been that its high crystalline melting point of 370 °C
(698 °F) is above its thermal decomposition temperature.
The Amodel® product portfolio contains well over 100
Therefore, it cannot be processed by most conventional
different grades. Each grade has been designed to
melt processing techniques, such as injection molding
have a unique balance of properties that are important
or extrusion. In addition, its melting point, among other
for specific application and processing requirements.
factors, complicates the polymerization process.
Applications for Amodel® PPA have been developed
in a wide range of industries including automotive/ The basic polyamide 6,T technology has been modified
transportation, industrial equipment, water handling, by adding comonomers to produce the Amodel® family
telecommunications, electrical/electronic, coatings, of polyphthalamide (PPA) resins which are composed of
composites, food service, and consumer goods. proprietary compositions of matter. Varying the amount
and nature of the comonomers leads to a family of resins.
This manual is intended to be an easy-to-use reference
All of these resins have melting points lower than polyamide
tool for designers and fabricators interested in Amodel®
6,T and exhibit rapid crystallization. The thermal properties
PPA as a solution to their material needs. It includes
of the Amodel® PPA base resins are shown in Table 1.1.
property data for select grades of the portfolio as well
as part design and processing recommendations. Table 1.1 A
 model® PPA base resin properties

Chemistry Base Tg Tm
Amodel® resins are classified in the general chemical Resin [°C(°F)] [°C(°F)]
family known as polyamides. Polyamides may be A-1000 123 (253) 313 (595)
produced by the reaction of a difunctional organic acid A-4000 100 (212) 325 (617)
with a difunctional amine, or the self-condensation of A-5000 89 (192) 294 (561)
either an ω-amino acid or a lactam. Polyamides can A-6000 88 (190) 310 (590)
be produced from a wide variety of acids and amines.

Amodel® PPA Design Guide / 3

 These base resins when combined with mineral, glass- In the case of semi-crystalline polymers, the modulus
fiber, and/or other compounding ingredients provide a also gradually decreases with increasing temperature.
wide range of injection molding compounds that offer an At or near the glass transition temperature, the modulus
excellent balance of processing and thermal/mechanical decreases rapidly to a lower but still useful level. Continuing
performance. Compounds based on A-1000 base resin to increase the temperature causes the modulus to
require molds using oil for temperature control; compounds remain at or near this new level (the crystalline plateau)
based on the other base resins can be processed using until the melting point temperature (Tm ) is reached. At Tm,
water controlled molds. the modulus decreases rapidly again. Semi-crystalline
polymers are often used at temperatures above their glass
Crystallinity transition temperatures, but below their melting points,
Thermoplastics are often divided into two classes: particularly when they are modified with glass fibers and/
amorphous and semi-crystalline. One of the major or mineral fillers.
differences between amorphous and semi-crystalline
When semi-crystalline polymers are processed, the
polymers is the way their properties change in response
amount of crystallinity can be affected by processing
to changes in temperature. Figure 1.1 shows a typical
conditions. For example, Amodel® A-1000 PPA based
response of modulus to temperature change for amorphous
products require mold surface temperatures of at least
and semi-crystalline polymers.
135 °C (275 °F) for development of the maximum amount
Figure 1.1 M
 odulus changes with temperature of crystallinity during injection molding. Products based
on Amodel® A-4000 or A-6000 base resin will give high
Amorphous 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
Tg
Modulus

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

Temperature
Amodel® base resins
Semi-crystalline
Temperature [ °F ]
100 200 300 400 500
1,800
A-1000 250
1,600 A-4000
1,400 A-6000
200
Modulus [ kpsi ]
Modulus

Tg 1,200
Modulus [ GPa ]

1,000 150
800
100
Tm 600
400 50
200
0 0
Temperature 0 50 100 150 200 250 300
Temperature [ °C ]
When the temperature is raised, the modulus of
amorphous polymers generally decreases slowly until
the glass transition temperature (Tg ) is reached. At
temperatures above the Tg, the modulus decreases
rapidly. Therefore, amorphous thermoplastics are
rarely used at temperatures higher than their glass
transition temperature.

4 \ Amodel® PPA Design Guide

Moisture Effects Figure 1.4 compares the dimensional change of Amodel®
Like other polymers, polyphthalamide resins absorb A-1000 resin to that of PA 6,6 after being immersed in
moisture from the environment. In general, polyphthalamides water at 23 °C (73 °F). Results shown are for 3.2 mm
will absorb less water than aliphatic polyamides, like PA (0.125 in.) thick plaques. After one year (about 8,800 hours),
6,6, and they will absorb the moisture at a slower rate. the dimensional change of the PA resin is approximately
three times that of the PPA resin.
When an article made from an Amodel® product based
on A-1000 base resin reaches equilibrium with a 100 % Not only do polyphthalamides absorb less moisture than
relative humidity (RH) atmosphere, the increase in weight typical polyamides, they do so much more slowly. The
due to moisture absorption will be roughly 5 % to 6 % of diffusion coefficient for water in Amodel® A-1000 resin
the polyphthalamide resin weight. is approximately 20 % of that for PA 6,6 at 23 °C (73 °F).

Figure 1.3 compares the glass transition temperatures Figure 1.4 Dimensional change vs. water
of Amodel® A-1000 resin and PA 6,6 at a range of immersion time
moisture contents. These materials absorb moisture
at different rates and they have different maximum 2.5
moisture adsorption amounts. The most useful and
2.0

Dimensional change [ % ]
practical comparison is achieved by plotting the Tg
versus the equilibrium moisture content at various
relative humidities. 1.5

Figure 1.3 E
 ffect of moisture on Tg 1.0

300
140 A-1000 PPA 0.5
120 PA 6,6 250 A-1000 PPA
PA 6,6
100 0.0
200
80 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000
Tg [ °F ]

150
Tg [ °C ]

60 Time [ hours ]
40 100
20
50
0
-20 0
-40 -50
0 10 20 30 40 50 60 70 80 90 100
Relative humidity [ % ]

Comparing dry PA 6,6 to dry Amodel® A-1000 resin,

Amodel® resin has a Tg advantage of about 60 °C (108 °F).
If the comparison is made at the 50 % RH equivalent
moisture content, the Tg advantage of Amodel® resin is
about 89 °C (160 °F). The exceptional dimensional stability
and property retention of Amodel® polyphthalamide is due
largely to the higher Tg and the fact that the Tg remains
well above room temperature, even at the moisture
content appropriate for 100 % RH. The Tg of PA 6,6, on
the other hand, falls to -15 °C (5 °F) at moisture contents
consistent with equilibria at 50 % to 60 % RH.

Amodel® PPA Design Guide / 5

 Product Data

Amodel® Resin Property Tables The base polymers are translucent white due to
crystallinity, and the natural color of a specific product will
Amodel® PPA resins are typically combined with
vary depending on the additives used. Most grades are
reinforcements, fillers, impact modifiers, flame retardants,
available in natural and black. Other colors can often be
colorants, and other additives to achieve a wide range of
provided. Please discuss your color requirements with
performance profiles. Currently the family contains over
your Solvay representative.
100 commercial grades. This document provides detailed
property information on 12 grades that were selected
to be representative of the product family. Your Solvay
representative can help you select the most cost-effective
material for your application.

Table 2.1 Amodel® resin nomenclature system

Position Characteristic Meaning/Example

1st letter Product family A = Amodel®
E = extra
Next letter(s) Optional descriptor E = electrical/electronic
F = flame retardant
P = paintable/plateable
S = thick-wall parts (>3 mm)
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 letter(s) 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 Z = UL 94 V0 at 0.8mm (0.032 in.)
Space
Next 2 letters Color code NT = natural, unpigmented
BK = black
WH = white, etc.

6 \ Amodel® PPA Design Guide

Nomenclature Product Selection
The Amodel PPA grade nomenclature system outlined
®
Solvay Specialty Polymers has the most comprehensive
in Table 2.1 is designed to communicate important portfolio of PPA resins in the industry. Table 2.2 shows
compositional information. There are a few exceptions the relative performance of several Amodel® products
to this nomenclature, such as ET for extra tough grades to assist you in selecting the right product for your
and HFZ for high-flow grades. specific application. The products listed here are a good
representation of the portfolio; however, there are many
To illustrate, consider Amodel® AFA-6133 V0 BK324 which
other grades not listed and one of these may be the
is a flame-retardant product (AFA) that uses an A-600x
perfect fit for you. It is recommended that you contact a
base resin containing 33 % glass fiber by weight (6133).
Solvay Specialty Polymers representative before making
It has a UL94 rating of V0 at 0.8 mm (0.032 in.) and is
a final product selection decision. Additional product
pigmented black with colorant formula 324.
selection resources and technical data can be found
on the website.

Table 2.2 Relative ranking of selected properties for major Amodel® PPA grades(1)

Strength Stiffness Stiffness Impact - Deflection Specific

at RT at RT at 100 °C Notched Temperature Gravity
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
A-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

(1)
Properties ranked from 1 to 10, with 10 being the highest

Amodel® PPA Design Guide / 7

 Property Data

Typical Properties The accelerated moisture conditioning method used

was to boil the test specimens in an aqueous solution
The typical property data contained in the following
containing 80 grams of potassium acetate per 100 grams
short-term property tables fall within the normal range of
of water for 96 hours. This procedure was developed
product properties. Actual properties of individual batches
empirically to approximate the moisture uptake of samples
will vary within specification limits.
that were placed in a constant humidity chamber until
These values should not be used to establish specification equilibrium was achieved. Because the temperatures
limits, nor should they be used alone as the basis for part involved in this conditioning are between 100 °C and
design. 130 °C (212 °F and 266 °F), some annealing takes place,
and the 50 % RH modulus values are sometimes a few
Accelerated Moisture Conditioning percent higher than the “dry, as molded” values.
In general, polyamides absorb moisture from the In addition, exposure to the aqueous conditioning
atmosphere, and the absorbed moisture can affect media at these relatively high temperatures combined with
some properties. To provide the design engineer with an exposure time of 96 hours results in some hydrolysis
more relevant property information, polyamide suppliers of the glass/resin matrix interface. In many cases, the
customarily list properties as molded (dry) and also after properties that depend on glass/resin adhesion, such
moisture absorption. The convention is to list a 50 % RH as tensile strength, notched Izod, etc., are about 10 %
value, which is intended to provide the property value after lower than would have been obtained had the samples
the material has achieved equilibrium with a 50 % relative been allowed to condition to 50 % RH in air at room
humidity environment. This convention is appropriate for temperature.
polyamide 6,6, 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 content. In order 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 more than two
years would be required. Because of this, a method of
accelerating the moisture absorption was developed.

8 \ Amodel® PPA Design Guide

Table 3.1 Mechanical properties – glass-reinforced grades (US units)

A-1133 A-1145 A-6135 AS-4133 Method

Property Temperature Units HS HS HN HS ASTM ISO
Tensile strength 23 °C (73 °F) kpsi 32.0 37.5 29.4 29.0 D638
Tensile strength 50 % RH 23 °C (73 °F) kpsi 28.0 33.0 25.5 25.0 D638
Tensile strength 23 °C (73 °F) kpsi 33.8 38.1 30.6 30.6 527
100 °C (212 °F) kpsi 21.5 25.1 17.6 18.1 527
150 °C (302 °F) kpsi 11.5 12.3 13.4 12.7 527
175 °C (347 °F) kpsi 10.4 11.0 11.9 11.5 527
Tensile elongation 23 °C (73 °F)  % 2.5 2.6 1.9 2.5 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 2.1 2.1 2.1 2.2 D638
Tensile elongation 23 °C (73 °F)  % 2.5 2.7 2.0 2.6 527
100 °C (212 °F)  % 2.9 2.5 4.3 4.3 527
150 °C (302 °F)  % 8.7 7.2 4.9 6.6 527
175 °C (347 °F)  % 8.5 6.5 4.7 6.6 527
Tensile modulus 23 °C (73 °F) Mpsi 1.90 2.50 2.00 1.70 D638
Tensile modulus 50 % RH 23 °C (73 °F) Mpsi 1.90 2.50 1.77 1.70 D638
Tensile modulus 23 °C (73 °F) Mpsi 1.94 2.44 1.67 1.83 527
100 °C (212 °F) Mpsi 1.57 1.62 1.06 0.99 527
150 °C (302 °F) Mpsi 0.97 1.16 0.91 0.77 527
175 °C (347 °F) Mpsi 0.62 0.78 0.77 0.70 527
Flexural strength 23 °C (73 °F) kpsi 46.0 52.6 45.0 42.0 D790
Flexural strength 50 % RH 23 °C (73 °F) kpsi 36.9 42.7 36.1 35.0 D790
Flexural strength 23 °C (73 °F) kpsi 46.3 54.7 43.5 42.9 178
100 °C (212 °F) kpsi 33.0 38.7 24.7 25.6 178
150 °C (302 °F) kpsi 13.5 16.1 17.8 16.1 178
175 °C (347 °F) kpsi 11.5 13.7 16.2 14.4 178
Flexural modulus 23 °C (73 °F) Mpsi 1.65 2.00 1.65 1.60 D790
Flexural modulus 50 % RH 23 °C (73 °F) Mpsi 1.65 2.00 1.59 1.60 D790
Flexural modulus 23 °C (73 °F) Mpsi 1.68 2.31 1.65 1.51 178
100 °C (212 °F) Mpsi 1.42 1.89 0.96 1.04 178
150 °C (302 °F) Mpsi 0.58 0.78 0.71 0.67 178
175 °C (347 °F) Mpsi 0.52 0.71 0.67 0.61 178
Shear strength 23 °C (73 °F) kpsi 14.7 15.6 12.7 13.0 D732
Shear strength 50 % RH 23 °C (73 °F) kpsi 12.9 13.3 10.7 11.0 D732
Compressive strength 23 °C (73 °F) kpsi 26.9 28.1 21.4 26.0 D695
Poisson’s ratio 23 °C (73 °F) 0.41 0.41 0.39 0.41
Izod impact, notched 23 °C (73 °F) ft-lb/in 1.5 2.1 1.6 1.5 D256
Izod impact, notched 50 % RH 23 °C (73 °F) ft-lb/in 1.1 1.9 1.3 1.5 D256
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 14 21 15 19 D4812
Izod impact, notched 23 °C (73 °F) ft-lb/in2 4.2 4.9 4.3 4.6 180/1A
2
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 23 29 30 28 180/1U
Charpy impact 23 °C (73 °F) ft-lb/in2 4.5 4.9 4.4 5.1 179/1eA
Charpy impact, unnotched 23 °C (73 °F) ft-lb/in2 35 44 28 32 179/1eU
Rockwell hardness 23 °C (73 °F) R 125 125 125 124 D785

Amodel® PPA Design Guide / 9

 Table 3.2 Mechanical properties – glass-reinforced grades (SI units)

A-1133 A-1145 A-6135 AS-4133 Method

Property Temperature Units HS HS HN HS ASTM ISO
Tensile strength 23 °C (73 °F) MPa 221 259 202 200 D638
Tensile strength 50 % RH 23 °C (73 °F) MPa 193 228 178 172 D638
Tensile strength 23 °C (73 °F) MPa 233 263 211 211 527
100 °C (212 °F) MPa 148 173 121 125 527
150 °C (302 °F) MPa 80 85 93 87 527
175 °C (347 °F) MPa 72 76 82 79 527
Tensile elongation 23 °C (73 °F)  % 2.5 2.6 1.9 2.5 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 2.1 2.1 2.1 2.2 D638
Tensile elongation 23 °C (73 °F)  % 2.5 2.7 2.0 2.6 527
100 °C (212 °F)  % 2.9 2.5 4.3 4.3 527
150 °C (302 °F)  % 8.7 7.2 4.9 6.6 527
175 °C (347 °F)  % 8.5 6.5 4.7 6.6 527
Tensile modulus 23 °C (73 °F) GPa 13.1 17.2 13.8 11.7 D638
Tensile modulus 50 % RH 23 °C (73 °F) GPa 13.1 17.2 12.2 11.7 D638
Tensile modulus 23 °C (73 °F) GPa 13.4 16.8 11.5 12.6 527
100 °C (212 °F) GPa 10.8 11.2 7.3 6.8 527
150 °C (302 °F) GPa 6.7 8.0 6.3 5.3 527
175 °C (347 °F) GPa 4.3 5.4 5.3 4.8 527
Flexural strength 23 °C (73 °F) MPa 317 363 310 290 D790
Flexural strength 50 % RH 23 °C (73 °F) MPa 254 294 249 241 D790
Flexural strength 23 °C (73 °F) MPa 319 377 300 296 178
100 °C (212 °F) MPa 227 267 171 176 178
150 °C (302 °F) MPa 93 111 123 111 178
175 °C (347 °F) MPa 80 95 112 100 178
Flexural modulus 23 °C (73 °F) GPa 11.4 13.8 11.4 11.0 D790
Flexural modulus 50 % RH 23 °C (73 °F) GPa 11.4 13.8 10.9 11.0 D790
Flexural modulus 23 °C (73 °F) GPa 11.6 15.9 11.4 10.4 178
100 °C (212 °F) GPa 9.8 13.0 6.6 7.2 178
150 °C (302 °F) GPa 4.0 5.4 4.9 4.6 178
175 °C (347 °F) GPa 3.6 4.9 4.6 4.2 178
Shear strength 23 °C (73 °F) MPa 101 108 88 90 D732
Shear strength 50 % RH 23 °C (73 °F) MPa 89 92 74 76 D732
Compressive strength 23 °C (73 °F) MPa 185 194 148 179 D695
Poisson’s ratio 23 °C (73 °F) 0.41 0.41 0.39 0.41
Izod impact, notched 23 °C (73 °F) J/m 80 110 85 80 D256
Izod impact, notched 50 % RH 23 °C (73 °F) J/m 60 100 70 70 D256
Izod impact, unnotched 23 °C (73 °F) J/m 770 1105 780 1030 D4812
2
Izod impact, notched 23 °C (73 °F) kJ/m 8.8 10.3 9.1 9.7 180/1A
Izod impact, unnotched 23 °C (73 °F) kJ/m2 49 61 62 59 180/1U
Charpy impact 23 °C (73 °F) kJ/m2 9.5 10.3 9.2 10.7 179/1eA
Charpy impact, unnotched 23 °C (73 °F) kJ/m2 73 93 60 68 179/1eU
Rockwell hardness 23 °C (73 °F) R scale 125 125 125 124 D785

10 \ Amodel® PPA Design Guide

Table 3.3 Thermal, electrical, and general properties – glass-reinforced grades

Method
A-1133 A-1145 A-6135 AS-4133
Property Units HS HS HN HS ASTM ISO
Thermal
Deflection temperature under load, 264 psi  °C 285 287 291 300 D648
 °F 545 549 556 572
Deflection temperature under load, 1.8 MPa  °C 280 281 288 294 75AF
 °F 536 538 550 561
Vicat softening temperature  °C 303 304 301 314 D1525 306
 °F 577 580 573 597
Melting point  °C 313 310 310 327 D3418 11357-3
 °F 595 590 590 620
Flammability, 3.2 mm (0.125 in.) bar HB HB HB HB UL-94
Electrical
Dielectric strength at 3.2 mm (0.125 in.) V/mil 533 584 — 510 D149
kV/mm 21 23 — 21
Dielectric strength at 1.6 mm (0.062 in.) V/mil 813 ­— — 813 D149
kV/mm 32 — — 32
Volume resistivity ohm-cm 1x1016 1x1016 — 1x1016 D257
15 15
Surface resistivity ohms 1x10 — — 1x10 D257
Comparative tracking index volts 550 550 — >600 D3638
Dielectric constant at 60 Hz 4.4 4.6 — 3.8 D150
Dielectric constant at 100 Hz 5.1 — — 4.6 D150
Dielectric constant at 10 6 Hz 4.2 4.4 — 3.6 D150
9
Dielectric constant at 10 Hz 3.7 — — 3.6 D150
Dissipation factor at 60 Hz 0.005 0.005 — 0.004 D150
Dissipation factor at 10 6 Hz 0.017 0.016 — 0.012 D150
Dissipation factor at 10 9 Hz 0.016 — — 0.013 D150
General
Specific gravity 1.48 1.59 1.45 1.45 D792 1183A
Moisture absorption, 24 hours  % 0.2 0.1 0.3 0.3 D570 62
Mold shrinkage, flow direction  % 0.4 0.2 0.6 0.5 D955 294-4
Mold shrinkage, transverse direction  % 0.8 0.6 0.9 1.0 D955 294-4

Amodel® PPA Design Guide / 11

 Table 3.4 Mechanical properties – toughened grades (US units)

AT-1002 ET-1000 Method

Property Temperature Units HS HS ASTM ISO
Tensile strength 23 °C (73 °F) kpsi 12.1 10.0 D638
Tensile strength 50 % RH 23 °C (73 °F) kpsi 11.1 9.1 D638
Tensile stress at yield 23 °C (73 °F) kpsi 10.9 10.2 527
Tensile stress at break 23 °C (73 °F) kpsi 9.9 8.7 527
Tensile stress at yield 100 °C (212 °F) kpsi 5.6 4.9 527
Tensile stress at break 100 °C (212 °F) kpsi 527
Tensile elongation at yield 23 °C (73 °F)  % 5.0 6.0 D638
Tensile elongation at break 23 °C (73 °F)  % 10-12 20.0 D638
Tensile elongation at break 50 % RH 23 °C (73 °F)  % 30.0 18 D638
Tensile strain at yield 23 °C (73 °F)  % 5.0 5.0 527
Tensile strain at break 23 °C (73 °F)  % 10.0 7.0 527
Tensile strain at yield 100 °C (212 °F)  % 3.7 4.3 527
Tensile strain at break 100 °C (212 °F)  % >95 >95 527
Tensile modulus 23 °C (73 °F) kpsi 400 350 D638
Tensile modulus 50 % RH 23 °C (73 °F) kpsi 400 350 D638
Tensile modulus 23 °C (73 °F) kpsi 400 350 527
Tensile modulus 100 °C (212 °F) kpsi 305 290 527
Flexural strength 23 °C (73 °F) kpsi 14.9 15.8 D790
Flexural strength 50 % RH 23 °C (73 °F) kpsi 10.6 12.4 D790
Flexural strength 23 °C (73 °F) kpsi 11.5 10.2 178
Flexural strength 100 °C (212 °F) kpsi 7.2 6.4 178
Flexural modulus 23 °C (73 °F) kpsi 320 330 D790
Flexural modulus 50 % RH 23 °C (73 °F) kpsi 330 310 D790
Flexural modulus 23 °C (73 °F) kpsi 330 260 178
Flexural modulus 100 °C (212 °F) kpsi 250 190 178
Shear strength 23 °C (73 °F) kpsi 9.3 8.5 D732
Shear strength 50 % RH 23 °C (73 °F) kpsi 8.3 D732
Poisson’s ratio 23 °C (73 °F) 0.38 0.39
Izod impact, notched 23 °C (73 °F) ft-lb/in 2.4 17.0 D256
Izod impact, notched 50 % RH 23 °C (73 °F) ft-lb/in 2.6 20.0 D256
Izod impact, unnotched 23 °C (73 °F) ft-lb/in No break No break D4812
Izod impact, notched 23 °C (73 °F) ft-lb/in2 6.0 34.9 180/1A
2
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 84 No break 180/1U
Charpy impact 23 °C (73 °F) ft-lb/in2 6.4 36.9 179/1eA
Charpy impact, unnotched 23 °C (73 °F) ft-lb/in2 No break No break 179/1eU
Rockwell hardness 23 °C (73 °F) R 119 120 D785

12 \ Amodel® PPA Design Guide

Table 3.5 Mechanical properties – toughened grades (SI Units)

AT-1002 ET-1000 Method

Property Temperature Units HS HS ASTM ISO
Tensile strength 23 °C (73 °F) MPa 83 69 D638
Tensile strength 50 % RH 23 °C (73 °F) MPa 76 63 D638
Tensile stress at yield 23 °C (73 °F) MPa 75 70 527
Tensile stress at break 23 °C (73 °F) MPa 68 60 527
Tensile stress at yield 100 °C (212 °F) MPa 39 34 527
Tensile stress at break 100 °C (212 °F) MPa – – 527
Tensile elongation at yield 23 °C (73 °F)  % 5.0 6.0 D638
Tensile elongation at break 23 °C (73 °F)  % 10-12 20.0 D638
Tensile elongation at break 50 % RH 23 °C (73 °F)  % 30.0 18.0 D638
Tensile strain at yield 23 °C (73 °F)  % 5.0 5.0 527
Tensile strain at break 23 °C (73 °F)  % 10.0 7.0 527
Tensile strain at yield 100 °C (212 °F)  % 3.7 4.3 527
Tensile strain at break 100 °C (212 °F)  % >95 >95 527
Tensile modulus 23 °C (73 °F) GPa 2.8 2.4 D638
Tensile modulus 50 % RH 23 °C (73 °F) GPa 2.8 2.4 D638
Tensile modulus 23 °C (73 °F) GPa 2.8 2.4 527
Tensile modulus 100 °C (212 °F) GPa 2.1 2.0 527
Flexural strength 23 °C (73 °F) MPa 103 109 D790
Flexural strength 50 % RH 23 °C (73 °F) MPa 73 85 D790
Flexural strength 23 °C (73 °F) MPa 80 70 178
Flexural strength 100 °C (212 °F) MPa 50 44 178
Flexural modulus 23 °C (73 °F) GPa 2.2 2.3 D790
Flexural modulus 50 % RH 23 °C (73 °F) GPa 2.3 2.2 D790
Flexural modulus 23 °C (73 °F) GPa 2.3 1.8 178
Flexural modulus 100 °C (212 °F) GPa 1.8 1.3 178
Shear strength 23 °C (73 °F) MPa 64 59 D732
Shear strength 50 % RH 23 °C (73 °F) MPa 57 – D732
Poisson’s ratio 23 °C (73 °F) 0.38 0.39
Izod impact, notched 23 °C (73 °F) J/m 130 905 D256
Izod impact, notched 50 % RH 23 °C (73 °F) J/m 140 1065 D256
Izod impact, unnotched 23 °C (73 °F) J/m No break No break D4812
Izod impact, notched 23 °C (73 °F) kJ/m 2 13 74 180/1A
2
Izod impact, unnotched 23 °C (73 °F) kJ/m 177 No break 180/1U
Charpy impact 23 °C (73 °F) kJ/m2 14 78 179/1eA
Charpy impact, unnotched 23 °C (73 °F) kJ/m2 No break No break 179/1eU
Rockwell hardness 23 °C (73 °F) 119 120 D785

Amodel® PPA Design Guide / 13

 Table 3.6 Thermal, electrical, and general properties – toughened grades

A-1002 ET-1000 Method

Property Units HS HS ASTM ISO
Thermal
Deflection temperature under load, 264 psi  °C 121 120 D648
 °F 250 248
Deflection temperature under load, 1.8 MPa  °C 118 109 75AF
 °F 244 228
Vicat softening temperature  °C 286 283 D1525 306
 °F 547 542
Melting point  °C 315 310 D3418 11357-3
 °F 599 590
Flammability, 3.2 mm (0.125 in.) bar HB HB UL-94
Electrical
Dielectric strength at 3.2 mm (0.125 in.) V/mil 431 — D149
kV/mm 17 —
Volume resistivity ohm-cm 1x1016 — D257
13
Surface resistivity ohm 8x10 — D257
Comparative tracking index volts >600 — D3638
Dielectric constant at 60 Hz 3.3 — D150
6
Dielectric constant at 10 Hz 3.3 — D150
Dissipation factor at 60 Hz 0.004 — D150
6
Dissipation factor at 10 Hz 0.016 — D150
General
Specific gravity 1.13 1.13 D792 1183A
Moisture absorption, 24 hours  % 0.5 0.7 D570 62
Mold shrinkage, flow direction  % 2.0 1.5 D955 294-4
Mold shrinkage, transverse direction  % 2.1 1.5 D955 294-4

14 \ Amodel® PPA Design Guide

Table 3.7 Mechanical properties – toughened glass-reinforced and flame retardant grades (US units)

AT-1116 AT-6115 AFA-6133 Method

Property Temperature Units HS HS V0 Z ASTM ISO
Tensile strength 23 °C (73 °F) kpsi 23.3 17.7 28.8 D638
Tensile strength 50 % RH 23 °C (73 °F) kpsi 19.0 13.9 24.1 D638
Tensile strength 23 °C (73 °F) kpsi 23.2 16.5 27.0 527
100 °C (212 °F) kpsi 9.5 9.9 16.5 527
150 °C (302 °F) kpsi – – 10.9 527
175 °C (347 °F) kpsi – – 9.2 527
Tensile elongation 23 °C (73 °F)  % 3.8 3.4 1.7 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 2.8 5.3 1.7 D638
Tensile elongation 23 °C (73 °F)  % 3.7 3.9 1.6 527
100 °C (212 °F)  % 4.2 7.7 2.4 527
150 °C (302 °F)  % – – 5.1 527
175 °C (347 °F)  % – – 4.9 527
Tensile modulus 23 °C (73 °F) Mpsi 0.94 0.78 2.33 D638
Tensile modulus 50 % RH 23 °C (73 °F) Mpsi 1.03 0.97 1.99 D638
Tensile modulus 23 °C (73 °F) Mpsi 1.00 0.78 2.10 527
100 °C (212 °F) Mpsi 0.97 0.45 1.33 527
150 °C (302 °F) Mpsi – – 0.86 527
175 °C (347 °F) Mpsi – – 0.74 527
Flexural strength 23 °C (73 °F) kpsi 32.8 24.0 32.5 D790
Flexural strength 50 % RH 23 °C (73 °F) kpsi 29.1 16.7 33.2 D790
Flexural strength 23 °C (73 °F) kpsi 28.6 24.7 37.6 178
100 °C (212 °F) kpsi 20.5 9.7 23.3 178
150 °C (302 °F) kpsi – – 14.6 178
175 °C (347 °F) kpsi – – 12.7 178
Flexural modulus 23 °C (73 °F) Mpsi 0.87 0.64 1.90 D790
Flexural modulus 50 % RH 23 °C (73 °F) Mpsi 0.90 0.50 1.93 D790
Flexural modulus 23 °C (73 °F) Mpsi 0.97 0.62 1.83 178
100 °C (212 °F) Mpsi 0.72 0.34 1.17 178
150 °C (302 °F) Mpsi – – 0.72 178
175 °C (347 °F) Mpsi – – 0.67 178
Shear strength 23 °C (73 °F) kpsi 10.1 8.2 11.6 D732
Shear strength 50 % RH 23 °C (73 °F) kpsi 9.5 6.4 9.0 D732
Compressive strength 23 °C (73 °F) kpsi 18.0 14.5 21.1 D695
Poisson’s ratio 23 °C (73 °F) 0.40 0.39 0.37
Izod impact, notched 23 °C (73 °F) ft-lb/in 1.8 1.7 1.6 D256
Izod impact, notched 50 % RH 23 °C (73 °F) ft-lb/in 0.9 1.5 1.5 D256
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 18 16 13 D4812
Izod impact, notched 23 °C (73 °F) ft-lb/in 2 3.8 5.5 3.9 180/1A
2
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 25 26 21 180/1U
Charpy impact 23 °C (73 °F) ft-lb/in2 4.3 5.2 6.6 179/1eA
Charpy impact, unnotched 23 °C (73 °F) ft-lb/in2 41 36 22 179/1eU
Rockwell hardness 23 °C (73 °F) R scale 124 116 125 D785

Amodel® PPA Design Guide / 15

 Table 3.8 Mechanical properties – toughened glass-reinforced and flame retardant grades (SI units)

AT-1116 AT-6115 AFA-6133 Method

Property Temperature Units HS HS V0 Z ASTM ISO
Tensile strength 23 °C (73 °F) MPa 161 122 199 D638
Tensile strength 50 % RH 23 °C (73 °F) MPa 131 96 166 D638
Tensile strength 23 °C (73 °F) MPa 160 114 186 527
100 °C (212 °F) MPa 66 68 114 527
150 °C (302 °F) MPa – – 75 527
175 °C (347 °F) MPa – – 63 527
Tensile elongation 23 °C (73 °F)  % 3.8 3.4 1.7 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 2.8 5.3 1.7 D638
Tensile elongation 23 °C (73 °F)  % 3.7 3.9 1.6 527
100 °C (212 °F)  % 4.2 7.7 2.4 527
150 °C (302 °F)  % – – 5.1 527
175 °C (347 °F)  % – – 4.9 527
Tensile modulus 23 °C (73 °F) GPa 6.5 5.4 16.1 D638
Tensile modulus 50 % RH 23 °C (73 °F) GPa 7.1 6.7 13.7 D638
Tensile modulus 23 °C (73 °F) GPa 6.9 5.4 14.5 527
100 °C (212 °F) GPa 6.7 3.1 9.2 527
150 °C (302 °F) GPa – – 5.9 527
175 °C (347 °F) GPa – – 5.1 527
Flexural strength 23 °C (73 °F) MPa 226 165 224 D790
Flexural strength 50 % RH 23 °C (73 °F) MPa 201 115 229 D790
Flexural strength 23 °C (73 °F) MPa 197 170 259 178
100 °C (212 °F) MPa 141 67 161 178
150 °C (302 °F) MPa – – 101 178
175 °C (347 °F) MPa – – 88 178
Flexural modulus 23 °C (73 °F) GPa 6.0 4.4 13.1 D790
Flexural modulus 50 % RH 23 °C (73 °F) GPa 6.2 3.4 13.3 D790
Flexural modulus 23 °C (73 °F) GPa 6.7 4.3 12.6 178
100 °C (212 °F) GPa 5.0 2.4 8.1 178
150 °C (302 °F) GPa – – 5.0 178
175 °C (347 °F) GPa – – 4.6 178
Shear strength 23 °C (73 °F) MPa 70 56 80 D732
Shear strength 50 % RH 23 °C (73 °F) MPa 66 44 62 D732
Compressive strength 23 °C (73 °F) MPa 124 100 145 D695
Poisson’s ratio 23 °C (73 °F) 0.40 0.39 0.37
Izod impact, notched 23 °C (73 °F) J/m 95 90 85 D256
Izod impact, notched 50 % RH 23 °C (73 °F) J/m 45 80 80 D256
Izod impact, unnotched 23 °C (73 °F) J/m 945 825 710 D4812
Izod impact, notched 23 °C (73 °F) kJ/m 2 8.1 11.6 8 180/1A
2
Izod impact, unnotched 23 °C (73 °F) kJ/m 53 54 44 180/1U
Charpy impact 23 °C (73 °F) kJ/m2 9.1 11.0 14.0 179/1eA
Charpy impact, unnotched 23 °C (73 °F) kJ/m2 85 75 47 179/1eU
Rockwell hardness 23 °C (73 °F) R scale 124 116 125 D785

16 \ Amodel® PPA Design Guide

Table 3.9 Thermal, electrical, and general properties – toughened glass-reinforced and flame retardant grades

AT-1116 AT-6115 AFA-6133 Method

Property Units HS HS V0 Z ASTM ISO
Thermal
Deflection temperature under load, 264 psi  °C 254 271 277 D648
 °F 489 519 531
Deflection temperature under load, 1.8 MPa  °C 258 265 282 75AF
 °F 497 509 540
Vicat softening temperature  °C 295 296 291 D1525 306
 °F 563 565 556
Melting point  °C 310 307 310 D3418 11357-3
 °F 590 585 590
Flammability, 3.2 mm (0.125 in.) bar HB HB V-0 UL 94
Electrical
Dielectric strength at 3.2 mm (0.125 in.) V/mil – 533 609 D149
kV/mm 21 24
Dielectric strength at 1.6 mm (0.062 in.) V/mil – 711 686 D149
kV/mm 28 27
Volume resistivity ohm-cm – 1x1016 1x1016 D257
15 15
Surface resistivity ohm 1x10 1x10 D257
Comparative tracking index volts – – – D3638
Dielectric constant at 60 Hz – – – D150
Dielectric constant at 100 Hz – 4.0 4.8 D150
Dielectric constant at 10 6 Hz – 3.3 4.1 D150
9
Dielectric constant at 10 Hz – 3.1 3.7 D150
Dissipation factor at 60 Hz – – – D150
Dissipation factor at 100 Hz – – – D150
6
Dissipation factor at 10 Hz – 0.013 0.011 D150
Dissipation factor at 10 9 Hz – 0.011 – D150
General
Specific gravity 1.28 1.22 1.68 D792 1183A
Moisture absorption, 24 hours  % 0.2 0.2 0.2 D570 62
Mold shrinkage, flow direction  % 0.6 1.0 0.3 D955 294-4
Mold shrinkage, transverse direction  % 0.6 1.1 0.6 D955 294-4

Amodel® PPA Design Guide / 17

 Table 3.10 Mechanical properties – mineral and mineral/glass filled grades (US units)
Method
A-1240 A-1565 AS-1566
Property Temperature Units L HS HS ASTM ISO
Tensile strength 23 °C (73 °F) kpsi 15.0 19.0 30.0 D638
Tensile strength 50 % RH 23 °C (73 °F) kpsi 13.5 17.9 25.4 D638
Tensile strength 23 °C (73 °F) kpsi 15.1 20.0 29.0 527
100 °C (212 °F) kpsi 10.1 13.3 18.4 527
150 °C (302 °F) kpsi 4.2 6.7 7.6 527
175 °C (347 °F) kpsi 3.5 4.7 6.3 527
Tensile elongation 23 °C (73 °F)  % 1.6 1.2 1.7 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 1.2 1.2 1.8 D638
Tensile elongation 23 °C (73 °F)  % 1.6 1.0 1.4 527
100 °C (212 °F)  % 1.9 1.3 1.5 527
150 °C (302 °F)  % 9.1 2.4 3.4 527
175 °C (347 °F)  % 7.3 1.8 3.1 527
Tensile modulus 23 °C (73 °F) Mpsi 1.30 3.00 2.90 D638
Tensile modulus 50 % RH 23 °C (73 °F) Mpsi 1.20 3.02 3.03 D638
Tensile modulus 23 °C (73 °F) Mpsi 1.45 2.86 3.26 527
100 °C (212 °F) Mpsi 0.81 2.23 2.49 527
150 °C (302 °F) Mpsi 0.16 0.83 1.06 527
175 °C (347 °F) Mpsi 0.13 0.74 0.90 527
Flexural strength 23 °C (73 °F) kpsi 30.0 30.5 42.0 D790
Flexural strength 50 % RH 23 °C (73 °F) kpsi 25.6 28.4 38.1 D790
Flexural strength 23 °C (73 °F) kpsi 24.9 30.6 41.2 178
100 °C (212 °F) kpsi 17.6 23.6 29.7 178
150 °C (302 °F) kpsi 4.0 10.1 13.9 178
175 °C (347 °F) kpsi 3.2 8.1 11.0 178
Flexural modulus 23 °C (73 °F) Mpsi 1.10 2.60 2.70 D790
Flexural modulus 50 % RH 23 °C (73 °F) Mpsi 1.00 2.61 2.88 D790
Flexural modulus 23 °C (73 °F) Mpsi 1.00 1.32 2.98 178
100 °C (212 °F) Mpsi 0.87 0.99 2.44 178
150 °C (302 °F) Mpsi 0.16 0.36 1.06 178
175 °C (347 °F) Mpsi 0.13 0.33 0.93 178
Shear strength 23 °C (73 °F) kpsi 13.9 10.3 11.6 D732
Shear strength 50 % RH 23 °C (73 °F) kpsi 13.5 7.2 9.1 D732
Compressive strength 23 °C (73 °F) kpsi 26.8 27.4 25.3 D695
Poisson’s ratio 23 °C (73 °F) 0.29 0.31 0.35
Izod impact, notched 23 °C (73 °F) ft-lb/in 0.9 0.7 1.2 D256
Izod impact, notched 50 % RH 23 °C (73 °F) ft-lb/in 0.6 0.6 1.0 D256
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 7 7 13 D4812
Izod impact, notched 23 °C (73 °F) ft-lb/in2 2.2 1.9 3.1 180/1A
2
Izod impact, unnotched 23 °C (73 °F) ft-lb/in 11 15 21 180/1U
Charpy impact 23 °C (73 °F) ft-lb/in2 1.9 1.6 2.9 179/1eA
Charpy impact, unnotched 23 °C (73 °F) ft-lb/in2 14 21 16 179/1eU
Rockwell hardness 23 °C (73 °F) R scale 125 124 122 D785

18 \ Amodel® PPA Design Guide

Table 3.11 Mechanical properties – mineral and mineral/glass filled grades (SI units)

A-1240 A-1565 AS-1566 Method

Property Temperature Units L HS HS ASTM ISO
Tensile strength 23 °C (73 °F) MPa 103 131 207 D638
Tensile strength 50 % RH 23 °C (73 °F) MPa 93 123 175 D638
Tensile strength 23 °C (73 °F) MPa 104 138 200 527
100 °C (212 °F) MPa 70 92 127 527
150 °C (302 °F) MPa 29 46 53 527
175 °C (347 °F) MPa 24 32 44 527
Tensile elongation 23 °C (73 °F)  % 1.6 1.2 1.7 D638
Tensile elongation 50 % RH 23 °C (73 °F)  % 1.2 1.2 1.8 D638
Tensile elongation 23 °C (73 °F)  % 1.6 1.0 1.4 527
100 °C (212 °F)  % 1.9 1.3 1.5 527
150 °C (302 °F)  % 9.1 2.4 3.4 527
175 °C (347 °F)  % 7.3 1.8 3.1 527
Tensile modulus 23 °C (73 °F) GPa 9.0 20.7 20.0 D638
Tensile modulus 50 % RH 23 °C (73 °F) GPa 8.3 20.8 20.9 D638
Tensile modulus 23 °C (73 °F) GPa 10.1 20.0 22.8 527
100 °C (212 °F) GPa 5.6 15.4 17.2 527
150 °C (302 °F) GPa 1.1 5.7 7.3 527
175 °C (347 °F) GPa 0.9 5.1 6.2 527
Flexural strength 23 °C (73 °F) MPa 207 210 290 D790
Flexural strength 50 % RH 23 °C (73 °F) MPa 177 196 263 D790
Flexural strength 23 °C (73 °F) MPa 172 211 284 178
100 °C (212 °F) MPa 121 162 205 178
150 °C (302 °F) MPa 27 70 96 178
175 °C (347 °F) MPa 22 56 76 178
Flexural modulus 23 °C (73 °F) GPa 7.6 17.9 18.6 D790
Flexural modulus 50 % RH 23 °C (73 °F) GPa 6.9 18.0 19.8 D790
Flexural modulus 23 °C (73 °F) GPa 7.0 9.1 20.8 178
100 °C (212 °F) GPa 6.0 6.8 16.8 178
150 °C (302 °F) GPa 1.1 2.5 7.3 178
175 °C (347 °F) GPa 0.9 2.3 6.4 178
Shear strength 23 °C (73 °F) MPa 96 71 80 D732
Shear strength 50 % RH 23 °C (73 °F) MPa 93 50 63 D732
Compressive strength 23 °C (73 °F) MPa 185 189 174 D695
Poisson’s ratio 23 °C (73 °F) 0.29 0.31 0.35
Izod impact, notched 23 °C (73 °F) J/m 50 35 65 D256
Izod impact, notched 50 % RH 23 °C (73 °F) J/m 30 30 55 D256
Izod impact, unnotched 23 °C (73 °F) J/m 345 395 700 D4812
Izod impact, notched 23 °C (73 °F) kJ/m2 4.7 4.0 6.6 180/1A
2
Izod impact, unnotched 23 °C (73 °F) kJ/m 24 31 44 180/1U
2
Charpy impact 23 °C (73 °F) kJ/m 4.1 3.4 6.2 179/1eA
Charpy impact, unnotched 23 °C (73 °F) kJ/m2 29 44 34 179/1eU
Rockwell hardness 23 °C (73 °F) R 125 124 122 D785

Amodel® PPA Design Guide / 19

 Table 3.12 Thermal, electrical, and general properties – mineral and mineral/glass filled grades

A-1240 A-1565 AS-1566 Method

Property Units L HS HS ASTM ISO
Thermal
Deflection temperature under load, 264 psi  °C 179 271 278 D648
 °F 355 520 532
Deflection temperature under load, 1.8 MPa  °C 174 271 280 75AF
 °F 346 520 536
Vicat softening temperature  °C 302 296 298 D1525 306
 °F 575 565 569
Melting point  °C 310 311 311 D3418 11357-3
 °F 590 592 592
Flammability, 3.2 mm (0.125 in.) bar HB HB HB UL-94
Electrical
Dielectric strength at 1.6 mm (0.062 in.) V/mil — — 737 D149
kV/mm — — 29
15 14
Volume resistivity ohm-cm 9x10 4x10 1x1016 D257
Surface resistivity ohm — — 1x1015 D257
Comparative tracking index volts 550 >600 — D3638
Dielectric constant at 60 Hz — — — D150
Dielectric constant at 100 Hz 4.2 — 5.7 D150
Dielectric constant at 10 6 Hz 4.0 — 4.7 D150
Dissipation factor at 60 Hz — — — D150
Dissipation factor at 100 Hz 0.006 — — D150
6
Dissipation factor at 10 Hz 0.017 — 0.011 D150
General
Specific gravity 1.54 1.90 1.84 D792 1183A
Moisture absorption, 24 hours  % 0.1 0.1 0.1 D570 62
Mold shrinkage, flow direction  % 1.0 0.3 0.3 D955 294-4
Mold shrinkage, transverse direction  % 1.0 0.5 0.5 D955 294-4

20 \ Amodel® PPA Design Guide

Mechanical Properties Tensile Properties
The mechanical properties of a material are of Test methods
fundamental importance to engineers when designing a There are two widely accepted methods of testing tensile
part. The designer must match the mechanical properties properties: ASTM method D638 and ISO method 527.
of various candidate materials to the performance These test methods measure the same property, but
requirements of each application in order to determine slightly different test specimens and test procedures
which material is suitable for a given part design. are used. If the same material is tested using both
Conversely, the designer can use the material property procedures, the results will be similar but not the same.
values to achieve an optimum part design. Therefore, only values obtained using the same method
To assist the designer, the material properties listed should be compared. In this document, whenever a tensile
in this manual have been grouped into short-term property value is given, the test method is also given.
or instantaneous and long-term or time-dependent In many cases values by both methods are provided.
properties. The short-term properties generally measure For both test methods, tensile properties are determined
strength at failure while the long-term properties show by clamping each end of a test specimen in the jaws of a
how the material properties are affected by temperature, testing machine that applies a unidirectional axial force to
continuous loading, or chemical exposure as a function the specimens at a specified rate. The force required to
of time. separate the jaws divided by the minimum cross-sectional
area of the test specimen is defined as the tensile stress.
Short-Term Mechanical Properties
The test specimen will elongate as a result of the stress
Short-term mechanical properties typically include being applied. The amount of elongation divided by the
tensile strength and modulus, flexural strength and original length of the test specimen is the strain.
modulus, several impact tests, compressive strength,
shear strength, and surface hardness. These properties When the applied stress is plotted against the resulting
are usually reported at room temperature and at other strain, a curve similar to that shown in Figure 3.1 for
temperatures as appropriate. Since some polymers Amodel® ET-1000 HS resin is obtained. This is known as
absorb atmospheric moisture that may affect the a stress/strain curve and is very useful in determining the
properties, the moisture content may also be specified, short term behavior of a material when a load is applied.
often using the Relative Humidity (RH) convention. The curve of a ductile metal would have a similar shape.

The data sheets provided by material suppliers typically Figure 3.1 Typical stress/strain curve for
list short-term properties, and their primary utility is for Amodel® ET-1000
comparing similar materials. When using data sheets to
70 10
compare materials, it is very important to insure that the
same test methods have been used and that the data is 60
8
reported in similar units.
50
Stress [ MPa ]

Stress [ kpsi ]
The utility of short-term mechanical properties in design 40 6
is limited. Typically, the properties are measured using
molded test specimens that have been specifically 30
4
designed to yield reproducible results, under carefully 20
controlled environmental conditions, using specified 2
loading rates. These measurements often provide the 10
highest value obtainable for any property and material. 0 0
0 5 10 15 20
When parts are fabricated by a molding process they
Strain [ % ]
will likely contain a number of features such as stress
concentrations, weld lines, corners or other aspects
that may reduce strength. The strength of a material in
an actual component may also be reduced, or in some
cases enhanced, by reinforcing fiber orientation, relative
degree of crystallinity, or thermal history (annealing). In
addition, short-term properties do not provide any insight
regarding time-related effects or the influence of chemical
environments.

Amodel® PPA Design Guide / 21

 Figure 3.2 shows a typical stress/strain curve for a non- arbitrarily designated strain level, usually 1 %. The tangent
ductile material, Amodel® A-1933 PPA. Strain at failure method has been removed from the ISO test method and
is much lower than that of the unreinforced grade. replaced with a slope calculation based on specified strain
The addition of glass fiber reinforcement improves values of 0.0005 and 0.0025. Alternatively, computerized
the strength and stiffness but reduces the elongation machines can use the least squares method to calculate
or strain at failure. the slope over the same strain region.

Figure 3.2 Typical stress/strain curve for The tangent method was used for the tensile data run by
Amodel® A-1933 ASTM D638 presented in this brochure.

30 Ductile polymers undergo yield prior to rupture. At this

200
point, the material undergoes additional elongation
25 without an increase in stress. The stress level at which
150 yield occurs is often referred to as tensile strength at
20
Stress [ MPa ]

Stress [ kpsi ]
yield or tensile stress at yield. The elongation achieved at
100 15 this point is called the elongation at yield, yield strain or
tensile strain at yield. As the test proceeds, the specimen
10 continues to elongate until rupture occurs. The stress level
50 at this point is called tensile strength at break, ultimate
5
tensile strength or tensile stress at break. Tensile strength
0 0 is defined as the greater of the measured stresses, which
0.0 5 1.0 1.5 2.0 could be either the stress at yield or the stress at rupture.
Strain [ % ]
Tensile property comparison
The initial portion of the stress/strain curve is also of Amodel® A-1133 HS resin has higher tensile strength
special interest because its slope relates to the stiffness at room temperature than 33 % GR polyamide (PA) 6,6,
or modulus of the material as shown in Figure 3.3. 30 % GR polyphenylene sulfide (PPS), and 30 % GR
polyetherimide (PEI), as shown in Figure 3.4. Even after
Figure 3.3 Secant and tangent methods for moisture conditioning, Amodel® PPA is stronger than the
estimating modulus other resins.

Figure 3.4 Tensile strength of 30 % – 33 % GR resins

DAM 30
200 50% RH
Stress [ MPa ]

25
Tensile strength [ MPa ]

Tensile strength [ kpsi ]

150
20

100 15

Stess/strain curve 10
Secant 50
Tangent 5

Strain [ % ] 0 0
A-1133 HS PA 6,6 PPS PEI
This figure shows that the strain is directly proportional
to stress up to a certain amount of stress. This region is
known as the “Hookean” or elastic region. The maximum
stress level that results in a proportional amount of strain
is known as the proportional limit.

The tensile or elastic modulus is the slope of the stress/

strain curve when a specimen is subjected to a tensile
loading. Since the stress/strain plot is non-linear above
the proportional limit, some conventions have been
developed to standardize the measurements and reduce
the variability in test results. One method uses the slope of
a line drawn tangent to the curve. Another method utilizes
the slope of a secant drawn through the origin and some

22 \ Amodel® PPA Design Guide

The tensile modulus of 33 % GR Amodel® PPA is Figure 3.7 Tensile strength of 33 % GR PPA vs.
compared to the same resins in Figure 3.5. The Amodel® temperature
resin has a higher modulus as molded and shows no
Temperature [ °F ]
decline when moisture conditioned, while the PA 6,6
50 100 150 200 250 300 350
exhibits a reduction of over 20 %.
250
Figure 3.5 Tensile modulus of 30 % – 33 % GR resins
200 30

Tensile strength [ MPa ]

Tensile strength [ kpsi ]

14 2.0
DAM
150
12 50% RH 20

Tensile modulus [ Mpsi ]

Tensile modulus [ GPa ]

10 1.5 100

8 10
50 A-1133 HS
1.0 A-4133 L
6 A-6135 HN
0 0
4 0 50 100 150 200
0.5
Temperature [ °C ]
2
Figure 3.8 Tensile modulus of 33 % GR PPA vs.
0 0.0
A-1133 HS PA 6,6 PPS PEI temperature
Temperature [ °F ]
This same comparison for tensile elongation is shown in 50 100 150 200 250 300 350
Figure 3.6. The tensile elongation of the resins is low due
to the glass fiber reinforcement. Moisture conditioning 14 2.0
the PA 6,6 results in an increase in elongation due to the 12

Tensile modulus [ Mpsi ]

Tensile modulus [ GPa ]

reduction in Tg.
10 1.5

Figure 3.6 Tensile elongation of 30 % – 33 % GR 8

resins 1.0
6
5
DAM 4
A-1133 HS 0.5
50% RH
2 A-4133 L
4
A-6135 HN
Tensile elongation [ % ]

0 0.0
3 0 50 100 150 200
Temperature [ °C ]

2 Figure 3.9 Tensile elongation of 33 % GR PPA vs.

temperature
1 Temperature [ °F ]
50 100 150 200 250 300 350
0 10 10
A-1133 HS PA 6,6 PPS PEI A-1133 HS
Tensile elongation at break [ % ]
Tensile elongation at break [ % ]

A-4133 L
8 A-6135 HN 8
Tensile properties for GR PPA vs. temperature
Figures 3.7 through 3.9 show the tensile properties of GR 6 6
grades of Amodel® PPA based upon A-1000, A-4000, and
A-6000 base resins from RT to 175 °C (347 °F). Amodel® 4 4
A-1133 HS has the highest strength and stiffness at room
temperature, but A-4133 L and A-6135 HN have better 2 2
strength and stiffness above 150 °C (302 °F).
0 0
0 50 100 150 200
Temperature [ °C ]

Amodel® PPA Design Guide / 23

 Tensile properties of A-1000 GR grades at Figure 3.12 Tensile elongation of GR A-1000 PPA
elevated temperatures grades vs. temperature
Figures 3.10 through 3.14 show the tensile properties of Temperature [ °F ]
three glass-reinforced grades of Amodel® PPA based 50 100 150 200 250 300 350
on the A-1000 base resin containing 33 %, 45 % and 10 10
60 % glass fiber from room temperature (RT) to 175 °C A-1133 HS

Tensile elongation at break [ % ]

Tensile elongation at break [ % ]
(347 °F). The tensile strength and modulus increase with A-4133 L
8 A-6135 HN 8
glass fiber content, which is typical of semi-crystalline
thermoplastics.
6 6
Both strength and modulus decrease as temperatures
rise. Elongation increases with increasing temperature. As 4 4
a semi-crystalline material, Amodel® resins show a slow
but steady loss in mechanical properties from ambient 2 2
temperature up to the glass transition temperature
(Tg ). At the Tg, there is a more significant loss over a
0 0
narrow temperature range, followed by another gradual
0 50 100 150 200
decline. This behavior is typical of all semi-crystalline Temperature [ °C ]
thermoplastics.
Figure 3.13 Tensile strength of mineral/glass PPA
Figure 3.10 Tensile strength of GR A-1000 PPA grades vs. temperature
grades vs. temperature
Temperature [ °F ]
Temperature [ °F ]
50 100 150 200 250 300 350
50 100 150 200 250 300 350
300 200
A-1240 L 30
35 A-1340 HS
250 A-1565 HS 25
Tensile strength [ MPa ]

30

Tensile strength [ kpsi ]

AS-1566 HS
Tensile strength [ MPa ]

Tensile strength [ kpsi ]

150
200 25 20

20 100 15
150
15
10
100
10 50
A-1133 HS 5
50 5
A-1145 HS
A-1160 HSL 0 0
0 0
0 50 100 150 200
0 50 100 150 200 Temperature [ °C ]
Temperature [ °C ]

Figure 3.14 Tensile modulus of mineral/glass PPA

Figure 3.11 Tensile modulus of GR A-1000 PPA grades vs. temperature
grades vs. temperature
Temperature [ °F ]
Temperature [ °F ]
50 100 150 200 250 300 350
50 100 150 200 250 300 350 25
30 A-1240 L 3.5
A-1133 HS 4.0 A-1340 HS
A-1145 HS 20 A-1565 HS 3.0
Tensile modulus [ Mpsi ]
Tensile modulus [ GPa ]

25 A-1160 HSL 3.5 AS-1566 HS

Tensile modulus [ Mpsi ]
Tensile modulus [ GPa ]

2.5
20 3.0 15
2.0
2.5
15 10 1.5
2.0
10 1.5 1.0
5
1.0 0.5
5
0.5
0 0.0
0 0.0 0 50 100 150 200
0 50 100 150 200 Temperature [ °C ]
Temperature [ °C ]

24 \ Amodel® PPA Design Guide

Flexural Properties Glass fibers and mineral additives increase the flexural
strength and modulus of Amodel® PPA compared to
Like tensile strength and modulus, the flexural strength
the unfilled resin. The resultant higher modulus may
and modulus of a plastic material can be increased by
be desirable in many applications.
adding glass fibers to the plastic resin. Treatment of the
glass fibers can produce a strong chemical bond between Flexural property comparison
the plastic and the glass that enhances both tensile and The flexural strength of 33 % GR Amodel® PPA is
flexural properties over a wide range of environmental compared to that of comparable PPS, PEI, and PA 6,6
conditions. As the amount of glass fiber reinforcement materials in Figure 3.15. Amodel® PPA’s strength is superior
is increased in the plastic, both the flexural strength and to the other resins. Although it declines somewhat with
modulus increase. moisture conditioning, it is still higher than most of the
other materials as molded.
Test methods
Flexural properties of thermoplastic materials are Figure 3.15 Flexural strength of 30 % – 33 % GR
determined in accordance with either ASTM D790 or resins
ISO 178. ASTM D790 includes a three-point loading test
45
(Method I) and a four-point loading test (Method II). 300 DAM
50% RH 40
In this document, whenever D790 is referenced, Method
250

Flexural strength [ MPa ]

1 was used. ISO 178, Plastics - Determination of Flexural 35

Flexural strength [ kpsi ]

Properties, specifies three-point loading. 30
200
The two test methods differ in test specimen dimensions, 25
150
apparatus specifications, maximum deflection, and 20
calculation details. The three-point loading refers to the 15
100
specimen being supported at two points separated by a
10
specified span and a vertical load applied to the top of the 50
test specimen at a point midway between the supports. 5
The test specimen deforms or bends as a result of the 0 0
A-1133 HS PA 6,6 PPS PEI
load. The specimen is deflected until rupture occurs or
the maximum fiber strain is reached. The flexural strength
This comparison for flexural modulus is shown in
is defined as the maximum fiber stress at the moment of
Figure 3.16. The flexural modulus of the Amodel® resin
rupture or maximum strain. The maximum strain specified
shown is quite high and it is not affected by moisture
by the ISO 178 method is 3.5 %, while ASTM D790
conditioning. The modulus of the PA 6,6 material declines
specifies 5 %.
significantly with moisture conditioning.
When the flexural properties of one material are
determined by both methods, the results obtained by the Figure 3.16 Flexural modulus of 30 % – 33 % GR
ASTM are different from those obtained using the ISO resins
method. Data by both methods are shown in the property 12
tables. When comparing materials, ensure that the data DAM 1.6
being compared was obtained using the same test 10 50% RH
1.4
method and test condition.
Flexural modulus [ Mpsi ]
Flexural modulus [ GPa ]

8 1.2
The flexural modulus of elasticity is the ratio, within the
1.0
elastic limit, of the stress in the outermost fiber of the
6
object being stressed to corresponding strain. As in 0.8
tensile testing, the modulus is calculated from the slope of 0.6
4
the load deflection curve in the linear “Hookean” region.
0.4
Flexural testing provides information about the relative 2
0.2
strength and stiffness of materials when subjected
0 0.0
to bending loads. The material with the higher flexural A-1133 HS PA 6,6 PPS PEI
strength can endure higher bending loads without
fracture. Parts produced 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.

Amodel® PPA Design Guide / 25

 Flexural properties at elevated temperatures Figures 3.19 and 3.20 present the flexural properties of
Figures 3.17 and 3.18 show the flexural properties of Amodel® PPA resins based on A-1000 containing different
three glass-reinforced Amodel® grades based on A-1000, glass reinforcement levels. As expected, the higher glass
A-4000, A-6000 base resins from room temperature up content grades have the higher strength and stiffness
to 175 °C (347 °F). The grade based on A-1000 has across the temperature range.
higher strength and stiffness and room temperature, but
Figure 3.19 Flexural strength of GR A-1000 PPA
the grades based on A-4000 and A-6000 are better at
grades vs. temperature
temperatures above 125 °C (257 °F).
Temperature [ °F ]
Figure 3.17 Flexural strength of GR PPA resins vs. 50 100 150 200 250 300 350
temperature 60
400
Temperature [ °F ]
50
50 100 150 200 250 300 350

Flexural strength [ MPa ]

Flexural strength [ kpsi ]

350 300
50 40
300
40 200 30
Flexural strength [ MPa ]

Flexural strength [ kpsi ]

250
20
200 30
100
A-1133 HS
10
150 A-1145 HS
20 A-1160 HSL
100 0 0
A-1133 HS 10 0 50 100 150 200
50 A-4133 L Temperature [ °C ]
A-6135 HN
0 0
0 50 100 150 200 Figure 3.20 Flexural modulus of GR A-1000 PPA
Figure 3.18 FlexuralTemperature
modulus of[ °CGR
] PPA resins vs. grades vs. temperature
temperature Temperature [ °F ]

Temperature [ °F ] 50 100 150 200 250 300 350

50 100 150 200 250 300 350 30
A-1133 HS 4.0
A-1145 HS
12 1.8 25 3.5
A-1160 HSL

Flexural modulus [ Mpsi ]

Flexural modulus [ GPa ]

1.6
3.0
Flexural modulus [ Mpsi ]

20
Flexural modulus [ GPa ]

10 1.4
2.5
8 1.2 15
2.0
1.0
6 10 1.5
0.8
0.6 1.0
4 5
A-1133 HS 0.4 0.5
2 A-4133 L 0
0.2 0.0
A-6135 HN
0 0.0 0 50 100 150 200
Temperature [ °C ]
0 50 100 150 200
Temperature [ °C ]

26 \ Amodel® PPA Design Guide

Figure 3.21 Flexural strength of mineral/glass PPA Shear Properties
resins vs. temperature Shear strength is the resistance to yield or fracture of two
Temperature [ °F ] planes moving relative to one another in the direction of
50 100 150 200 250 300 350 load. Shear strength can also be defined as the maximum
300 load required to shear the specimen being tested in such
A-1240 L 40 a manner that the moving plane has completely cleared
A-1340 HS
250 A-1565 HS 35 the stationary plane. Shear strength values are important
Flexural strength [ MPa ]

Flexural strength [ kpsi ]

AS-1566 HS
30 in designing structural components because in actual
200
applications the maximum stress on a component is often
25
150 a shear stress.
20
15
Shear strength was determined in accordance with
100
ASTM D732. In this test, a plaque molded from the
10
50 material to be tested is placed on a plate with a circular
5 hole in it. A circular punch whose diameter is slightly
0 0 smaller than the hole in the plate is pushed through
0 50 100 150 200 the molded plaque, punching out a circular disc. The
Temperature [ °C ] maximum stress is reported as the shear strength and
is calculated by dividing the load required to shear the
Figure 3.22 Flexural modulus of mineral/glass PPA specimen by the sheared area, which is calculated by
resins vs. temperature multiplying the circumference of the hole by the thickness
Temperature [ °F ] of the plaque.
50 100 150 200 250 300 350 Figure 3.23 compares the shear strength of Amodel® PPA
25 to PA 6,6, PPS, and PEI. The shear strength of Amodel®
A-1240 L 3.5
A-1340 HS PPA is comparable to that of PA 6,6 and PEI and superior
20 A-1565 HS 3.0
to that of PPS.
Flexural modulus [ Mpsi ]
Flexural modulus [ GPa ]

AS-1566 HS
2.5
15 Figure 3.23 Shear strength of 30 % – 33 % GR resins
2.0
120
10 1.5 DAM
16
50% RH
1.0 100 14
Shear strength [ MPa ]

Shear strength [ kpsi ]

5
0.5 80 12
10
0 0.0
60
0 50 100 150 200 8
Temperature [ °C ] 40 6
4
20
2
0 0
A-1133 HS PA 6,6 PPS PEI

Amodel® PPA Design Guide / 27

 Compressive Strength and Modulus Figure 3.24 Compressive strength of 30 % – 33 %
Compressive strength and modulus are measured in GR resins
accordance with ASTM D695. The test specimen is 250
35
molded from the material to be tested and then placed

Compressive strength [ MPa ]

Compressive strength [ kpsi ]

between parallel plates. These plates then exert a 200 30
compressive force on the specimen, while the force and 25
the distance between the parallel plates is monitored. The 150
compressive strain is given by the change in the distance 20
between the plates. The stress at failure, calculated by 100 15
dividing the force by the cross-sectional area, is the
10
compressive strength, and the slope of the stress/strain 50
curve is the compressive modulus. 5
0 0
Impact Strength A-1133 HS PA 6,6 PPS PEI
Because polymers are viscoelastic, their properties
depend upon the rate at which a load is applied. When Figure 3.25 Compressive strength of A-1000 resins
the loading rate is rapid, the part is said to be subjected vs. temperature
to impact loading. If a plastic part is to survive an impact
Temperature [ °F ]
without damage, it must be able to absorb the kinetic
energy transferred by the collision. 50 100 150 200 250 300

The ability of a plastic part to absorb energy is a function 200

A-1133 HS 30
A-1145 HS
Compressive strength [ MPa ]

Compressive strength [ kpsi ]

of its shape, size, thickness, and the type of plastic used A-1160 HSL 25
to make the part. The impact resistance testing methods
150
most frequently used may not adequately provide the 20
designer with information that can be used analytically.
100 15
These tests are most useful for determining relative
impact resistance and comparing the notch sensitivities 10
of materials. While the results may not adequately predict 50
practical toughness in actual applications, they will serve 5
to offer comparisons between materials.
0 0
0 20 40 60 80 100 120 140 160
Temperature [ °C ]

Figure 3.26 Compressive modulus of A-1000 resins

vs. temperature
Temperature [ °F ]
50 100 150 200 250 300

A-1133 HS
12
A-1145 HS
Compressive modulus [ Mpsi ]
Compressive modulus [ GPa ]

A-1160 HSL 1.5

10

8
1.0
6

4
0.5
2

0 0.0
0 20 40 60 80 100 120 140 160
Temperature [ °C ]

28 \ Amodel® PPA Design Guide

Izod (Cantilevered Beam) Impact Data using both methods are included in this document.
Izod impact can be determined using ASTM D256, The dimensions for the test specimens used are given in
Impact Resistance of Plastics and Electrical Insulating Table 3.13.
Materials, or ISO 180, Plastics – Determination of Izod
Table 3.13 Izod test specimen dimensions
Impact Strength. In both of these tests, a test specimen,
as illustrated in Figure 3.27, with a notch of specified ISO 180 ASTM D256
radius cut in its edge is struck by a swinging pendulum. Dimension [mm (inch)] [mm (inch)]
After the impact, the pendulum continues to swing, but Length 80.00 (3.150) 63.50 (2.500)
with less energy due to the collision. The methods differ
Width 10.00 (0.394) 12.70 (0.500)
in the dimensions of the test specimen and in the way
Thickness 4.00 (0.157) 3.20 (0.125)
the results are calculated. When using ASTM D256,
Notch radius 0.25 (0.010) 0.25 (0.010)
the energy lost is divided by the width of the specimen
remaining after notching, and the units are either Joules
Izod impact property comparison
per meter (J/m) or foot-pounds per inch (ft-lb/in.). When
using ISO 180, the amount of energy lost is multiplied by Figure 3.28 shows a comparison of the notched Izod
1,000 and divided by the product of the remaining width impact strength of 33 % glass fiber reinforced Amodel®
and the specimen thickness, and the units are either PPA to glass fiber reinforced grades of PA 6,6, PPS,
kiloJoules per square meter (kJ/m2) or foot-pounds per and PEI. The glass fiber reinforcement adds strength to
square inch (ft-lb/in2). these materials but reduces elongation, and all of these
materials have low Izod values. PA 6,6 shows an increase
Figure 3.27 Izod impact test specimen in impact strength when moisture conditioned.

Figure 3.28 Izod impact strength of 30 % – 33 % GR

Impact
resins, ASTM D256

140 DAM
2.5

Izod impact strength [ ft-lb/in ]

50% RH
Izod impact strength [ J/m ]

120
Notch 2.0
radius 100

80 1.5
60
1.0
40
0.5
Clamp 20

0 0.0
Izod impact can also be run on un-notched specimens. A-1133 HS PA 6,6 PPS PEI
The applicable test methods are ASTM D4812 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.

Amodel® PPA Design Guide / 29

 Figure 3.29 shows the Izod impact strength of a Figure 3.31 shows that ET-1000 HS has good Izod
toughened grade of Amodel® PPA, ET-1000 HS, and impact at temperatures lower than room temperature,
that of high impact grades of PA 6,6 and PA 6, as well but Amodel® AT-1001 L has superior impact resistance
as polycarbonate (PC) and a polycarbonate-polyester at temperatures as low as -40 °C (-40 °F).
(PC/PBT) blend. The Amodel® grade has impact strength
comparable to or better than the other materials. Figure 3.30 Figure 3.31 Low temperature Izod of Amodel® PPA
shows that this grade is not as sensitive to notch radius as grades
most amorphous polymers are. Temperature [ °F ]
-40 -20 0 20 40 60
Figure 3.29 Izod impact of Amodel® ET-1000 1,400
compared to PA and PC 25
1,200
1,000
18 20

Izod impact [ ft-lb/in ]

1,000

Izod impact [ J/m ]

16
800

Izod impact [ ft-lb/in ]

800 15
Izod impact [ J/m ]

14
12 600
600 10
10
400
400 8
5
6 200 AT-1001 L
ET-1000 HS
200 4 0 0
2 -50 -40 -30 -20 -10 0 10 20
0 0 Temperature [ °C ]
ET-1000 PA PA6 PC PC/PBT
HS 6,6
Charpy (supported beam) impact
Figure 3.30 Notch radius sensitivity of ET-1000 HS
Charpy is similar to Izod because a test specimen is
and PC
struck by a falling pendulum and the energy to break the
Notch radius [ mils ] specimen measured. The primary difference is that in the
0 5 10 15 20 Charpy test the specimen is supported at both ends and
1,000 struck in the middle, as shown in Figure 3.32. The test
methods used were ISO 179/1eA and 179/1eU.
800 15
Izod impact [ ft-lb/in ]

Figure 3.32 Charpy impact test specimen

Izod impact [ J/m ]

600 Support blocks

10
400
5
200 Polycarbonate
ET-1000 HS
Standard radius
0 0 Test specimen
0.0 0.1 0.2 0.3 0.4 0.5 0.6
Notch radius [ mm ]
Impact

30 \ Amodel® PPA Design Guide

Figure 3.33 Notched charpy impact strength of Table 3.14 Penetration impact of impact modified
30 % – 33 % GR resins PPA, ASTM D3763

14 DAM 2.0 Max Load Total Energy

Charpy impact strength [ ft-lb/in2 ]

Charpy impact strength [ kJ/m2 ]

50% RH
Grade Condition N lb J ft-lb
12
1.5 AT-1001 L DAM 4,900 1,100 54 40
10
AT-1002 HS DAM 4,400 1,000 54 40
8 AT-1002 HS 50 % RH 4,000 900 47 35
1.0
6 AT-5001 DAM 4,400 1,000 54 40
AT-5001 50 % RH 4,000 900 50 37
4 0.5 ET-1000 HS DAM 4,670 1,050 54 40
2 ET-1001 L DAM 5,600 1,260 64 47
0 0.0
A-1133 HS PA 6,6 PPS PEI
Poisson’s Ratio
Falling weight impact properties Poisson’s ratio is a measure of the strain characteristics
ASTM D3763, High-Speed Puncture Properties of imposed on a material transverse to the applied load.
Plastics Using Load and Displacement Sensors, was Poisson’s ratio is the ratio of lateral strain to longitudinal
used to measure the practical toughness of Amodel® strain within the proportional limit. To illustrate, consider
polyphthalamide resins. a cylindrical bar subjected to tensile stress: the length (L)
increases and simultaneously its diameter (D) decreases.
In this test, an injection molded specimen is clamped
down over a 76 mm (3 in.) diameter hole and a weighted In this case, Poisson’s ratio (υ) would be calculated by:
plunger is dropped from a predetermined height to give it -ΔD
a predetermined impact velocity. The plunger assembly D
consists of a 12.7 mm (0.500 in.) diameter steel rod with υ=
ΔL
a hemispherical end. The plunger assembly is attached
L
to a load cell which measures the energy needed to cause
a sample to fail. Most plastic materials have a Poisson’s ratio between
0.3 and 0.5.
Specimens can fail in either a brittle or a ductile mode.
In a ductile failure mode, the specimen is permanently
deformed to the shape of the plunger, but remains in
one piece after the penetration by the plunger. In a brittle
failure mode, the specimen does not have sufficient
ductility to be deformed without failure, and therefore
breaks into two or more pieces when impacted by
the plunger.

This method is preferred to ASTM D3029, because although

the impact values obtained are similar in natureto the “stair
step” falling weight impact test, the instrumented test
results are obtained via a computerized data reduction
technique and fewer samples are required.

Amodel® PPA Design Guide / 31

 Table 3.15 gives the Poisson’s ratios for various Amodel® The long-term property data presented in this manual
formulations at 23 °C (73 °F), “dry, as molded”. have been generated to show trends and property loss
for a number of Amodel® PPA grades under a variety of
Table 3.15 Poisson’s ratio for Amodel® products representative conditions. Due to the time required to
Grade Poisson’s Ratio [υ] generate the data, not all grades or sets of conditions
ET-1000 HS 0.40 can be included. The data are intended to show trends
as a function of filler/reinforcement systems so that the
A-1115 HS 0.41
designer may make educated decisions.
AS-1133 HS 0.41
AS-1145 HS 0.41 In some instances, attempts to generate data on long
A-1230 L 0.31 term properties utilize “accelerated” test conditions to
A-1240 L 0.29
speed data acquisition. Caution should be taken when
evaluating data generated in this manner as it is often
A-1340 HS 0.38
non-linear. This is especially true when measuring
property loss as a function of elevated temperature
Long-term Mechanical Properties and/or chemical exposure. Thermal “thresholds” such
In order for any engineered component fabricated from as the glass transition temperature (Tg ) and, ultimately,
a polymeric resin to perform within specified parameters the melting point are the main contributors to this non-
throughout its intended design life, the design engineer linear behavior.
must consider the long term effects of a number of
factors. A variety of stress loads as well as property Creep
changes due to environmental factors must be taken When a material is subjected to stress, an immediate
into consideration. To assess the time related effects strain occurs. For small strains, this strain is proportional
of stress on the behavior of polymeric materials, creep to the stress and calculable from the appropriate modulus.
and fatigue properties are measured. A wide variety of If the application of stress continues for an extended
environmental factors can also affect the performance of period of time, additional strain may be observed. This
an engineered component which is discussed in detail in behavior is referred to as creep and the additional strain
the section entitled “Environmental Resistance” starting as creep strain.
on page 56. However, certain environmental factors are
While creep is observed in metals, the phenomenon is
so pervasive that it was deemed appropriate to consider
more significant with plastics. Their lower modulus means
them in this section. These are the effects of moisture
that at the same stress level, the magnitude of the strain is
absorption and long-term exposure to high ambient
larger and a higher proportion of ultimate strain. In general,
temperatures.
the closer the initial strain is to the ultimate strain, the more
This section will present data generated to assist the likely it is that creep is significant.
design engineer with the analysis of design life
The reality of creep must be factored into a design to
requirements. The data in this section includes:
ensure long term satisfactory performance. The initial task
• Creep modulus in tension, flexure, is to determine if the creep will have a significant effect on
and compression modes the dimensions or function of the part. If the stress levels
• Tensile creep rupture are low enough so that any dimensional change will be
insignificant, creep may be ignored. However, if the stress
• Fatigue endurance
levels are such that creep will result in unacceptable
• Property changes due to moisture absorption deformation, an alternative design must be considered.
• Dimensional changes due to moisture absorption This may include investigating a material with a higher
• Property changes due to long-term exposure to creep modulus, or incorporation of an alternate design
elevated temperatures such as a metallic insert to serve as the load bearing
member. Additional discussion can be found in the
Design Information section.

32 \ Amodel® PPA Design Guide

In general, glass and mineral/glass reinforced grades Another aspect of creep may further complicate the
creep less than the unreinforced grades. The time analysis: under a given stress, creep will occur at the
required to observe measurable creep will also be expected rate based on the apparent modulus. However,
shorter for the unreinforced grades. Apparent or creep depending on how the stress is applied, the initial creep
modulus will decrease at elevated temperatures with can result in stress relaxation. Consider a plastic part
a corresponding increase in creep. At temperatures clamped with a bolt torqued to achieve a compressive
above the glass transition temperature (Tg), the apparent stress on the plastic. As creep strain occurs, the
modulus of the unreinforced grades is so low that even compressive stress will drop, resulting in less creep.
relatively low loads can result in significant creep, and The compressive stress will drop until an equilibrium is
therefore these unreinforced grades are usually not established at a lower stress level. A “single point” analysis
recommended for use in structural applications above would indicate that torque retention would drop to a failure
these temperatures. Structural applications that will be level, while, in reality, an acceptable equilibrium is reached
exposed to elevated temperatures should be specified before failure levels occur.
in the glass or mineral/glass reinforced grades.
Further discussion of the influence of creep on part
Creep can occur in tension, compression, or flexural design, including examples, can be found on page 68.
modes. Therefore, to evaluate creep properties, strain
is measured as a function of time while a specimen is Tensile creep
subjected to a constant tensile, compressive or flexural Tensile creep was measured at three temperatures:
load at specified environmental conditions. The procedure 23 °C (73 °F); 125 °C (257 °F); and 175 °C (347 °F) and
followed is described in ASTM D2990, Standard Test two stress levels: 13.8 MPa (2000 psi) and 34.5 MPa
Methods for Tensile, Compressive, and Flexural Creep (5000 psi). Test specimens were 3.2 mm (0.125 in.)
and Creep-Rupture of Plastics. ISO Method 899, Plastics - thick injection molded ASTM D638 Type I tensile
Determination of Creep Behaviour is similar, but because bars. Samples were placed under test in the “dry,
of differences in the test specimen may not yield exactly as molded” condition. The samples tested at the two
the same results. The general trends shown by either elevated temperatures were placed in air circulating
method should be comparable, but material comparisons ovens. Although the strain is measured, the results are
should only be done using data generated by the same typically presented as the apparent modulus, which is
method. calculated by dividing the strain by the applied stress.
The apparent modulus is the value design engineers use
The normal progression of creep occurs in these in their mechanical design calculations when designing
three stages: components that must perform when subjected to
• A rapid initial deformation sustained load.
• Continued deformation at a slow and constant rate The materials tested were A-1133 HS (33 % glass fiber)
• Yield followed by rupture for ductile materials, and A-1145 HS (45 % glass fiber). The results of the room
or rupture for non-ductile materials temperature testing are shown in Figures 3.34 and 3.35.

The significance of data from creep tests is that they The results of the tensile creep testing at 125 °C (257 °F)
can be used to calculate the time dependent creep strain are shown in Figures 3.36 and 3.37; results for 175 °C
and creep modulus for use in stress calculations and to (347 °F) are shown in Figures 3.38 and 3.39.
determine the safe stress levels for specific time
and temperature conditions. If the creep tests are
conducted until failure occurs at various stress levels,
a creep rupture curve can be produced.

Amodel® PPA Design Guide / 33

 Figure 3.34 Apparent modulus at 23 °C (73 °F) and Figure 3.37 Apparent modulus at 125 °C (257 °F)
13.8 MPa (2 kpsi) and 34.5 MPa (5 kpsi)

3.0 12
20
1.5

Apparent modulus [ Mpsi ]

Apparent modulus [ GPa ]

2.5 10

Apparent modulus [ Mpsi ]

Apparent modulus [ GPa ]
15
2.0 8
1.0
10 1.5 6

1.0 4
5 0.5
A-1133 HS 0.5 2
A-1145 HS A-1133 HS
0 0.0 A-1145 HS
0 0.0
1 10 100 1,000
1 10 100 1,000
Time [ hours ]
Time [ hours ]

Figure 3.35 Apparent modulus at 23 °C (73 °F) and Figure 3.38 Apparent modulus at 175 °C (347 °F)
34.5 MPa (5 kpsi) and 13.8 MPa (2 kpsi)
3.0 10
20 1.4
Apparent modulus [ Mpsi ]
Apparent modulus [ GPa ]

2.5 1.2

Apparent modulus [ Mpsi ]

Apparent modulus [ GPa ]
8
15 1.0
2.0
6
0.8
10 1.5
4 0.6
1.0
5 0.4
0.5 2
A-1133 HS A-1133 HS 0.2
A-1145 HS A-1145 HS
0 0.0 0 0.0
1 10 100 1,000 1 10 100 1,000
Time [ hours ] Time [ hours ]

Figure 3.36 Apparent modulus at 125 °C (257 °F) Figure 3.39 Apparent modulus at 175 °C (347 °F)
and 13.8 MPa (2 kpsi) and 34.5 MPa (5 kpsi)
14 2.0 8

12 7 1.0
Apparent modulus [ Mpsi ]

Apparent modulus [ Mpsi ]

Apparent modulus [ GPa ]

Apparent modulus [ GPa ]

10 1.5 6
0.8
5
8
1.0 4 0.6
6
3 0.4
4
0.5 2
2 0.2
A-1133 HS 1 A-1133 HS
A-1145 HS A-1145 HS
0 0.0 0 0.0
1 10 100 1,000 1 10 100 1,000
Time [ hours ] Time [ hours ]

34 \ Amodel® PPA Design Guide

Isochronous stress/strain curves Tensile creep rupture
Another format for presenting creep data is through Creep rupture is defined as a failure or rupture that occurs
the use of isochronous (equal time) stress versus strain as a result of a sustained load. Because the stress level at
curves. To prepare an isochronous curve, plot the which rupture occurs due to sustained load is lower than
stresses and the resultant strains for a single time interval the short-term strength, creep rupture can be the limiting
and draw a smooth curve through the points. Repeat this design property.
process for each time interval.
The objective of tensile creep rupture testing is to determine
This method has the advantage of providing a concise the time required for a sustained load to produce a rupture.
summary of a large amount of data. The apparent A plot of stress versus the time to rupture is commonly
modulus at any point can be calculated by dividing known as a “creep rupture envelope”. Because the strength
the stress by the indicated strain. Please note that of a material varies with temperature, a “creep rupture
the figures show strain expressed in percent; actual strain envelope” can be generated for each temperature of
is the plotted value divided by 100. concern.

The isochronous stress/strain curves for Amodel® Creep rupture envelopes were developed in accordance
A-1133 HS resin at 23 °C (73 °F), 125 °C (257 °F), and with ASTM D2990. Tensile specimens were 3.2 mm
175 °C (347 °F) are shown in Figure 3.40. (0.125 in.) thick injection molded ASTM D638 Type I
tensile bars. The environments were the same as in the
Figure 3.40 Isochronous stress-strain of A-1133 tensile creep testing above. The samples were loaded in
HS PPA tension using pneumatically actuated bellows to maintain
Tensile creep - A-1133HS indicated stress levels.
40
The tensile creep rupture envelopes for Amodel®
35 5 AS-1133 HS resin are shown in Figure 3.42 at 65 °C
30 (149 °F), 100 °C (212 °F), and 150 °C (302 °F).
4
25
Stress [ MPa ]

Figure 3.42 Tensile creep rupture of AS-1133 HS

Stress [ kpsi ]

20 3
200
15 25
2
10 150
1 20
Stress [ MPa ]

Stress [ kpsi ]
5
100 15
0 0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
10
Strain [ % ]
50
65 °C ( 149 °F )
1 hr 23 °C 1 hr 125 °C 1 hr 175 °C® 5
Figure 10
3.41 shows 100 °C ( 212 °F )
hr 23 °C the same
10 hr information
125 °C for10
Amodel
hr 175 °C 150 °C ( 303 °F )
A-1145100
HS.hrAs
23 expected,
°C thehrmore
100 125 °Cglass reinforcement
100 hr 175 °C in 0 0
1,000 hr 23 °C 1,000 hr 125 °C 1,000 hr 175 °C
the compound, the better the creep resistance. 0.01 0.1 1 10 100 1,000 10,000
Time to rupture [ hours ]
Figure 3.41 Isochronous stress-strain of A-1145
HS PPA
Tensile creep - A-1145HS
40

35 5
30
4
25
Stress [ MPa ]

Stress [ kpsi ]

20 3

15
2
10
1
5

0 0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Strain [ % ]

1 hr 23 °C 1 hr 125 °C 1 hr 175 °C
10 hr 23 °C 10 hr 125 °C 10 hr 175 °C
100 hr 23 °C 100 hr 125 °C 100 hr 175 °C Amodel® PPA Design Guide / 35
1,000 hr 23 °C 1,000 hr 125 °C 1,000 hr 175 °C
 Flexural creep Figure 3.44 Apparent flex modulus at 14 MPa
Flexural creep was determined according to ASTM D2990 (2 kpsi) at 83 °C (181 °F)
using the three-point bending mode with a 50.8 mm (2 in.) 3.0
span. Test specimens were 127 mm x 12.7 mm x 3.2 mm ET-1000 400
PA 6,6
(5.0 in. x 0.5 in. x 0.125 in.) injection molded bars placed 2.5

Apparent modulus [ GPa ]

Apparent modulus [ kpsi ]

High impact PA 6,6
on test “dry, as molded”. The environment was maintained
2.0 300
at 50 % relative humidity and 23 °C (73 °F). Stress levels
were predetermined from flexural strength versus 1.5
temperature curves and chosen to be 25 % to 35 % of the 200
ultimate strength of the material at the test temperature. 1.0
100
Creep resistance can be predicted to a large extent by the 0.5
relationship of the service temperature to the material’s
glass transition temperature. Typically, creep resistance 0.0 0
is good at service temperatures much lower than Tg, and 0.1 1 10 100 1,000
becomes poorer as service temperature approaches Tg. Time [ hours ]
Therefore, it is not surprising that Amodel® resins have
creep resistance superior to many traditional semi- Compressive creep
crystalline thermoplastics. For example, Amodel® A-1000 Compressive creep was determined according to
resin has a glass transition temperature of 123 °C (253 °F) ASTM D2990. Test specimens were 12.7 mm x
as determined by Differential Scanning Calorimetry (ASTM 12.7 mm x 25.4 mm (0.5 in. x 0.5 in. x 1.0 in.) injection
D3418). The corresponding Tg for PA 6,6 is 65 °C (149 °F). molded bars. The ends of the bars were machined
At all temperatures up to its Tg, Amodel® resins do have until they were parallel to each other within 0.025 mm
superior creep resistance. (0.001 in.) and perpendicular to the axis. Displacement
was monitored with bonded strain gauges. As in the
Figure 3.43 compares the apparent flexural modulus flexural creep experiments, the stress levels were chosen
of Amodel® AS-1133 HS and A-1240 L resins to a 33 % to be less than 35 % of the compressive strength at the
glass reinforced PA 6,6. While the AS-1133 HS resin temperature of the test.
is clearly superior to the glass reinforced PA, even the
mineral filled Amodel® A-1240 resin has an effectively Figure 3.45 shows the compressive creep moduli of
higher creep modulus after 1000 hours under load. Amodel® AS-1133 HS resin at 23 °C, 100 °C, and 150 °C
(73 °F, 212 °F, and 302 °F). These moduli are lower than
Figure 3.43 Apparent flex modulus at 69 MPa the flexural creep moduli given in Figure 3.43. This is due
(10 kpsi) at 23 °C (73 °F) to less fiber orientation in the direction of the induced strain.
12
Figure 3.45 Apparent compressive modulus of
1.6
10
AS-1133 HS
Apparent modulus [ Mpsi ]

1.4
Apparent modulus [ GPa ]

8
8 1.2
1.0 7 1.0 Apparent modulus [ Mpsi ]
Apparent modulus [ GPa ]

6 6
0.8
0.8
4 0.6 5 23 °C - 34 MPa ( 73 °F - 5 kpsi )
100 °C - 28 MPa ( 212 °F - 4 kpsi ) 0.6
AS-1133 HS 0.4 4
150 °C - 21 MPa ( 302 °F - 3 kpsi )
2
33% GR PA 6,6 0.2 3
A-1240 L 0.4
0 0.0 2
1 10 100 1,000 10,000 0.2
1
Time [ hours ]
0 0.0
Figure 3.44 compares the apparent flexural modulus 0.1 1 10 100 1,000
of Amodel® ET-1000 resin with that of unreinforced Time [ hours ]
and impact modified grades of PA 6,6 at 83 °C (181 °F)
and 14 MPa (2 kpsi). In most applications where Amodel® resin will be loaded
in a compressive manner, the load will be applied in the
direction 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.

36 \ Amodel® PPA Design Guide

Fatigue Resistance Fatigue strength of Amodel® resin
When a material is stressed cyclically, failure or rupture When measuring and/or comparing the fatigue strength
will occur at stress levels much lower than its short-term of plastic materials, it is critical to specify the mode
ultimate strength. Examples of cyclic stress would include (tensile, compressive, or flexural), the frequency, and
components subjected to severe vibration, components of the stress profile.
reciprocating or rotating devices where loading is cyclic,
The fatigue strength of Amodel® resins was determined
and mechanical devices such as gears where the cyclic
in accordance with ASTM test method D671. This method
load is a function of position.
uses a cantilever beam configuration with a constant
This phenomenon is well known in metals. Metallurgists deflection. The results shown in Figure 3.46 were
have defined the term “Fatigue Endurance Limit” to generated at a frequency of 32 Hz. Failure was defined
represent the maximum cyclical stress that a material when the stress level decayed to 90 % of its initial value.
can be subjected to without failure. Normally, this stress The Amodel® resins resist higher cyclic loads longer
level corresponds to the highest stress level that does not than PA 6,6.
cause failure in 10 million (107) cycles.
Figure 3.46 Flex fatigue of GR resins at 23 °C
While the term “Fatigue Endurance Limit” is sometimes (73 °F) and 32 Hz
used in design discussions involving plastic materials,
140 20
the response of plastics to cyclic stress is more complex AS-1145 HS
than the response of metals, and the term is not strictly 120 AS-1133 HS 18
33% GR PA 6,6 16
applicable. Fatigue data is typically presented by plotting
100 14

Stress [ kpsi ]
stress versus number of cycles at rupture. A smooth curve Stress [ MPa ]
is calculated that represents the best fit to the data. For 80 12
component design purposes, this S–N (stress–number 10
60 8
of cycles) curve provides strength values appropriate
40 6
for the components required life.
4
When designing a component that will be subjected 20
2
to cyclic loading, the establishment of fatigue strength 0 0
requirements is desirable. However, analysis of the fatigue 103 104 105 106 107
strength requirements is complicated by a large number Cycles to failure
of factors that may influence them. Some of these factors
include the following:
Figure 3.47 gives the fatigue behavior of Amodel® AS-1145
• Shape of the component HS resin at 110 °C and 170 °C (230 °F and 338 °F). As
• Stress concentration factors expected, raising the temperature reduces the amount
of cyclic stress that can be endured.
• Rate of load application
• Any temperature change caused by load application A good example of an application involving cyclical stress
is a gear. As the driving gear causes the driven gear to
• Type of stress induced by load, that is, tensile,
rotate, each tooth is subject to stress. This is then followed
compressive, or shear, etc.
by a period of time at low or zero stress. In designing a
• Environmental factors, such as, chemicals, radiation,
gear tooth, the appropriate strength criteria is the fatigue
ambient temperature
endurance limit of the material at the operating conditions
• Residual stresses of the gear.
• Duty cycle
• Desired component life

Amodel® PPA Design Guide / 37

 Figure 3.47 Flex fatigue of AS-1145 resin at elevated Moisture Effects
temperature As with most thermoplastic resins, parts made
70 10 from Amodel® resins can absorb moisture from the
110 °C ( 230 °F ) atmosphere. Because absorption is a physical change
60 170 °C ( 338 °F )
8 and not a chemical change, it is a reversible process, in
50 that parts can be “dried out” under proper conditions.
Stress [ MPa ]

Stress [ kpsi ]
6 Amodel® polyphthalamide resins have significant amounts
40
of aromatic character in the polymeric “backbone” and
30 this causes them to absorb much less moisture than
4
aliphatic polyamides such as PA 6,6 and PA 6. As a result,
20
the dimensions, strength, and stiffness of Amodel® parts
2
10 will be significantly less affected by the absorption of
moisture than traditional aliphatic PA parts. Since moisture
0 0
is ubiquitous, knowledge of the effects of moisture on the
103 104 105 106 107
Cycles to failure properties of a material is critical to the design engineer
trying to meet end use requirements.
After all of the calculations have been made, the part
Significance of moisture absorption
design can be modified to best utilize the properties
of the selected material. Conversely, the material grade When a polymer absorbs atmospheric moisture, a number
can be modified to best suit the application requirements. of changes may occur. Obviously, the part weight will
An extremely useful tool to verify a design is to perform increase and this weight increase is typically used to
Finite Element Analysis (FEA). In FEA, the part is measure the amount of moisture absorbed. Additionally,
electronically modeled and a computer program is used there may be some dimensional changes and generally
to simulate the anticipated loads and stresses. The the parts become larger. The presence of reinforcing fillers
resulting strain levels can be evaluated and, if necessary, such as fiberglass may result in anisotropic dimensional
part design or material changes can be made. It is much change due to the fact that the fibers align themselves
easier to make changes to the FEA model than to a in the direction of polymer flow as the resin fills the tool.
fabricated part or tooling. Similar to mold shrinkage values, dimensional changes
due to moisture absorption are often reported in flow and
Even after calculations and FEA’s have been performed, transverse directions.
the best way of evaluating a material for a component
subject to dynamic stresses is actual prototype testing. Mechanical properties may also be affected by moisture
Prototype parts can be machined from available stock absorption. Generally, a slight decrease in physical
shapes and subject to performance testing under the properties such as tensile and flexural strength are seen.
requirements of the application. Stock shapes are usually The respective moduli also decrease slightly. Impact
available as extruded slabs or rods and generally exhibit strength values tend to increase slightly since the presence
slightly lower mechanical properties than the injection of moisture can tend to plasticize the polymer. Since water
molded part. Additionally, the machining operations is a conductor, absorbed moisture can have a negative
usually induce stresses that would not normally be effect on the dielectric properties of a molded part.
present in an injection molded part. As a result, a Manufacturers of polymers that absorb moisture usually
successful prototype test imparts an extremely high publish two sets of data, one listing test results on test
confidence level in the reliability of the design. specimens that have no absorbed moisture, commonly
referred to as “Dry–As Molded” (DAM), and a second set
of data that is generated on test specimens that have
been allowed to come to an equilibrium weight in a 50 %
Relative Humidity environment, known as “50 % RH”.
Polymers like PA 6 and PA 6,6 absorb moisture relatively
quickly and reach equilibrium in a 50 % Relative Humidity
environment quickly. Providing 50 % RH data for these
materials is fairly easy and extremely relevant to design,
as will be understood in the subsequent discussion.

38 \ Amodel® PPA Design Guide

On the other hand, polymers like Amodel® PPA absorb Alternatively, consider the Amodel® A-1000 series polymers,
moisture very slowly and can take years to reach an which have a dry Tg of 123 °C (253 °F). Absorption of
equilibrium at 50 % RH. In order to provide 50 % RH data, moisture at room temperature can reduce this Tg to 84 °C
a method was developed to accelerate the conditioning of (183 °F)and have a slight reduction in “room temperature”
test specimens. This involves boiling the test specimens properties. However, since moisture absorption is a
in an aqueous solution of potassium acetate until constant reversible phenomenon (moisture absorption is a physical,
specimen weight is obtained, typically for several days. not a chemical reaction), at temperatures above 100 °C
As would be expected, this accelerated procedure has (212 °F), the polymer actually dries out, returning the
some side effects that influence the test values. In the Tg to the original 123 °C (253 °F) value. Therefore, the
accelerated procedure, the test specimens are annealed Tg reduction due to moisture absorption is essentially
and stress relieved, which may actually cause in an insignificant for Amodel® resins. The following data are
improvement in the property test results. Conversely, presented for consideration in applications in which
exposure to boiling water can cause some hydrolysis of moisture absorption is expected at ambient temperatures
the polymer, yielding a loss in properties. Additionally, and a slight loss of properties may be anticipated.
exposure to the boiling salt solution has been shown Since the polymer “desorbs” moisture and regains dry
to degrade the bond between the polymer and a properties on exposure to temperatures above 100 °C
reinforcing media, such as fiberglass, resulting in a loss of (212 °F), moisturized test data above 100 °C (212 °F) is
mechanical properties such as tensile, flexural and impact. irrelevant for Amodel® resins, but quite important for
Nonetheless, the effect of absorbed moisture on Amodel® polymers that have a Tg near or below 100 °C (212 °F).
resins is minimal.
Absorption amount
Moisture absorption and glass transition As has been mentioned, water absorption is a
temperature (Tg) reversible process. At each specified relative humidity
Perhaps much more significant than the effect of moisture and temperature, a resin will absorb moisture until an
absorption on room temperature properties is the effect of equilibrium is established. At equilibrium, a polymer
moisture absorption on the Glass Transition Temperature absorbs moisture at the same rate, it releases moisture,
(Tg) of a polymer. By definition, the Tg of a polymer is the achieving a constant weight. Since the polymer, not the
temperature, above which the crystalline region of the filler or reinforcement additives, absorbs the moisture, the
polymer matrix is no longer dominant over the amorphous amount of water absorbed is proportional to the amount
region. Above the Tg, the amorphous region is dominant of polymer present in each grade; the more highly filled
and there is a noticeable loss in mechanical properties grades will have lower absorption than the unfilled grades.
as seen in the discussion on mechanical properties vs. Figure 3.48 compares the increase in weight due to
temperature. In unreinforced grades, this is very significant moisture absorption of Amodel® AS-1133 HS to that of
in that the properties drop to levels which are essentially 33 % glass reinforced PA 6,6 at room temperature and
useless from a mechanical design perspective. In the specified relative humidities. The 33 % glass reinforced
reinforced grades, while the properties above Tg are still PA 6,6 absorbs significantly more moisture than Amodel®
useful from a design perspective, the loss of mechanical AS-1133 HS resin. The amount of time required for
properties is significant enough to make major design Amodel® resins to reach equilibrium is also significantly
considerations. longer than PA 6,6.

The effect of absorbed moisture on semi-crystalline

Figure 3.48 Moisture absorption of GR resins
polymers is to lower the glass transition temperature. The
severity of reduction is dependent on the specific polymer 6
AS-1133 HS
and the amount of moisture absorbed. 33% GR PA 6,6
5
Weight change [ % ]

This phenomenon becomes of significant concern

when designing with a polymer that has a Tg near 4
or below 100 °C (212 °F). For example, a polymer with
3
a Tg of 80 °C (176 °F) (Dry as molded) might exhibit a Tg of
only 60 °C (140 °F) after absorbing moisture. The designer 2
must consider the significant loss in properties above
60 °C due to the reduction in Tg when making decisions. 1
Polymers with even lower dry Tgs can have a Tg reduction
0
at or near room temperature with moisture absorption.
0 10 20 30 40 50 60 70 80 90 100
This can create a significant design consideration.
Relative humidity [ % ]

Amodel® PPA Design Guide / 39

 Effect of moisture on strength and stiffness Dimensional change due to moisture
Figure 3.49 compares the tensile strength of Amodel ®
To evaluate the effect of moisture absorption on part
AS-1133 HS resin to that of 33 % glass reinforced PA 6,6 dimensions, plaques 102 mm x 102 mm x 3.6 mm
at 23 °C (73 °F) and specified moisture content. The tensile (4 in. x 4 in. x 0.125 in.) were molded, measured, and
strength of the Amodel® resin is superior to that of the PA then placed into environments at room temperature,
“dry, as molded” and the difference increases with higher 23 °C (73 °F), and either 50 % or 100 % relative humidity.
moisture levels. Periodically the plaques were removed and measured.
Figure 3.49 Effect of moisture on tensile strength of The direction of flow during the molding process was
GR resins noted and data for both the flow direction and transverse
to flow were reported. The dimensional change was
calculated by subtracting the initial length from the final
200 30
length, dividing the result by the original length, and
Tensile strength [ MPa ]

Tensile strength [ kpsi ]

25 multiplying the result by 100 to express the change
150 in percent.
20
Figure 3.51 shows the results of this testing for Amodel®
100 15
AS-1133 resin. Even at 100 % relative humidity, the
10 dimensions continue to change for a considerable length
50
AS-1133 HS 5 of time. These graphs show that after one year, the rate of
33% GR PA 6,6 change has greatly diminished but the dimensions are still
0 0 changing. Dimensions in the flow direction change less
0 10 20 30 40 50 60 70 80 90 100 than the transverse direction, most likely due to alignment
Relative humidity [ % ]
of the reinforcement fiber in the flow direction. The
magnitude of the dimensional change is relatively small
Figure 3.50 compares the flexural modulus of Amodel® (less than 0.6 %), but could be important in applications
AS-1133 HS resin to that of a 33 % glass reinforced requiring extremely tight dimensional tolerances and
PA 6,6 at 23 °C (73 °F) and various moisture contents. stability.
The modulus of the Amodel® resin is higher as molded
and remains relatively constant. The modulus of the PA
Figure 3.51 Dimensional change of 33 % GR PPA
resin drops rapidly with increasing moisture level and 0.6
TD @ 100% RH
temperature due to the fact that the Tg of PA 6,6 is below
Dimensional change [ % ]

FD @ 100% RH
100 °C (212 °F) and decreases further with moisture 0.5
TD @ 50% RH
absorption. FD @ 50% RH
0.4

Figure 3.50 Effect of moisture on flex modulus of 0.3

GR resins
0.2
12 1.8
1.6 0.1
FD = flow direction
Flexural modulus [ mpsi ]
Flexural modulus [ GPa ]

10 1.4 TD = transverse direction

0.0
8 1.2
0 2 4 6 8 10 12 14
1.0 Time [ month ]
6
0.8
4 0.6
0.4
2 AS-1133 HS
0.2
33% GR PA 6,6
0 0.0
0 10 20 30 40 50 60 70 80 90 100
Relative humidity [ % ]

40 \ Amodel® PPA Design Guide

Figure 3.52 shows the same results for Amodel® A-1340 Figure 3.53 Dimensional comparison of GR PA 6,6
PPA, a 40 % mineral filled grade. Not only is the magnitude to GR PPA at 100 % RH
of the dimensional change smaller, but the difference
1.2
between flow and transverse direction is almost negligible.

Dimensional change [ % ]
1.0
Figure 3.52 Dimensional change of 40 % mineral AS-1133 HS - TD
AS-1133 HS - FD
Filled PPA 0.8
33% GR PA 6,6 - TD
33% GR PA 6,6 - FD
0.6 0.6
TD @ 100% RH
Dimensional change [ % ]

FD @ 100% RH
0.5 0.4
TD @ 50% RH
FD @ 50% RH
0.4 0.2
FD = flow direction
0.3 TD = transverse direction
0.0
0 2 4 6 8 10 12 14
0.2
Time [ month ]
0.1
FD = flow direction
Amodel® resin absorbs moisture much more slowly
TD = transverse direction
0.0 than PA 6,6, because the diffusion coefficient at room
0 2 4 6 8 10 12 14 temperature of water in PA 6,6 is approximately five times
Time [ month ] larger than that of Amodel® resins. Therefore, for these
plaques, PA 6,6 reaches equilibrium in approximately four
Dimensional change compared to PA 6,6
months while Amodel® AS-1133 HS resin requires more
Figure 3.53 compares the dimensional change due than two years.
to moisture absorption of Amodel® AS-1133 HS resin
with that of 33 % glass reinforced PA 6,6 at 100 % RH.
To ensure a valid comparison, both resins were molded
under conditions that promote maximum crystallinity.
In the case of the Amodel® resin, a mold temperature
of 135 °C (275 °F) was used. For the PA 6,6, the mold
temperature was 93 °C (200 °F). Plaques with a thickness
of 3.2 mm (0.125 in.) were exposed to 100 % RH at room
temperature.

Amodel® PPA Design Guide / 41

 Thermal Properties unless otherwise specified. Other test parameters that
should be considered are specimen thickness and
In general, the thermal properties characterize the way a
thermal history. The test may be performed as molded
material responds to changing temperatures, both in the
or after heat treating or “annealing” for several hours
short-term and long-term. Thermal properties include the
at a temperature slightly above the glass transition
effects of temperature on the following:
temperature, or about 160 °C (320 °F) for Amodel® PPA.
• Strength and stiffness
In general, annealing reduces the variability in deflection
• Dimensions
temperature measurements, in addition to raising the
• Chemical changes in the polymer itself value slightly. Figure 3.54 shows the effects of mold
due to thermal or oxidative degradation temperature and annealing on the deflection temperature at
• Softening, melting, or distortion 1.8 MPa (264 psi) for Amodel® AS-1133 HS resin. As can
• Morphology be seen, mold temperature and/or annealing effects can
cause the deflection temperature to vary by as much as
The properties of the material in its molten state are 17 °C (30 °F). The deflection temperature data in this
discussed in the Amodel® PPA Processing Guide. manual were generated on specimens annealed at 160 °C
The behavior of the material while burning is discussed (320 °F) for 2 hours.
in the section on combustion properties.
Figure 3.54 Mold temperature and annealing
Heat Distortion Temperature – HDT effects on HDT of Amodel® AS-1133 HS
The tests most commonly used by the plastics industry 300
to measure short-term thermal capability are ASTM D648, 570
295
Standard Test Method for Deflection Temperature of
Deflection temperature [ °C ]

Deflection temperature [ °F ]
560
Plastics Under Flexural Load and ISO 75, Plastics - 290
550
Determination of Temperature of Deflection Under 285
Load. These tests are commonly referred to as Heat 540
280
Distortion Temperature (HDT) or Deflection Temperature 530
under Load (DTUL). Both tests are similar in that the 275
test specimen is supported at two points while a load 270 520
is applied to the center. The temperature is increased 265 510
at a constant rate until the specimen deflects a specified
260 500
amount as indicated by a dial micrometer. 121 °C 135 °C Annealed
Mold temperature 2 hours @ 160 °C
Although details such as specimen geometry, deflection Thermal history
endpoint, specimen orientation, and distance between
the supports are different for these methods, the desired Deflection temperature measures modulus at temperature
stress levels for both methods includes a loading of measurement. Classical stress/strain analysis indicates
1.8 MPa (264 psi) and 0.45 MPa (66 psi). When comparing that the ASTM D648 test actually measures the
data from multiple sources, it is important to verify that temperature at which the flexural modulus is 240 MPa
the same test method was used for all the data being (35,000 psi) when the applied stress is 0.45 MPa (66 psi),
compared. In the product property tables starting on or 965 MPa (140,000 psi) when the applied stress is
page 9, data collected using both methods is listed. 1.8 MPa (264 psi). Because the test method directs that
Examination of the data will reveal a considerable amount the indicator be re-zeroed after five minutes, any creep
of difference between the values for some grades. strain that occurs in the first five minutes is effectively
Certain test parameters can have a significant influence subtracted from the endpoint strain lowering the actual
upon the results obtained in this test. The designer modulus at the end point of the test. The initial modulus
should be certain that data from multiple sources are can be related to the creep strain.
comparable. The most common and critical error is to
compare the results from testing performed at 1.8 MPa
(264 psi) with results obtained from testing at 0.45 MPa
(66 psi). All Amodel® resins are tested at 1.8 MPa,

42 \ Amodel® PPA Design Guide

In summary, deflection temperature does not measure Coefficient of Linear Thermal Expansion
thermal capability, it simply provides one point on the The dimensions of most materials increase with increasing
modulus versus temperature curve. temperature. The coefficient of linear thermal expansion
In general, HDT can only be used as a general indicator (CLTE) is the ratio of the change in length to the change
of short-term thermal capability. It is useful for comparing in temperature.
similar materials but can be misleading if, for example, If the coefficient α is known, the change in length of an
an amorphous material is compared to a semi-crystalline uniform straight bar raised to a temperature TF can be
material. It doesn’t provide any information about long- calculated from:
term thermal stability. The actual loads and performance
requirements will dictate the suitability of the material. Δ L = αL ( TF − TO )
Many semi-crystalline resins can be used in applications
that experience temperatures higher than their deflection Where:
Δ L = change in length
temperature value.
L = original length
α = coefficient of linear thermal expansion
Deflection Temperature Values for TF = final temperature
Amodel® Resins TO = initial temperature
Deflection temperature values by both ASTM D648
The CLTE (α), as measured by ASTM E831, of several
and ISO 75Af for representative grades of Amodel® PPA
Amodel® grades and some common metals is given in
are shown in the Tables starting on page 7.
Table 3.16. This method provides an average value for
Figure 3.55 compares the deflection temperature at the expansion coefficient over a temperature range.
1.8 MPa (264 psi) of Amodel® AS-1133 HS resin with a
The thermal expansion behavior of metals is uniform
33 % glass fiber reinforced PA 6,6, a 30 % glass fiber
over the temperature range of concern. As shown in
reinforced PPS, and a 30 % glass fiber reinforced PEI.
Table 3.16, the thermal expansion coefficients of the
Amodel® resin offers a 75 °C HDT advantage relative to
polymer materials are a function of the temperature
PEI, a 42 °C advantage relative to PA 6,6, and a 22 °C
range used for the measurement. In general, the polymer
advantage relative to PPS.
materials expand slightly more above their glass transition
temperature than they do below it and the behavior in the
Figure 3.55 HDT of 30 % – 33 % GR resins vicinity of the Tg is also somewhat non-linear. However,
300 over large temperature ranges, the variations are usually
550 insignificant and an excellent prediction of dimensional
280
Deflection temperature [ °C ]

Deflection temperature [ °F ]

properties can be obtained using the values provided

260 500 in the table. Also, the addition of glass fiber and other
240 reinforcing additives results in the thermal expansion
450 becoming directional. Since fibers tend to become
220
oriented in the flow direction, and since glass has a lower
200 400
thermal expansion coefficient than the polymers, the
180 coefficients of expansion are generally lower in the flow
350
direction than the transverse direction.
160
A-1133HS PA 6,6 PPS PEI The values shown in Table 3.16 should allow the design
engineer to estimate the magnitude of the thermal
stresses in parts molded from Amodel® resins due
to thermal expansion.

Amodel® PPA Design Guide / 43

 Table 3.16 Coefficients of linear thermal expansion(1)
0-50 °C 50-100 °C 100-150 °C 150-200 °C
Temperature (32-122 °F) (122-212 °F) (212-302 °F) (302-392 °F)
Direction FD(2) TD(3) FD TD FD TD FD TD
per per per per per per per per
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-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-1000 HS 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-1633 V0 Z 18 (10) 56 (31) 16 (9) 72 (40) 11 (6) 93 (52) 3 (2) 120 (67)
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-9240 NL 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)
(1) -6
Values are 10 L/L per degree where L is length
(2)
FD = Flow direction
(3)
TD = Transverse direction or perpendicular to flow direction

44 \ Amodel® PPA Design Guide

Table 3.17 Thermal conductivity of Amodel® PPA resins
Average Temperature
40 °C (104 °F) 100 °C (212 °F) 150 °C (302 °F)
Btu in./ Btu in./ Btu in./
Grades Additive Amount [%] W/mK hr ft 2 °F W/mK hr ft 2 °F W/mK hr ft 2 °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

Thermal Conductivity Figure 3.56 Thermal conductivity of glass reinforced

Thermal conductivity is the rate at which heat energy Amodel® PPA
will flow through a material. This property is important Temperature [ °F ]
in applications where the polymeric material is used as 100 150 200 250 300
a thermal insulator, or where heat dissipation is of 0.45

Thermal conductivity [ BTU-in/hrft2 °F ]

concern. 3.0

Thermal conductivity [ W/m-K ]

0.40 2.8
The measurement of thermal conductivity was performed
2.6
in accordance with ASTM F433. The test is conducted by
0.35 2.4
placing a sample between plates controlled at different
temperatures and monitoring the heat flow through the 2.2
0.30
sample. The thermal conductivity was determined at three 2.0
average temperatures, 40 °C (104 °F), 100 °C (212 °F), and 1.8
150 °C (302 °F), by setting the hot plate about 7 °C (12 °F) 0.25 15% GR
33% GR 1.6
above the average and setting the cold plate about 7 °C 45% GR
0.20 1.4
(12 °F) below the average temperature.
40 60 80 100 120 140 160
The thermal conductivity of various grades of Amodel® Temperature [ °C ]
resin was measured at each of the stated temperatures
and the results are presented in Table 3.17. Higher thermal
conductivity values indicate greater heat flow, while lower
values indicate better thermal insulating characteristics.

Figure 3.56 shows that the thermal conductivity increases

with glass content and temperature.

Amodel® PPA Design Guide / 45

 Specific Heat Figure 3.59 Amodel® A-5000 PPA, specific heat
Specific heat is defined as the amount of heat required vs. temperature
to change the temperature of a unit mass one degree. Temperature [ °F ]
Figures 3.57 through 3.60 show the specific heat as 100 200 300 400 500 600
a function of temperature for the Amodel® base resins. 6 1.4
Notice that the specific heat changes significantly
at the melting point. This behavior is typical of semi- 5 1.2

Specific heat [ Btu/lb °F ]

Specific heat [ J/g °C ]
crystalline thermoplastics. 4 1.0

This information can be used by process engineers 0.8

3
to calculate the heat input needed to process Amodel® 0.6
resins on equipment such as extruders or injection 2
0.4
molding machines.
1 0.2
Figure 3.57 Amodel® A-1000 PPA, specific heat
vs. temperature 0 0.0
0 50 100 150 200 250 300 350
Temperature [ °F ] Temperature [ °C ]
100 200 300 400 500 600
6 1.4 Figure 3.60 Amodel® A-6000 PPA, specific heat
vs. temperature
5 1.2
Specific heat [ Btu/lb °F ]
Specific heat [ J/g °C ]

Temperature [ °F ]
4 1.0
100 200 300 400 500 600
0.8 6
3 1.4
0.6
5 1.2

Specific heat [ Btu/lb °F ]

2
Specific heat [ J/g °C ]

0.4
4 1.0
1 0.2
0.8
3
0 0.0
0.6
0 50 100 150 200 250 300 350 2
Temperature [ °C ] 0.4
1 0.2
Figure 3.58 Amodel® A-4000 PPA, specific heat
vs. temperature 0 0.0
0 50 100 150 200 250 300 350
Temperature [ °F ] Temperature [ °C ]
100 200 300 400 500 600
6 1.4

5 1.2
Specific heat [ Btu/lb °F ]
Specific heat [ J/g °C ]

4 1.0

0.8
3
0.6
2
0.4
1 0.2

0 0.0
0 50 100 150 200 250 300 350
Temperature [ °C ]

46 \ Amodel® PPA Design Guide

Thermal Stability Thermal oxidative stability limits the acceptable long-term
The general term, thermal stability, is used to describe use temperature of some polymers. To evaluate these
the ability of a material to resist loss of properties due to long-term effects on the properties of Amodel® PPA,
heat. Various methods are used to evaluate this tendency. molded test specimens of Amodel® resins were placed
In the next section, we will discuss several of these in circulating air ovens at several elevated temperatures.
methods, including thermogravimetric analysis, and Specimens were removed from the oven at regular
long-term heat aging. intervals, then tested at room temperature for tensile
strength and impact resistance.
Thermogravimetric analysis (TGA)
Typically, these aging tests are run until the property
Thermogravimetric analysis is performed by increasing being monitored has been reduced to one-half its
the temperature of a small sample of the test material at a starting value. The aging tests are conducted at
constant rate while monitoring its weight. The atmosphere several aging temperatures and an “Arrhenius Plot” is
is controlled and the test can be performed using air or prepared. An “Arrhenius plot” plots the heat aging time
an inert atmosphere, such as nitrogen. Figure 3.61 shows required to reduce a property to one-half of its starting
the weight loss of Amodel® A-1000 resin as a function of value, sometimes referred to as its half-life, against the
temperature in air at a heating rate of 10 °C/min (18 °F/min). reciprocal of the aging temperature in degrees Kelvin.
The graph shows that Amodel® PPA resins are thermally The advantage of analyzing the data in this manner is
stable beyond the recommended upper processing that the plot is theoretically a straight line and, therefore,
temperature limit of 350 °C (662 °F). easily extrapolated.
Figure 3.61 Thermogravimetric analysis Figure 3.62 shows the plot of tensile strength half-lives
of A-1000 in air of Amodel® AS-1133 HS resin and GR PA 6,6 versus
Temperature [ °F ] the aging temperature. Amodel® PPA maintains its tensile
500 600 700 800 900 1,000 1,100 1,200 strength longer than PA 6,6 does.

Figure 3.62 Thermal aging comparison - tensile

100
strength
80 Temperature [ °F ]
320 340 360 380 400 420 440
Weight [ % ]

60 100,000
AS-1133 HS
Time to tensile strength half-life

33% GR PA 6,6
40

20 10,000

0
250 300 350 400 450 500 550 600 650 1,000
Temperature [ °C ]

Thermal aging
100
Nearly all polymeric materials exhibit some loss of 150 160 170 180 190 200 210 220 230
performance properties after long-term exposure to Temperature [ °C ]
elevated temperatures. While some polymers are more
stable than others, the property loss is typically a function
of both exposure time and temperature. Because the
property losses result from both oxidative attack and
thermal degradation, the term “thermal oxidative stability”
is frequently used.

Amodel® PPA Design Guide / 47

 Figure 3.63 shows the thermal aging curves for notched The Relative Thermal Index or RTI is determined by a
Izod half-lives of Amodel® AS-1133 HS resin and GR PA statistical analysis of thermal aging data for the properties
6,6 versus aging temperature. Amodel® PPA also requires being evaluated. The RTI predicts the aging temperature
longer aging times before loss of impact resistance occurs that a material can endure for 100,000 hours and still
than the PA 6,6 resin. retain at least fifty percent of the initial property or
properties being measured.
Figure 3.63 Thermal aging comparison - Izod
impact Because the rate of decay is greater for thinner specimens,
UL gives RTI ratings for each thickness tested.
Temperature [ °F ]
320 340 360 380 400 420 440 To obtain a UL RTI rating, a long-term heat aging program
100,000 is performed. Sets of test specimens molded from
AS-1133 HS the material to be tested are put into ovens at preset
Time to tensile strength half-life

33% GR PA 6,6
temperatures. Periodically specimens are removed and
tested. The results for each aging temperature are plotted
10,000
on a time versus property graph, until the property being
measured has declined to 50 % or less of its initial value.
This combination of time and aging temperature can be
1,000 referred to as the “half-life” for that property, material,
and thickness.

The half-lives (time to 50 % or less) for a particular

100 property, which were experimentally determined at four
150 160 170 180 190 200 210 220 230 aging temperatures, are plotted against the reciprocal
Temperature [ °C ] of the absolute aging temperature. The points should
establish a straight line that can be extrapolated to predict
Thermal aging tests like this are used to compare plastic the half-life of the material for the particular property at
materials and to estimate their service life. The service other temperatures. This is called an “Arrhenius plot”.
life of a material at a particular end-use temperature
will be largely dependent upon the requirements of the To estimate the RTI for the material, the best-fit straight
application and should be judged on the basis of its heat line is drawn through the four half-life points for tensile
aging data and actual or simulated end-use testing. strength and extended to 100,000 hours. The temperature
at which this line crosses the 100,000 hours line is an
Relative thermal index (UL) estimate of the RTI for the material. If only three half-life
A primary function of Underwriters Laboratories Inc is points are available, such as when the data for the fourth
to assist in the assessment of the risk of fire associated temperature is still under test, then a provisional RTI can
with electrical devices. Because insulating materials be granted. The RTI assigned by UL may be somewhat
may deteriorate over time some method of evaluating lower as statistical methods are used to compensate for
this tendency and providing guidance to designers and experimental variability.
users of electrical devices was required. Underwriters
Testing of Amodel® resins for the establishment of UL
Laboratories (UL) has developed a method and rating
Relative Thermal Indices is a continuing long-term activity.
system for this purpose. This method is UL Standard
The UL ratings of some Amodel® resins when this manual
746B, Polymeric Materials, Long-Term Property
was printed are shown in Table 3.18. Because this testing
Evaluation. A similar method is ASTM D3045, Standard
is ongoing, the Underwriters Laboratories website
Practice for Heat Aging of Plastics Without Load.
(http://data.ul.com) should be consulted for the latest RTI’s.
Based on the results of aging tests as described in the
previous section, Underwriters Laboratories assigns a
rating called the “Relative Thermal Index” to insulating
materials. Because all material properties do not decay
at the same rate, a material may have different Relative
Thermal Indices for electrical properties, mechanical
properties without impact, and mechanical properties
with impact.

48 \ Amodel® PPA Design Guide

Table 3.18 Relative thermal indices of Amodel® PPA grades
Relative Thermal Index (RTI)
Mechanical
Thickness Electrical With Impact Without Impact
Grade Color [mm] [°C (°F)] [°C (°F)] [°C (°F)]
AFA-4133 V0 Z All 0.75 130 (266) 130 (266) 130 (266)
1.5 130 (266) 130 (266) 130 (266)
3.0 130 (266) 130 (266) 130 (266)
AFA-6133 V0 Z All 0.75 130 (266) 130 (266) 130 (266)
1.5 130 (266F) 130 (266) 130 (266)
3.0 130 (266) 130 (266) 130 (266)
AFA-6145 V0 Z All 0.75 140 (284) – 130 (266)
1.5 140 (284) – 130 (266)
3.0 140 (284) 140 (284) 140 (284)

Combustion Properties Table 3.19 UL definitions of GWIT and GWFT

This section describes the resistance of Amodel® IEC Glow-Wire Ignitability Temperature (GWIT)
resins to burning and ignition, and the smoke density In accordance with IEC 695-2-1/3, is expressed as the
characteristics of the material once it has been ignited. temperature (in °C), which is 25 °C hotter than the maximum
temperature of the tip of the glow wire which does not cause
Described below are glow wire test results, classifications
ignition of the material during three subsequent tests
according to UL 94 and ASTM smoke density test results.
IEC Glow-Wire Flammability Temperature (GWFT)
Glow wire testing In accordance with IEC 695-2-1/2, is expressed as the highest
temperature (in °C) at which, during three subsequent tests,
The ability to support and sustain ignition in plastic
flaming or glowing of the test specimen extinguish within 30
materials may be characterized by the standardized glow seconds after removal of the glow wire without ignition of the
wire test. This test simulates conditions present when indicator by burning drips or particles.
an exposed, current carrying conductor contacts an
insulating material during faulty or overloaded operation. Amodel® resins have passed glow wire testing as shown
The test method followed is referenced in IEC 695-2-1/3. in Table 3.20.
The glow wire test apparatus consists of a loop of heavy
gauge nickel-chromium resistance wire, a thermocouple, Table 3.20 G
 low wire results
and a sample mounting bracket. GWIT GWFT
During the test, an electrical current is passed through a Grade (1)
[°C (°F)] [°C (°F)]
nickel-chromium loop in order to obtain a predetermined A(AS)-1133 HS 725 (1,337) 725 (1,337)
temperature. The sample is then brought in contact AT-6115 HS 750 (1,382) 800 (1,472)
with the wire for 30 seconds. The test is passed if after AT-6130 725 (1,337) 750 (1,382)
withdrawal, the sample displays no flame or glowing, AS-1566 HS 775 (1,427) 800 (1,472)
or if so, it is self-extinguishing after 30 seconds.
AS-4133 HS 750 (1,382) 750 (1,382)
The test can be applied at one or more recommended AFA-6133 V0 Z 960 (1,760) 960 (1,760)
temperatures and at any wall thickness needed. (1)
All samples tested at 0.8 mm (0.031 in.) thickness
Recommended temperatures are 550 °C (1022 °F),
650 °C (1202 °F), 750 °C (1382 °F), 850 °C (1562 °F), and
960 °C (1760 °F). Thickness is usually mandated by the
design or the requirements of the device. It is most difficult
to resist ignition at the high glow wire temperature and
thinner wall sections.

The UL definitions for the parameters usually reported

are shown in Table 3.19.

Amodel® PPA Design Guide / 49

 Smoke density test (NBS) Horizontal burning test
When a material burns, smoke is generated. The quantity For a 94HB classification rating, injection molded test
and density of the generated smoke is important in many specimens are limited to a 125 mm length, 13 mm width
applications. ASTM E662, Standard Test Method for and the minimum thickness for which the rating is desired.
Specific Optical Density of Smoke Generated by Solid The samples are clamped in a horizontal position with
Materials, provides a standard technique for evaluating a 20-mm blue flame applied to the unclamped edge of
relative smoke density. This test was originally developed the specimen at a 45 degree angle for 30 seconds or so
by the National Bureau of Standards (NBS), and is often as soon as the combustion front reaches a premarked
referred to as the NBS Smoke Density test. The data line 25-mm from the edge of the bar. After the flame is
in Table 3.21 was generated in both flaming and non- removed, the rate of burn for the combustion front to
flaming modes. A six-tube burner is used to apply a row travel from the 25-mm line to a premarked 100-mm line
of flamelets across the lower edge of the specimen. A is calculated. At least three specimens are tested in this
photometric system aimed vertically is used to measure manner. A plastic obtains an HB rating by not exceeding a
light transmittance as the smoke accumulates. The burn rate of 40 mm/min for specimens having a thickness
specific optical density (Ds) is calculated from the light greater than 3 mm or 75 mm/min for bars less than 3 mm
transmittance. The maximum optical density is called Dm. thick. The rating is also extended to products that do not
support combustion to the 100-mm reference mark.
Table 3.21 Smoke density
Amodel® AS-1133 HS resin has obtained a 94HB rating
Grade Ds at 4 min Dm Dm Corr. in the Horizontal Burning Test, at thicknesses down
Flaming Mode to 0.8 mm in a black color.
AS-1133 HS 565 510 469
50W (20 mm) Vertical burn test
Non-Flaming Mode
Materials can be classified V-0, V-1, or V-2 on the basis
AS-1133 HS 3 162 162
of results obtained from the combustion of samples
clamped in a vertical position. The 50W (20 mm) Vertical
Vertical flammability per UL 94 Burn Test is more aggressive than the HB test and is done
on samples that measure 125 mm long, 13 mm wide,
The UL 94 flammability standard established by
and the minimum thickness at which the rating is desired
Underwriters Laboratories is a system by which plastic
(typically 0.8 mm or 1.57 mm). The samples are clamped
materials can be classified with respect to their ability
in a vertical position with a 20-mm high blue flame applied
to withstand combustion. The flammability rating given
to the lower edge of the clamped specimen. The flame is
to a plastic material is dependent upon the response
applied for 10 seconds and removed. When the specimen
of the material to heat and flame under controlled
stops burning, the flame is reapplied for an additional 10
laboratory conditions and serves as a preliminary
seconds and then removed. A total of five bars are tested
indicator of its acceptability with respect to flammability
in this manner. Table 3.22 lists the criteria by which a
for a particular application. The actual response to heat
material is classified in this test.
and flame of a thermoplastic depends on other factors
such as the size, form, and end-use of the product
Table 3.22 UL Criteria for classifying materials
using the material. Additionally, characteristics in
V-0, V-1, or V-2
end-use application such as ease of ignition, burning rate,
flame spread, fuel contribution, intensity of burning, Criteria Conditions V-0 V-1 V-2
and products of combustion will affect the combustion Afterflame time for each
response of the material. individual specimen, ≤ 10s ≤ 30s ≤ 30s
(t1 or t2)
Three primary test methods comprise the UL 94 standard: Total afterflame time for
Horizontal Burning Test, the 50W (20 mm) Vertical Burning any condition set (t1 + t2 ≤ 50s ≤ 250s ≤ 250s
Test, and the 500W (125 mm) Vertical Burning Test. for the 5 specimens)
Afterflame plus afterglow
time for each individual
specimen after the ≤ 30s ≤ 60s ≤ 60s
second flame application
(t2 + t3)
Afterflame or afterglow of
any specimen up to the No No No
holding clamp
Cotton indicator ignited
by flaming particles or No No Yes
drops

50 \ Amodel® PPA Design Guide

500 W Vertical burning test Electrical Properties
A material which passes the flammability requirements Many applications for thermoplastic resins depend upon
established by the 500 W Vertical Burning Test earns their ability to function as electrical insulators. A wide
either a 5VA or 5VB rating. This particular test is the most variety of tests have been developed to measure specific
severe of the three described. The dimensions of the aspects of material performance in electrical applications.
molded bars used in this test are identical to those used A brief description of some of the more common tests are
for the 20 MM Vertical Burning Test. Additionally, plaques covered in this next section.
are required that measure 150 mm by 150 mm by the
minimum and maximum thicknesses required for the Dielectric Breakdown Voltage and Strength -
application. The bars are clamped in a vertical position ASTM D149
with a 125-mm high flame applied five times for five Dielectric strength is a measure of the ability of a material
seconds each time with a five second interval between to resist high voltage without dielectric breakdown. It is
each application. The plaques are clamped in a horizontal, measured by placing a specimen between two electrodes
flat position with a 125-mm high flame applied to the and increasing the applied voltage until dielectric breakdown
bottom surface at a 20° angle using the same burn times occurs. The dielectric strength is reported at the highest
described for the bars. Table 3.23 lists the criteria that voltage prior to failure. Of the various methods included in
must be met to obtain a 5VA or 5VB rating. ASTM D149, UL 746A specifies the short-time test using
a uniform rate of voltage increase of 500 volts per second.
Table 3.23 UL Criteria for classifying materials
5VA or 5VB Although the results are reported in units of kV/mm (volts/
mil), the dielectric strength is a function of thickness,
Criteria Conditions 5VA 5VB
moisture content, and temperature. Therefore, data on
Afterflame time plus afterglow time
different materials are comparable only for equivalent
after fifth flame application for each ≤ 60s ≤ 60s
individual bar specimen sample thickness, moisture content, and test temperature.
Cotton indicator ignited by flaming Table 3.24 shows the dielectric strengths of several
particles or drops from any bar No No
Amodel® grades. The dielectric strength of samples
specimen
conditioned to 50 % RH are the same as the dry as
Burn-through (hole) of any plaque
No Yes molded samples.
specimen

Table 3.24 Dielectric strength of selected

Table 3.24 lists the current UL 94 ratings of some Amodel® grades
Amodel® resins. Because ratings may change and
additional products rated please consult the Underwriters Thickness
Laboratories website for the latest information. 3.2 mm 1.6 mm
( 0.125 in.) ( 0.063 in.)
Table 3.24 UL 94 Ratings of Amodel® PPA grades kV/ V/ kV/ V/
Grade Cond.(1) mm mil mm mil
Thickness UL 94
Grade Color [mm] Rating A-1133 HS Dry 21 533 32 813

AFA-4133 V0 Z All 0.75 V-0 A-1133 HS 50 % RH 21 533 – –

1.5 V-0 A-1145 HS Dry 23 584 – –

3.0 V-0 A-1145 HS 50 % RH 23 584 – –

AS-4133 HS Dry 21 533 32 813
AFA-6133 V0 Z All 0.75 V-0
AS-4133 HS 50 % RH 21 533 – –
1.5 V-0
AT-1002 HS Dry 17 432 – –
3.0 V-0
AT-1002 HS 50 % RH 17 432 – –
AFA-6145 V0 Z All 0.75 V-0
AT-5001 Dry 17 432 – –
1.5 V-0
AT-5001 50 % RH 17 432 – –
3.0 V-0
AT-6115 HS Dry – – 28 711
AFA-6133 V0 Z Dry 24 610 27 686
A-1340 HS Dry – – 32 813
AS-1566 HS Dry – – 29 737
(1)
Condition: dry is dry as molded, 50 % RH is moisture
conditioned as described on page 8

Amodel® PPA Design Guide / 51

 Volume Resistivity - ASTM D257 Table 3.25 Volume and surface resistivity of
The volume resistivity of a material is defined as the Amodel® resins
electrical resistance of a unit cube of material. The Volume Surface
material is subjected to 500 volts DC for 1 minute, and Resistivity Resistivity
the current through the material is measured. Materials Grade Cond.(1) [ohm-cm] [ohm]
with higher volume resistivity are more effective at A-1133 HS Dry 1 x 1016 1 x 1015
electrically isolating components. A-1133 HS 50 % RH 2 x 1015 –

UL 746A specifies that the test be run on two sets A-1145 HS Dry 1 x 1016 –
15
of specimens: one set conditioned for 48 hours at A-1145 HS 50 % RH 2 x 10 –
16 15
23 °C (73 °F) and 50 % relative humidity; and the other AS-4133 HS Dry 1 x 10 1 x 10
conditioned for 96 hours at 35 °C (95 °F) and 90 % AS-4133 HS 50 % RH 5 x 1014 –
relative humidity. AT-1002 HS Dry 1 x 1016
8 x 1013

14
Volume resistivity is particularly sensitive to temperature AT-1002 HS 50 % RH 7 x 10 2 x 1013
15
changes as well as changes in humidity. Data on different AT-5001 Dry 4 x 10 4 x 1015
materials are comparable only for equivalent moisture AT-5001 50 % RH 2 x 1015 2 x 1015
content and temperatures. Materials with resistivities AT-6115 HS Dry 1 x 1016 1 x 1015
above 108 ohm-cm are considered insulators, while those AFA-6133 V0 Z Dry 1 x 1016
1 x 1015
with values of 103 to 108 ohm-cm are partial conductors.
A-1240 L Dry 9 x 1015 –

Surface Resistivity - ASTM D257 A-1240 L 50 % RH 2 x 1015 –

16
The surface resistivity of a material is the electrical A-1340 HS Dry 1 x 10 –
16 15
resistance between two electrodes on the surface of A-1340 HS 50 % RH 1 x 10 1 x 10
the specimen. The material is subjected to 500 volts DC A-1565 HS Dry 4 x 1014 –
for 1 minute, and the current along the surface of the AS-1566 HS Dry 1 x 1016
1 x 1015

material is measured. Although some finite thickness of (1)

Condition: dry is dry as molded, 50 % RH is moisture
material is actually carrying the current, this thickness is conditioned as described on page 8
not measurable; therefore, this property is an approximate
measure. Surface resistivity is affected by surface Dielectric Constant - ASTM D150
contamination and is not considered a basic material
The dielectric constant is defined as the ratio of the
property. UL specifies the same specimen conditioning
capacitance of a condenser using the test material as the
used for volume resistivity. Data from this test are best
dielectric to the capacitance of the same condenser with
used to compare materials for use in applications where
a vacuum replacing the dielectric. Insulating materials
surface leakage is a concern.
are used in two very distinct ways. First, to support and
insulate components from each other and the ground,
and second, to function as a capacitor dielectric. In the
first case, it is desirable to have a low dielectric constant.
In the second case, a high dielectric constant allows the
capacitor to be physically smaller. Dielectric constants
have been found to change rapidly with increasing
temperature or moisture contents, hence data on different
materials are comparable only at equivalent moisture
content and temperature.

52 \ Amodel® PPA Design Guide

Table 3.26 Dielectric constant of Amodel® resins Table 3.27 Dissipation factor of Amodel® resins
Frequency [Hz] Frequency [Hz]
Grade Cond.(1) 60 100 10 6 10 9 Grade Cond.(1) 60 100 10 6 10 9
A-1133 HS Dry 4.4 5.1 4.2 3.7 A-1133 HS Dry 0.005 – 0.017 0.016
A-1133 HS 50 % RH 4.7 – 4.3 – A-1133 HS 50 % RH 0.009 – 0.022 –
A-1145 HS Dry 4.6 – 4.4 – A-1145 HS Dry 0.005 – 0.016 –
A-1145 HS 50 % RH 4.9 – 4.5 – A-1145 HS 50 % RH 0.009 – 0.021 –
AS-4133 HS Dry 3.8 4.6 3.6 3.6 AS-4133 HS Dry 0.004 – 0.012 0.013
AS-4133 HS 50 % RH 4.3 – 3.4 – AS-4133 HS 50 % RH 0.020 – 0.019 –
AT-1002 HS Dry 3.3 – 3.3 – AT-1002 HS Dry 0.004 – 0.016 –
AT-1002 HS 50 % RH 3.8 – 3.8 – AT-1002 HS 50 % RH 0.018 – 0.035 –
AT-5001 Dry 3.2 – 3.2 – AT-5001 Dry 0.004 – 0.016 –
AT-5001 50 % RH 3.6 – 3.6 – AT-5001 50 % RH 0.012 – 0.027 –
AT-6115 HS Dry – 4.0 3.3 3.1 AT-6115 HS Dry – – 0.013 0.011
AFA-6133 V0 Z Dry – 4.8 4.1 3.7 AFA-6133 V0 Z Dry – – 0.011 –
A-1240L Dry – 4.2 4.0 – A-1240L Dry – 0.006 0.017 –
A-1240L 50 % RH – 4.4 4.0 – A-1240L 50 % RH – 0.007 0.019 –
A-1340 HS Dry – 4.5 4.3 – A-1340 HS Dry – 0.005 0.017 –
A-1340 HS 50 % RH – 4.5 4.3 3.8 A-1340 HS 50 % RH – 0.008 0.017 0.014
AS-1566 HS Dry – 5.7 4.7 4.5 AS-1566 HS Dry – – 0.011 0.011
(1) (1)
Condition: dry is dry as molded, 50 % RH is moisture Condition: dry is dry as molded, 50 % RH is moisture
conditioned as described on page 8 conditioned as described on page 8

Dissipation Factor - ASTM D150 High-Voltage, Low-Current, Dry Arc Resistance

Dissipation Factor (also referred to as loss tangent or – ASTM D495
tan delta) is a measure of the dielectric loss, or energy This test measures the time, in seconds, that a 12,500 volt
dissipated, when alternating current loses energy to an arc can travel between two tungsten rod electrodes on the
insulator. In general, low dissipation factors are desirable surface of a material, following a specified test sequence
because they correspond to a better dielectric material. of increasing severity, until a conductive path or track is
Contamination, testing frequency, temperature, and formed. This test is intended to approximate service
humidity can affect the dissipation factor. conditions in alternating-current circuits operating at high
voltage with currents generally limited to less than 0.1
UL 746A Short-Term Properties ampere. Table 3.28 shows the relationship between the
Certain electrical properties are included in the arc resistance and the UL assigned Performance Level
Underwriters Laboratories (UL) Standard 746A entitled Categories.
Standard for Polymeric Materials Short-term Property
Evaluations and these properties are reported by
Table 3.28 High-voltage, low-current, dry arc
“Performance Level Category” (PLC). For each property,
resistance performance level categories (PLC)
UL has specified test result ranges and corresponding
Performance Level Categories (PLC). Desired or best Value Range [Sec.]
performance is assigned to a PLC of 0; therefore, the > < Assigned PLC
lower the PLC, the better the performance in that test. 420 0
360 420 1
300 360 2
240 300 3
180 240 4
120 180 5
60 120 6
0 60 7

Amodel® PPA Design Guide / 53

 Comparative Tracking Index (CTI) – ASTM D3638 Hot Wire Ignition (HWI) - ASTM D3874
The Comparative Tracking Index is defined as the voltage This test measures the relative resistance of plastic
that causes the formation of a permanent electrically materials to ignition by an electrically heated wire. A
conductive carbon path when 50 drops of electrolyte portion of a test specimen is wrapped with a heater
are applied at a rate of 1 drop every 30 seconds. This wire under specified conditions and a current is passed
test measures the susceptibility of an insulating material through the wire at a linear power density of 2.6 W/mm
to tracking. Table 3.29 shows the relationship between (65 W/in.). The current flow is maintained until ignition
the voltage obtained and the PLC. occurs, and the time to ignition is recorded.

Under certain operational or malfunction conditions,

Table 3.29 Comparative tracking index performance
components become abnormally hot. If these overheated
level categories
components are in intimate contact with the insulating
Value Range [Volts] materials, the insulating material may ignite. The intention
> < Assigned PLC of this test is to determine relative resistance of insulating
600 0 materials to ignition under these conditions. Table 3.31
400 600 1
shows the hot wire ignition times and the assigned PLC.
250 400 2
Table 3.31 Hot wire ignition performance level
175 250 3
categories
100 175 4
0 100 5
Value Range [Sec.]
< > Assigned PLC
High-Voltage Arc-Tracking-Rate (HVTR) 120 0
120 60 1
This test measures the susceptibility of an insulating
60 30 2
material to form a visible carbonized conducting path
(track) over its surface when subjected to repeated high- 30 15 3
voltage, low-current arcing. The value of the high-voltage, 15 7 4
arc-tracking rate is the rate, in mm/minute, at which a 7 0 5
conducting path is produced on the surface of a material
under standardized test conditions. This test simulates
a malfunctioning high-voltage power supply with lower
values indicating better performance. Table 3.30 shows
the HVTR values and the corresponding PLC.

Table 3.30 High-voltage arc-tracking-rate

performance level categories
Value Range [mm/min]
> < Assigned PLC
0 10 0
10 25.4 1
25.4 80 2
80 150 3
150 4

54 \ Amodel® PPA Design Guide

High-Current Arc Ignition (HAI) The relationship between the mean time to ignition and
This test measures the relative resistance of insulating the Performance Level Categories is given in Table 3.33.
materials to ignition from arcing electrical sources. Under Table 3.33 High voltage arc resistance to ignition
certain conditions, insulating materials may be in proximity performance level categories
to arcing. If the intensity and duration of the arcing are
severe, the insulating material can ignite. This test measures HVAR - Mean Time to Ignition [Sec.]
the number of 240-volt 32.5 ampere arcs on the surface < > Assigned PLC
of a material required to cause ignition or a hole. The 300 0
distance between the electrodes in increased at a rate 300 120 1
of 254 mm (10 in.) per second. The maximum number 120 30 2
of arcs to be used is 200.
30 0 3
This test measures the performance of an insulating
material in close proximity to arcing. UL 746A Properties of Amodel® Resins
Table 3.32 shows the relationship between the Selected UL 746A properties for selected Amodel® grades
High-Current Arc Ignition value and the UL assigned are shown in Table 3.34. The grades selected are the ones
Performance Level Categories. most often used for electrically insulating applications.

Table 3.32 High-current arc ignition performance Table 3.34 UL 746A property PLC for Amodel® PPA
level categories grades
Value Range [Sec.] Grade mm(1) HWI HAI HVTR CTI
< > Assigned PLC A(AS)-1133 HS 0.80 0 0 4 0
(2)
120 0 AT-6115 HS 0.80 0 0 1 0
120 60 1 AT-6130 0.80 4 0 1 0
60 30 2 AS-1566 HS 0.80 – 0 0 0
(2)
30 15 3 A-1340 HS 0.80 0 0 1 1
15 7 4 AS-4133 HS 0.80 0(2) 0 1 0
7 0 5 AFA-4133 V0 Z 0.75 0 0 1 1
AFA-6133 V0 Z 0.75 0 0 1 1

High-Voltage Arc Resistance to Ignition AFA-6145 V0 Z 0.75 0 1 – 1

This test measures the susceptibility of a material to (1)

Minimum thickness, mm
resist ignition or form a visible carbonized conducting
(2)
This value measured at 1.5 mm thickness

path when subjected to high-voltage, low-current arcing.

The application of the high-voltage arc is continued UL Relative Thermal Indices
until ignition, a hole is burned through the specimen, The UL Relative Thermal Indices are the result of thermal
or 5 minutes. If ignition occurs, the time to ignition is aging tests and, therefore, appear in the Thermal Stability
reported. If ignition does not occur the value > 300 section on page 49.
is reported.

Amodel® PPA Design Guide / 55

 Environmental Resistance The material performance was rated as shown in Table
3.35. In addition to the performance rating, data on the
As previously mentioned, the performance of polymeric
percent change in tensile strength, length, and weight are
materials may be reduced by environmental factors. This
reported.
section discusses the effects of environmental factors
on the performance of Amodel® resins such as chemical
exposure, conditions likely to promote hydrolysis, and Table 3.35 Key
 to chemical resistance ratings
exposure to gamma and/or ultraviolet radiation. When Reduction in
appropriate, the effects of these environmental factors Symbol Rating Tensile Strength [%]
on the performance of competitive resins is included for E Excellent ≤ 10
comparison.
A Acceptable ≤ 50 but ≥ 10

Chemical Resistance U Unacceptable > 50

Amodel® resins are semi-crystalline polyphthalamides,

and like other members of the semi-crystalline polyamide
The chemicals used for the screening tests were classified
family, they exhibit excellent chemical resistance to
into three groups:
common organic solvents. However, the chemical
structure of Amodel® resins is highly aromatic, imparting • Organic solvents (Table 3.36)
an even greater degree of chemical resistance to an even • Aqueous solutions (Table 3.37)
broader range of chemicals.
• Automotive fluids (Table 3.38)
It is difficult to predict the exact effect of chemical
The screening evaluation using aqueous solutions at
exposure on a polymeric component because the
elevated temperatures showed a loss in tensile strength
reagent, the concentration of the reagent, the exposure
for all three of the resins tested. This phenomenon is
time, the temperature of the reagent, the temperature
common to all glass reinforced thermoplastics. The
of the polymeric component, and the stress on the
loss of tensile strength for Amodel® AS-1133 HS resin in
component all affect the extent of attack and any
deionized water at 93 °C (200 °F) is initially rapid due to
change in performance. While the only reliable method
loss of interfacial adhesion between the glass fibers and
for evaluating the effect of chemical attack on the
the resin matrix, and then slows to a gradual rate reflecting
performance of a polymeric component is prototype
hydrolytic attack. Aqueous solutions of antifreeze or
testing; screening tests are often performed to provide
zinc chloride produce a similar effect. PA 6,6 is severely
general guidance and compare materials.
attacked by the zinc chloride solution. PET is severely
Screening chemical resistance testing was performed attacked by the antifreeze solution and even badly
by immersing ASTM D638 Type I tensile bars in hydrolyzed by distilled water at elevated temperatures.
various chemicals for 30 days at the indicated test
temperatures. The Amodel® AS-1133 HS resin used was
the 33 % fiber glass reinforced grade. Data on 33 % glass
reinforced PA 6,6 and 30 % glass reinforced polyethylene
terephthalate (PET) is provided for comparison.

56 \ Amodel® PPA Design Guide

Table 3.36 Resistance to 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 E 97 0.0 0.4
Freon 113
®
Amodel AS-1133 HS
®
E 96 0.0 0.1
33 % Glass PA 6,6 E 99 0.0 0.2
n-Heptane Amodel® AS-1133 HS E 104 0.0 0.1
33 % Glass PA 6,6 E 96 0.0 0.2

Freon is a registered trademark of E. I. duPont de Nemours and Company.

Amodel® PPA Design Guide / 57

 Table 3.37 Resistance to aqueous chemical solutions — 30 day immersion at indicated temperature

Tensile
Conc. Temperature Strength Change in Change in
Reagent [%] [°C (°F)] Resin Rating Retained [%] Length [%] Weight [%]
Ammonium 10  23 (73) Amodel® AS-1133 HS E 96 0.1 0.8
hydroxide
33 % Glass PA 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 A 62 0.0 3.1
30 % Glass PET A 70 0.0 -4.2
Sodium 5 23 (73) Amodel® A-1133 HS E 94 0.0 1.4
hypochlorite
33 % Glass PA 6,6 A 57 0.0 -1.5
30 % Glass PET E 94 0.0 0.4

* Attacked

58 \ Amodel® PPA Design Guide

Table 3.38 Resistance to 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 104 (220) Amodel® AS-1133 HS A 77 0.2 5.6
solution 33 % Glass PA 6,6 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 6,6 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 6,6 E 100 0.0 0.3
30 % Glass PET E 100 -0.1 0.0
Gasohol (10 % 23 (73) Amodel AS-1133 HS
®
A 86 0.0 1.4
ethanol) 33 % Glass PA 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 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 6,6 E 99 0.1 0.1
30 % Glass filled PET E 99 0.0 0.1

* Attacked

Amodel® PPA Design Guide / 59

 Chemical Compatibility Table 3.39 General chemical compatibility
Table 3.39 can be used as a general guide to the guidelines for Amodel® PPA resins
chemical resistance of Amodel® resins. However, this Reagent Rating
data should be used for screening only. As mentioned
Aliphatic hydrocarbons E
earlier, the performance of Amodel® resins under actual
Aromatic hydrocarbons E
chemical exposure conditions will vary with differences
Oils E
in mechanical stress, concentration, time and/or
temperature. It is recommended that tests be conducted Greases E
under conditions close to those anticipated in the actual Chlorinated hydrocarbons E
application to get reliable performance information. Methylene chloride A
Chloro-fluoro carbons E
Gamma Radiation
Ketones E
Amodel® AS-1133 HS resin has excellent resistance to
Esters E
gamma radiation. Tests on injection molded tensile bars
Higher alcohols E
exposed to 5.0 megarads of gamma radiation indicate
Methanol A
essentially no significant affect on the mechanical
properties of Amodel® AS-1133 HS resin. Results are Phenols U
given in Table 3.40. Strong acids A
Alkalis E

Table 3.40 Effect of gamma radiation on Amodel®

AS-1133 HS
 % Retention of 5 mrad Exposure
Tensile strength [psi (kPa)] 90 (620)
Tensile elongation [%] 100

60 \ Amodel® PPA Design Guide

 Design Information

In this section, basic design principles and general Table 4.1 Design benefits of Amodel® resin over
recommendations are presented to assist the design metals
engineer in designing plastic components that meet
the cost/performance requirements of their applications. Amodel® Resin
Characteristics Benefit in Design
Guidelines are given on the effects of stresses caused
by assembly, temperature changes, environmental factors, Amodel resins are fabricated
®
Ribs, bosses, or cored
by the injection molding sections can be readily
and time as it relates to creep. process, which allows incorporated.
substantial design freedom
Of the various materials available to a design engineer,
Snap fits can be molded in,
thermoplastics offer the greatest variety, versatility
simplifying assembly.
and freedom of design. Plastics can be translucent or
Eliminate many secondary
opaque, rigid or flexible, hard or soft. Plastic materials are operations such as drilling,
available that provide a wide range of chemical resistance, tapping, boring, deburring,
from chemically inert to selective solubility in certain and grinding.
environments. Broad versatility is also available for other Metal inserts can be easily
properties like strength, stiffness and impact resistance, used where necessary to
optimize part strength.
lubricity and thermal capability. Blends and alloys are
possible that further increase the material choices for a Features from several metal
parts of an assembly may be
particular application. combined into a single part,
simplifying assembly and
At times, designing with plastics may appear more reducing cost.
complicated than with metals. But the diversity of
Amodel® resins Parts may be joined with
products, conversion processes, and secondary are thermoplastic ultrasonic or vibration
operations (welding, inserts, printing, painting, metallizing) welding rather than fasteners.
available with plastics gives the designer unprecedented Color may be molded-in
freedom as shown in Table 4.1. rather than added afterward
as paint.
A designer may be tempted to make a plastic part that Amodel® resins resist Parts will not rust, and resist
merely duplicates the dimensions of a metal part without chemicals corrosion.
taking advantage of the versatility of the plastic material
or the design freedom offered. This approach can lead
to inefficient designs or parts that are difficult to produce,
or whose performance is less than optimal.

The following sections discuss those areas of mechanical

design and stress analysis that relate to designing with
plastics, comparing metal to plastics and discussing
factors that are specific to plastics alone.

Amodel® PPA Design Guide / 61

 Mechanical Design
The use of classical stress and deflection equations
provide starting points for part design. Mechanical design
calculations 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. 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 to determine

the loads the part will be subjected to, and to calculate
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
assembly 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 bearing 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.

62 \ Amodel® PPA Design Guide

Figure 4.1 Maximum stress and deflection equations
Simply supported beam Cantilevered beam ( one end fixed )
Concentrated load at center Concentrated load at free end

F
FL F FL
σ= σ=
4Z Z
( at load ) ( at support )

FL3 FL3
Y= L Y=
48EI Y 8EI
L Y
( at load ) ( at load )

Simply supported beam Cantilevered beam ( one end fixed )

Uniformly distributed load Uniformly distributed load

F ( total load ) F ( total load )

FL FL
σ= σ=
8Z 2Z
( at center ) ( at support )

5FL3 FL3
Y= Y=
384EI 8EI
L L
( at center ) Y ( at support )
Y

Both ends fixed Both ends fixed

Concentrated load at center Uniformly distributed load

F F ( total load )
½L
FL Y FL
σ= σ=
8Z 12Z
( at supports ) ( at supports )

FL3 FL3
L Y Y= Y=
192EI L 384EI
( at load ) ( at center )

Amodel® PPA Design Guide / 63

 Figure 4.2 Area and moment equations for selected cross sections

Rectangular I-beam

t A = bd – h (b – t )
A = bd
d
d c=
c= 2
na 2
d
d bd3 – h3 (b – t )
bd3 na h I=
c I= 12
12 c
bd3 – h3 (b – t )
bd2 s Z=
Z= 6d
b 6
b

Circular H-beam

πd2 A = bd – h (b – t )
A= s h
4 b
c=
d 2
c=
na d 2 2sb3 + ht3
b na I=
πd4 12
c I= c
64
2sb3 + ht3
Z=
πd3 t 6b
Z= d
32

Tube Hollow rectangular

π ( d o2 – d i 2 ) A = b1d1 – b2d2
A=
4 d1
c=
d 2
c= o na d1
na di do 2
d2 b1d13 – b2d23
c b2 I=
c π ( d o4 – d i 4 ) 12
I=
64
b1d13 – b2d23
Z=
π ( d o4 – d i 4 ) b1 6d1
Z=
32do

T-beam or rib U-beam

s A = bs + ht A = bd – h (b – t )
b s h
2b2s + ht2
c=b–
d2t + s2 ( b – t ) 2A
na c=d– c
2 ( bs + ht ) t
d na 2b3s + ht3
b I= – A ( b – c )2
h c 3
I
Z= I
c Z=
c
t
d
tc3 + b ( d – c )3 – ( b – t ) ( d – c – s )3
I=
3

64 \ Amodel® PPA Design Guide

Using Classical Stress/Strain Equations Also, the impact resistance of a design is directly
related to its ability to absorb impact energy without
To use the classical equations, the following simplifying
fracture. It is difficult to predict the ability of a design to
assumptions are necessary:
absorb energy. In addition, even armed with the energy
• The part can be analyzed as one absorption requirements, practical toughness constants
or more simple structures for engineering resins don’t exist. The results of laboratory
• The material can be considered linearly testing vary with the type and speed of the impact test,
elastic and isotropic even for fixed geometries. Therefore, the ability of the
design to withstand impact must be checked by impact
• The load is a single concentrated or distributed
testing of prototype parts.
static load gradually applied for a short time
• The part has low residual or molded-in stresses Similarly, fatigue test results will vary depending on the
cyclic rate chosen for the test, the dynamics of the test,
While all of these assumptions may not be strictly valid for
and the test specimen used. Therefore, they should only
a particular situation, the classical equations can provide
be used as a rough indication of a material’s ability to
a starting point for analysis. The design engineer can then
perform in a fatigue application.
modify the analysis to take into consideration the effects
of the simplifying assumptions. Deflection Calculations
A variety of parts can be analyzed using a beam bending To determine the deflection of a proposed part design
model. Figure 4.1 lists the equations for maximum stress using classical equations, a modulus of elasticity value
and deflection for some selected beams. is required. It is important that the appropriate value
be used. The value must represent the modulus of the
The maximum stress (σ) occurs at the surface of the material at or near the temperature and humidity expected
beam furthest from the neutral surface and is given by: in the application. Room and elevated temperature values
can be found in the property tables on pages 7 to 20. If
σ = Mc = M the load is sustained, then the apparent or creep modulus
I Z
should be used. Values are given in the isochronous
Where: stress/strain curves, in Figures 3.40 and 3.41 on page
M = Bending moment, N · m (in.lb) 35.
c = Distance from neutral axis, m (in.)
I = Moment of inertia, m4 (in.4 ) Stress Calculations
Z = I = Section modulus, m3 (in.3 ) After the designer has calculated the maximum stress,
c
those values are then compared to the appropriate
Figure 4.2 gives the cross-sectional area (A), the moment material property, i.e., tensile, compressive, or shear
of inertia (I), the distance from the neutral axis (c), and the strength. The comparison should be appropriate in terms
section modulus (Z) for some common cross sections. of temperature and humidity to the requirements of the
For other cross-sections and/or geometries, the design application.
engineer can consult stress analysis handbooks or
Reinforcing Fiber Orientation Considerations
employ finite element analysis.
When designing with plastics, especially filled plastics,
Limitations of Design Calculations the designer must be cognizant of the effects of the fillers
The designs given by the application of the classical and reinforcing fibers on the mechanical properties of the
mechanical design equations are useful as starting plastic. The processing of filled plastics tends to cause
points, but some critical factors are simply not adequately orientation of fibers or high-aspect-ratio fillers parallel to
considered by these analyses. The viscoelastic behavior the direction of flow. Throughout this manual, properties
of polymeric materials limits application of some of the have been given both with and across flow direction
design equations to, for example, low deflection cases. whenever practical.
Often the calculation of maximum stress contains a Since the design of the part and the processing are
number of simplifying assumptions that can diminish interrelated, the designer should consider what portions
the credibility of the results, or the expected failure mode of the part are likely to be oriented and how the properties
is buckling or shear, where the appropriate property data will be affected. Shrinkage, strength, stiffness, and
is lacking. 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 orientation, the fibers act
more as fillers than as reinforcing agents.

Amodel® PPA Design Guide / 65

 When molding polymers, there are instances where melt If the metal part were magnesium having a modulus of
fronts meet (commonly known as weld lines) such as elasticity E of 44.8 GPa (6.5 Mpsi) and the thermoplastic
when the plastic melt flows around a core pin. However, chosen to replace it was Amodel® AS-1145 HS resin
the reinforcement in the plastic, if present, does not having a modulus of elasticity of 13.8 GPa (2.0 Mpsi),
cross the weld line. Thus the weld line does not have we need to increase the moment of inertia I of the plastic
the strength of the reinforced polymer and at times can version by increasing the part thickness or adding ribs.
even be less than the matrix polymer itself. These factors
Substituting the E values in equation 1:
must be taken into account when designing parts with
reinforced plastics.
( 44.8 × 109 ) I metal = ( 13.8 × 109 ) I Amodel
Designing for Equivalent Part Stiffness 3.25 I metal = I Amodel
Sometimes, a design engineer wants to replace a metal
part with one made of plastic, but still wants to retain the
From Figure 4.2, the moment of inertia for rectangular
rigidity of the metal part. There are two fairly simple ways
sections is:
to maintain the stiffness of a part when substituting one
material with another material, even though the materials
bd3
have different moduli of elasticity. I=
12
In the first method, the cross-sectional thickness is
where b is the width and d is the thickness of the section,
increased to provide the stiffness. In the second, ribs are
substituting into our equation to determine the required
added to achieve greater stiffness. An example of each
thickness yields:
approach follows.

Changing section thickness 3.25 d3 metal = d3 Amodel

In reviewing the deflection equations in Figure 4.1, the
deflection is always proportional to the load and length If d for the metal part is 2.54 mm (0.10 in.) then the
and inversely proportional to the modulus of elasticity thickness of Amodel® resin is:
and moment of inertia.

Selecting one case, for example, both ends fixed with a dAmodel = 3 3.25 ( 2.54 )3 = 3.76 mm ( 0.148 in. )
uniformly distributed load, the deflection is determined by:
or 48 % thicker than the magnesium part. However, ribs
FL3
Y= can be used to effectively increase the moment of inertia
384EI
as discussed in the next section.
Therefore, to equate the stiffness using two different
Adding ribs to maintain stiffness
materials, the deflections are equated as follows:
In the last section, it was determined that if a metal
FL3 FL3 part were to be replaced with a part molded of Amodel®
=Y=
384EI metal
384EI plastic AS-1145 HS resin, a part thickness of 3.7 mm (0.148 in.)
would be required to equal the stiffness of a 2.5 mm
Since the load and length are to remain the same, the FL3 (0.100 in.) thick magnesium part.
becomes a constant on both sides of the equation and
By incorporating ribs into the Amodel® design, the wall
what remains is:
thickness and weight can be reduced very efficiently,
Equation 1 yet be as stiff as the magnesium part.

[ EI ] metal = [ EI ] plastic

This, then, is the governing equation for equating

part stiffness.

66 \ Amodel® PPA Design Guide

To demonstrate this, the moment of inertia (I) of the Designing for Sustained Load
new rib design can be equated with that of the 3.7 mm Up to this point, the stress strain calculations and
(0.148 in.) thick plate design. Selecting the same material, examples have dealt with immediate stress/strain
Amodel® AS-1145 HS, the modulus of elasticity remains response and therefore short-term properties. If the part in
13.8 GPa (2.0 Mpsi) in both cases; therefore, if the question must sustain loads for long periods of time or at
moment of inertia of the ribbed design is equal to the elevated temperatures, apparent (creep) modulus values
plate design, the parts will have equivalent deflection must be used to account for the additional strain and part
and/or stiffness. deflection that may occur. An example showing how the
From Figure 4.2, the I for a ribbed section is selected. By calculations are modified for sustained load follows.
assuming that the section width “b” is the same for both,
Calculating deflection
the Irib has to be equal or greater than the Iplate. Assigning
a section width “b” = 25.4 mm (1.0 in.), the moment If a cantilever beam with a rectangular cross-section, as
of inertia of a ribbed construction that will satisfy that shown in Figure 4.4, is loaded with a 10 kg (22.0 lb) force
condition can be calculated. at the free end, what is the deflection after 1,000 hours?

The moment of inertia for the plate design is: Figure 4.4 Cantilever beam, bending load example
F = 10 kg ( 22.0 lb )
bh3 25.4 × ( 3.76 )3
Iplate = = = 112.5 mm4 ( 2.70 × 10-4 in4 ) d = 6 mm ( 0.24 in )
12 12

By choosing the arbitrary rib design shown in Figure 4.3,

and working through the calculations, the moment of
inertia is found to be:
Y
L = 100 mm ( 3.94 in )
Irib = 1379 mm4 ( 33.9 × 10-4 in4 ) b = 25 mm ( 0.98 in )

Figure 4.3 A
 dding ribs to increase stiffness
From Figure 4.1 on page 63, the deflection of a
1.9 mm ( 0.075 in ) cantilever beam is given by:

FL3
Y=
3EI

12.7 mm ( 0.50 in ) where I, the moment of inertia, as shown in Figure 4.2 is:

bd3
I=
12

and E is the flexural modulus of the material.

25.4 mm ( 1.00 in ) Calculating the moment of inertia for this example gives:

2.54 mm ( 0.100 in ) ( 25 )( 6 )3
I= = 450 mm4 ( 1.081 × 103 in4 )
12
Therefore, the ribbed design will be 9.5 times stiffer than
The data sheet for Amodel® A-1133 HS resin gives
the Amodel® plate design or the original magnesium part
11.6 GPa (1.68 Mpsi) for the flexural modulus. Using
that was 2.5 mm (0.100 in.) thick.
this value and the equation previously cited, the short-term
The same rib having half the height would still produce room temperature deflection can be calculated by:
a part twice as stiff as the magnesium part. The ribbed
( 10 kg × 9.8066 )( .1 m )3
design shown requires placing a rib every 25 mm (1 in.) Y=
3( 11.6 × 109 Pa )( 4.5 × 10-10 m4 )
of section width.
Y = 6.3 mm ( 0.25 in )

Amodel® PPA Design Guide / 67

 If the application requires that the load be sustained Calculating allowable stress - creep rupture
for a long time, we would expect the deflection to be If a load is sustained for a long time and if the load and/
greater than this because of creep. To calculate the or temperature are high enough, rupture of the part will
deflection considering the creep, we would use the eventually occur due to creep.
apparent modulus instead of the short-term flexural
modulus. The value of apparent modulus shown for To estimate the combinations of time, temperature, and
Amodel® A-1133 HS resin at 1,000 hours in Figure 4.5 is load that will cause this type of failure, creep rupture tests
7.58 GPa (1.10 Mpsi). Therefore the calculated deflection is: are conducted at various temperatures as shown in
Figure 4.5. This figure illustrates the actual time to failure
( 10 kg × 9.8066 )( .1 m )3 for different levels of stress so that a creep rupture
Y=
3( 7.58 × 109 Pa )( 4.5 × 10-10 m4 ) envelope can be obtained. From this envelope, the
safety factor in time or stress can be determined for
Y = 9.6 mm ( 0.38 in ) that particular temperature.
The deflection is about 50 % greater when a sustained For instance, if the application life is 1,000 hours at
load is considered. 65 °C (149 °F) for a part molded from Amodel® A-1133 HS
resin, the curve indicates that rupture will occur within
Figure 4.5 Tensile creep rupture, Amodel® A-1133 that time frame if the part is exposed to a stress level
HS resin
of approximately 158 MPa (23 kpsi).
200
If the part can be redesigned to reduce the stress to
25 124 MPa (18 kpsi), the predicted time to rupture is now
150 well beyond 10,000 hours. This automatically builds a
20
Stress [ kpsi ]

safety factor into the design. Actual part testing is still

Stress [ MPa ]

15 recommended to confirm these results.

100
For operating temperatures that are different from the
10
tested temperatures, information is usually extrapolated
50
65 °C ( 149 °F )
5 from known creep rupture envelopes to approximate the
100 °C ( 212 °F )
envelope for the temperature of interest.
150 °C ( 302 °F )
0 0
0.01 0.1 1 10 100 1,000 10,000
Time to rupture [ hours ]

68 \ Amodel® PPA Design Guide

Considering Stress Concentrations Considering Thermal Stresses
Classical mechanical design may result in a component When a plastic part attached to metal undergoes
design which fails prematurely or at a much lower temperature changes, stresses may be induced that
stress than predicted. This could arise due to stress should be considered by the designer in the development
concentration. Stress concentrations may occur at of the part design.
sharp corners, around holes, or other part features.
Figure 4.7 illustrates a typical plastic flange fastened by a
Impact and fatigue situations are especially sensitive
steel bolt to a steel frame. Because the thermal expansion
to stress concentrations.
of the plastic is significantly greater than that of the steel,
Minimizing sharp corners reduces stress concentrations an increase in temperature will produce an increase in
and results in parts with greater structural strength. compressive stresses in the plastic and tension in the bolt.
To avoid stress concentration problems, inside corner It is the increase in compressive stress under the washer
radii should be equal to at least half of the nominal wall that must be considered if creep and loss of torque load
thickness. A filled radius of 0.4 mm (0.015 in.) should on the bolt is of concern.
be considered minimum.
Figure 4.7 Stress concentration factor at inside
Figure 4.6 shows the effect of inside corner radius on the corners
stress concentration factor. For example, if the nominal
wall thickness is 2 mm (0.080 in.) and an inside corner Steel bolt
radius is 0.5 mm (0.020 in.), then the radius to thickness Washer
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 Plastic L

of the radius of the inside corner and the wall thickness
to maintain a uniform wall thickness.

Figure 4.6 Stress concentration factor at inside

corners Steel

2.6
Stress concentration factor

2.4
2.2 For example, the change in length of a material when
2.0 exposed to a change in temperature is given by:

1.8 Δ L = L ( TF − TO ) α
1.6
Where:
1.4 Δ L = change in length
L = original length
1.2
α = coefficient of thermal expansion
1.0 TF = final temperature
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 TO = initial temperature
Radius / thickness ratio

Amodel® PPA Design Guide / 69

 Since the plastic is constrained, the unit elongation, To evaluate this tendency, 6.4 mm (0.250 in.) thick plaques
combining both thermal expansion and strain, of both of Amodel® A-1133 HS resin, 33 % glass reinforced PA 6,6
the steel bolt and the plastic, will be as follows: and 30 % glass reinforced PA 4,6 were bolted to a metal
surface with steel machine bolts tightened to 6.8 N-m
F F (60 in-lb) of torque with a torque wrench compressing
αS ( TF − TO ) + = αp ( TF − TO ) − the plastic plaque under the bolt face. The temperature
ASES ApEp
of the bolted assemblies was then raised to the indicated
Where:
AS = cross-sectional area of the bolt temperatures shown in Figure 4.8, held for one hour, and
Ap = cross-sectional area of the washer then cooled to room temperature. The torque required to
ES = modulus of steel loosen the bolts was then measured.
Ep = modulus of plastic
αS = coefficient of thermal expansion of steel Figure 4.8 compares the amount of torque retained versus
αp = coefficient of thermal expansion of plastic temperature. The coefficient of linear thermal expansion
F = increase in the tensile force of the bolt of Amodel® resin is lower than those of the other materials
tested, and therefore closer to that of the steel.
Solving for F
Figure 4.8 Bolt torque retention
( αp − αs ) ( TF − TO ) ASES Temperature [ °F ]
F=
AE 50 75 100 125 150 175 200 225
1+ S S
ApEp 7 60
6
and the increase in compressive stress on the plastic 50
will be: 5
Torque [ N-m ]

Torque [ in-lb ]
40
4
F
σ= 30
Ap 3

2 20
Loss of Bolt Tightness Due to Creep A-1133 HS
1 33% GR PA 6,6 10
When threaded metal fasteners are used to retain or 30% GR PA 6,6
secure plastic parts to an assembly, and the assembly 0 0
is subjected to changes in temperature, the difference 20 40 60 80 100 120
between the thermal expansion coefficients of the metal Temperature [ °C ]
and the plastic can cause problems. When a threaded
fastener is tightened, the fastener is elongated slightly and The smaller difference in thermal expansion results in
a compressive stress is generated on the substrate. This lower induced stress due to the compressive strain
compressive stress maintains the tightness of the bolt. caused by the thermal excursion in the constrained part.
This translates to lower creep and therefore better torque
When the assembly is heated, both the plastic part and retention for such bolted assemblies.
the metal fastener will expand. The plastic part, however,
is constrained by the metal fastener, and cannot expand.
This results in increased compressive stresses in the
plastic and a corresponding increased tendency for
compressive creep or stress relaxation to occur. The
relaxation of the compressive stress will result in reduced
torque retention in the bolts.

70 \ Amodel® PPA Design Guide

Designing for Assembly If the shaft and hub are made from the same grade
of Amodel® resin, then:
Interference or Press Fits
One of the most economical methods that can be used to Eh = ES = E
assemble two parts is a press fit. The joint is achieved by and the interference is:
pressing or forcing the shaft into a hole whose diameter
is smaller than the diameter of the shaft. The difference in Sd F+1
I= D
diameter between the hole and shaft is referred to as the E s F
diametrical interference. The force maintaining the joint is
primarily a compressive stress on the shaft resulting from If the hub is made from Amodel® resin and the shaft is
the hoop stress in the hub created by the insertion of the made from metal, then the interference is:
shaft. Depending upon the relative moduli of the shaft and
hub materials, the compressive stress in the shaft can Sd Ds F + υh
I=
F Eh
also contribute to maintaining the joint. The stress holding
an interference fit will exhibit relaxation over time in a
When a press fit is used with dissimilar materials, the
manner that is analogous to creep, because the apparent
differences in thermal expansion can increase or decrease
modulus of the polymeric material decreases over time.
the interference between two mating parts. This could
Calculating the Allowable Interference increase or reduce the stress affecting joint strength.

The allowable interference between a shaft and a hub A press fit can creep or stress relax over time. This could
can be determined by using the general equation: cause a decrease in the retention force of the assembly.
Therefore, testing the assembly under its expected
operating conditions is highly recommended.
SdDs F + υh 1 – υs
I= +
F Eh Es

and the geometry factor is given by:

2
Ds
1+
Dh
F=
2
Ds
1–
Dh

Where:
I = Diametrical interference
Sd = Working stress
Dh = Outside diameter of the hub
Ds = Diameter of the shaft
Eh = Modulus of the hub material
Es = Modulus of the shaft material
υh = Poisson’s ratio of the hub material
υs = Poisson’s ratio of the shaft material
F = Geometry factor

Amodel® PPA Design Guide / 71

 Mechanical Fasteners Self-tapping screws
Mechanical fasteners provide an economical method of A common type of mechanical fastener used with plastics
joining dissimilar materials together. Fasteners frequently is a self-tapping screw. A self-tapping screw cuts or forms
used with injection molded plastic parts include screws, threads as it is inserted into the plastic and eliminates
bolts, nuts, lock washers and lock nuts. When using metal the need for molding internal threads or the secondary
mechanical fasteners, good design practice should be operation of tapping the thread form by machining. The
used to prevent the plastic parts being assembled from major types are thread-forming and thread-cutting.
becoming overstressed.
The modulus of elasticity of the plastic material plays an
The most obvious procedure for preventing a highly important role in deciding what type of self-tapping screw
stressed assembly is to control the tightening of the is most suitable for the application. For plastic materials
mechanical fasteners with torque limiting drivers. When with a modulus less than 3.0 GPa (440 kpsi), such as
torque cannot be controlled, as might be the case with most unreinforced resins, thread-forming screws
field assembly, shoulder screws will limit compression are best since the plastic is ductile enough to be
on the plastic part. Other alternatives may be to use deformed without cracking or shearing. For glass and
flange-head screws, large washers or shoulder washers. mineral filled grades, thread-cutting screws are preferred.
Figure 4.9 presents some preferred designs when using
For optimum strip-out torque, the hole diameter of the
mechanical fasteners.
boss should be equal to the pitch diameter of the screw.
Figure 4.9 D
 esigning for mechanical fasteners The outer diameter of the boss should be equal to two or
three times the hole diameter and the boss height should
Poor Better
be more than twice the thickness of the boss.

Figure 4.10 illustrates the basic boss design for use with
self-tapping screws.

Figure 4.10 Boss design for self-tapping screws

High bending stress Added bosses with small Boss o.d. < = 2 × pitch diameter
as bolt is tightened gap, when bosses touch,
stress becomes compressive
Pitch diameter

Flathead screw Truss or round head screw

Radius 1 mm ( 0.039 in )

High stress from wedging Recessed design avoids

action of screw head wedging stresses

Standard screw can allow Shoulder screw limits

high stress on tightening stress when tightened
To avoid stripping or high stress assemblies, torque
controlled drivers should be used on assembly lines.
Repeated assembling and disassembling should be
avoided when using self-tapping screws. If repeated Improving torque retention
assembly is required, thread-forming screws are
To minimize the loss of torque due to creep, reduce
recommended.
the 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

72 \ Amodel® PPA Design Guide

Tightening torque Pull-out force calculation
Figure 4.11 shows how torque changes as a function of The strength of a joint can be characterized by the amount
screw penetration. Tightening torque is the recommended of force required to pull out a screw. The pull-out force
installation torque for a given application. It must be high can be estimated by using the following equation:
enough to fully engage the screw threads and develop
clamp load but lower than the torque that would cause F = π SDL
failure of the threads, known as the stripping torque.
where
Figure 4.11 Torque developed during F = Pull-out force
S = Shear strength
screw installation
D = Pitch diameter
Stripping torque L = Thread engagement length

When repeated assembly and disassembly are required

or expected, threaded metal inserts should be used
instead of self-tapping screws.
Clamp
Torque

load Threaded inserts

Head makes contact Threaded metal inserts can be used to provide permanent
Thread with captured material
forming metal threads in a plastic part; a wide variety of sizes
torque and types are available. Inserts are usually installed in
molded bosses whose internal diameter is designed for
Driving torque
the insert. The most commonly used metal inserts are
either molded-in or ultrasonically placed in the part as a
Penetration depth
secondary operation. In the case of the molded-in insert,
the insert is placed in the mold and the plastic is injected
The optimum tightening torque value can be calculated
around it. Stress will develop when the plastic cools
from the average driving torque and the average stripping
around the insert. To reduce this stress, heat the inserts
torque using the following equation.
to the temperature of the mold.

The ultrasonic insert is pressed into the plastic by melting

1 3 1
TT = T + T the plastic with high-frequency vibrations generated by
2 2 D 2 s
an ultrasonic welding machine. The ultrasonic welding
melts material around the metal insert as it is being
where installed, forming a bond between the insert and the
TT = Tightening torque plastic that is usually strong and relatively free of stress.
TD = Average driving torque
TS = Average stripping torque Figure 4.12 depicts the recommended insert and boss
designs for use with Amodel® PPA resin.
Some self-tapping screws have been designed specifically
Figure 4.12 Boss design for ultrasonic inserts
for use with plastics and these have the advantage of
having a greater difference between driving and stripping Insert diameter
torque than the typical screws designed for metal. These
special fasteners can provide an additional safety factor Boss diameter =
for automated assembly. 2 × insert diameter

t
0.7 t

Amodel® PPA Design Guide / 73

 Molded-in threads Straight cantilever beam equation
One of the benefits of using plastic materials instead of The relationship between maximum deflection and strain
metals is the ability to mold thread forms directly into the for a straight cantilevered beam was calculated as follows:
part. This eliminates the secondary machining operations From Table 4.1, the cantilever beam was chosen and the
needed with metal parts to form the threads. Molded-in drawing is repeated as Figure 4.14. The maximum stress,
threads can be either external or internal. In the case of is given by the following:
internal threads, some type of unscrewing or collapsible
core is required. External threads can be formed more FL
σ=
easily if the parting line of the mold is perpendicular to Z
the thread.
Figure 4.14 Cantilever beam - concentrated load at
Designing with snap fits free end
F
The use of snap fits in plastics is very prevalent. All snap-
fit designs require the plastic to flex like a cantilever
spring as it moves past an interference that is designed
on the mating part. Once the flexible arm moves past the
interference, it returns to its normal unflexed, unstressed
position. Usually a step or protrusion has been designed
on the cantilever that engages and locks into the mating L
part, creating a simple assembly method without Y
additional parts. This is shown in Figure 4.13.

Figure 4.13 Cantilever type snap fit

Since this beam has a rectangular cross-section,

bd2
Z= and
6

b bd3
I=
12
d
Therefore:
L
Y FLd
σ=
2I
Each cantilever arm must deflect a distance “Y” in order
to be inserted. The key to proper snap design is to not The deflection of the beam, Y, is given by:
exceed the strain/stress limits of the material being used.
A snap fit design that has been used for a ductile, low FL3
Y=
modulus plastic will probably not be suitable for a highly 3EI
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.

74 \ Amodel® PPA Design Guide

Table 4.2 Strain recommendations for cantilever Tapered Cantilever Beam Equation
snap-fits For the tapered design shown in Figure 4.15, hL is the
Grade Maximum Strain [%] thickness at the free end. The value of the proportionality
ET-1000 HS 1.0
constant, K, for a tapered beam design can be found in
Figure 4.16. The maximum strain can be calculated from:
A-1230 L 0.5
AS-1133 HS 1.0 Equation 4

Solving the deflection equation for F, the force needed

3Yh0
to deflect the beam can be calculated as follows: ε=
2L2K

Equation 1
Figure 4.15 Snap fit design using tapered beam
L
3YEI
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: Y maximum hL

Equation 2
h0

FLd
ε=
2EI
For example, if the beam thickness has been gradually
Using the relationship of equation 1 and substituting reduced to half its fixed end thickness; the ratio of hL
for F in equation 2 the relationship between strain to h0 would be 0.5 and K (from Figure 4.16) would be 1.6.
and deflection is derived: Therefore, the maximum strain and the corresponding
stress would be multiplied the reciprocal of K, 0.625.
Equation 3 The strain will be reduced by about 40 % of the strain
of a constant thickness cantilever beam design with
3Yd
ε= equal deflection.
2L2
Figure 4.16 Proportionality constant (K) for tapered
This equation allows the designer to calculate the strain
beam
required from the maximum deflection of a design.
Table 4.2 summarizes maximum strain recommendations 2.4
for several grades of Amodel® resins.
Proportionality constant [ K ]

2.2
Once a suitable grade of Amodel resin has been
®
2.0
selected, the basic equations can be used to find the load,
1.8
F, needed to deflect the cantilever the required amount.
1.6
In a cantilever snap fit, the stress and strain are maximum
at the base of the cantilever and become proportionately 1.4
lower toward the tip where the load is applied. In fact 1.2
the stress and strain at any point can be calculated by
1.0
substituting a different L, the distance from the load
0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
toward the fixed end. Therefore, if the cantilever thickness
Ratio of hL to hO
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 capability of the material can be maximized.

Amodel® PPA Design Guide / 75

 Designing for Injection Molding Draft Angle
Many of the applications for Amodel PPA resins will
® To aid in the release of the part from the mold, parts
be manufactured using the injection molding process. are usually designed with a taper. The taper creates a
An engineer who has designed a part to meet the clearance as soon as the mold begins to move, allowing
performance requirements of the application must also the part to break free from its mold cavity. The taper is
take into account the fact that there are elements in the commonly referred to as draft, and the amount of taper
part design that can influence moldability. These factors as draft angle, as shown in Figure 4.18.
include wall thickness and wall thickness transitions, draft,
ribs, bosses, and coring. The effect of these factors on Figure 4.18 Draft – designing for mold release
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
ideally 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 Draft angle
potential for voids in a molded part. However, structural,
appearance, and draft considerations may require varying Adequate draft angle should be provided to allow easy
wall thicknesses. When changes in wall section thickness part removal from the mold. Generally, the designer
are necessary, the designer should consider a gradual should allow a draft angle of 0.5° to 1° per side for both
transition, such as the tapered or gradual designs shown inside and outside walls for Amodel® resins. However,
in Figure 4.17. in some special cases, smaller draft angles, as low as
1 ∕8 ° to 1 ∕4 °, have been used with draw polish on the
Figure 4.17 Wall thickness transition
mold surface.

Poor Sharp 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 0.025 mm (0.001 in.) of
texture depth.

Good Tapered

Best Gradual

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.

76 \ Amodel® PPA Design Guide

Ribs Coring
The stiffness of a part design can be increased with Proper design practice should include uniform wall
properly designed and located ribs, without creating thick thickness throughout a part. Heavy sections in a part can
walls as illustrated in the Design Section entitled “Adding extend cycle time, cause sink marks on the part surface,
Ribs to Maintain Stiffness” on page 66. Proper rib cause voids within the part and increase molded-in
design will allow for decreased wall thickness. This stresses.
will save material and weight, and shorten molding cycles.
Heavy sections should be cored to provide uniform wall
It will also eliminate thick walls, which can cause molding
thickness. For simplicity and economy in injection molds,
problems like sink marks on the surface of parts or voids
cores should be parallel to the line of draw of the mold.
on the inside of parts. Ribs that are correctly positioned
Cores placed in any other direction usually create the
may also function as internal runners, assisting plastic
need for some type of side action or manually loaded and
melt flow during molding.
removed loose cores.
In general, the following guidelines should be used when
Cores which extend into the cavity will be subject to high
designing with ribs. The thickness at the rib base should
pressure. For blind cores (cores that are unsupported) that
be no greater than 60 % of the adjacent wall thickness.
have diameters greater than 1.5 mm (0.060 in.) the core
When ribs are opposite appearance areas, the width
lengths should not exceed three times the diameter, while
should be kept as thin as possible. If there are areas in
blind cores with diameters less than 1.5 mm (0.060 in.)
the molded part where structure is more important than
should not exceed twice their diameter in length. These
appearance, then ribs are often 75 %, or even 100 %, of
recommendations may be doubled for through cores
the outside wall thickness. Whenever possible, ribs should
(cores that telescope into or shut off with the opposite
be smoothly connected to other structural features such
side of the mold). Draft should be added to all cores,
as side walls, bosses, and mounting pads. If there are
and all tooling draws should be polished for best ejection.
several ribs in a part, they need not be constant in height
or width, and are often matched to the stress distribution Bosses
in the part. All ribs should have a minimum of ½ ° of draft
Bosses are projections from the nominal wall of a part that
per side and should have a minimum radius of 0.8 mm
will eventually be used as mounting or fastening points.
(0.03 in.) at the base to reduce stress concentrations and
The design of bosses is largely dependent upon their role
sink marks.
in a given part. Cored bosses can be used for press fits,
Figure 4.19 shows the recommended rib size relationships. self-tapping screws, and ultrasonic inserts. Each of these
will exert stress on the wall of the boss.
Figure 4.19 Draft – recommended rib design
As a general guideline, the outside diameter of a boss
½° to 1½° draft
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
t override appearance requirements. Figure 4.20 illustrates
these guidelines.

Figure 4.20 Boss design – general guidelines

t = 0.6T
O.D. = 2 × I.D.
R = > 0.8 mm ( 0.03" )
O.D.

T
I.D.

0.3 T T

Amodel® PPA Design Guide / 77

 Additional forces imposed on bosses may tend to be Under some circumstances, it may be possible to eject
transmitted down the boss and into the nominal wall. a part with an undercut if the core can be pulled first and
For this reason, a minimum radius of 25 % of the wall the undercut ratio is 8 or less.
thickness is required at the base of the boss to provide
strength and reduce stress concentration. A boss can Undercut 100 ( bead diameter ( A ) − tube OD ( B ) )
=
be further strengthened by using gusset-plate supports ratio ( R ) Tube ID ( C )
around the boss, or attaching it to a nearby wall with a
properly designed rib. Bosses should be designed in the If the part must be molded without side pulls and the
same manner as ribs. Heavy sections should be avoided undercut ratio calculated is greater than 8, the design
to prevent the occurrence of sink marks on the surface should be modified. One possible modification is to taper
and voids in the interior of the part. the tube inside diameter effectively reducing the wall
thickness under the bead. For tubes with inside diameters
Undercuts less than 25 mm (1 in.), it may be necessary to modify the
Some design features, depending on orientation, can bead geometry to get an undercut ratio of 8 or less.
place portions of the mold in the way of ejecting the part. The success of this approach is based upon removing the
These features are called undercuts and can require part from the mold while the part is still hot and therefore
special mold configurations, such as slides or cams, to more flexible than it will be a room temperature.
move prior to ejection. In some cases, the material being
molded will have enough flexibility that the part can be Figure 4.22 Undercut diagram
pushed off the undercut without damage.

For example, the typical automotive thermostat housing,

as shown in Figure 4.21, has beads to provide for leak-
proof hose connections. To provide a smooth surface B
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.

Figure 4.21 Thermostat housing showing beads

78 \ Amodel® PPA Design Guide

 Secondary Operations

Welding The hot plate welding machine used was a Bielomatic HV

4806 welding machine manufactured in 1986 by Leuze
Components produced from Amodel® resins can be
GMBH. The specimens used were bars 102 mm long x
readily joined using hot-plate, vibration, spin,or ultrasonic
25 mm wide x 6 mm thick (4 in. x 1 in. x 0.25 in.) thick.
welding.
The welding machine was set up to provide a nominal lap
In this section, each welding method is described, and the shear weld of 13 mm x 25 mm (0.5 in. x 1 in.). A diagram
apparatus and the conditions that produced acceptable of the weld joint is shown in Figure 5.1.
welds with Amodel® AS-1133 HS resin are discussed.
These conditions are the suggested starting points for Figure 5.1 Joint design for hot plate welding
determining welding conditions for actual applications.
Other Amodel® grades may require refinement of the
noted process conditions. In some instances, additional
information will be provided, such as sensitivity to welding
conditions, sample geometry, or moisture content.

Because Amodel® resins absorb moisture, tests were

performed on specimens conditioned to three different
moisture levels: 0 %, 1.8 % and 3.8 % moisture. These
moisture contents were selected to represent the moisture
levels for parts molded from Amodel® AS-1133 HS resin
that had reached equilibrium in air with relative humidity
levels of 0 %, 50 %, and 100 % respectively. To simplify
the discussion of results, the term dry will be used for the Best results were obtained using a hot plate temperature
dry, as molded specimens, normal for those containing of 330 °C (626 °F), a clamping pressure of 207 KPa
1.8 % moisture, and saturated for those containing 3.8 % (30 psi). The optimum heating time for the test samples
moisture. proved to be 40 seconds, with a holding time of
In summary, acceptable welds can be achieved using 20 seconds. The strength of the bond produced was
all of the welding techniques evaluated and described in comparable to the strength of the material itself, i.e., the
this section. Ultrasonic welding does require near-field majority of the specimens failed at points other than the
energy application for strong welds. In general, absorbed joint during mechanical testing.
moisture does not interfere with welding, but best results Test plaques occasionally stuck to the hot plate unless a
are obtained using samples that contain normal amounts silicone mold release was applied and the hot plate was
of moisture (1.8 %) or less. allowed to reach thermal equilibrium. Tests showed that
the use of mold release did not reduce the weld strength.
Hot Plate Welding
Absorbed moisture did not significantly affect weld
In hot plate welding, the thermoplastic samples are strength at dry (0 %) and normal (1.8 %) levels, but it did
pressed against a heated element causing the contact reduce weld strength at the saturated (3.8 %) condition.
surface to melt. The element is then removed and the
samples are forced together under pressure. This welding Vibrational Welding
method typically requires a longer cycle time than other In vibrational welding, friction is used to generate heat
methods, but it allows for the joining of parts that have at the weld joint. One of the parts to be assembled is
a much larger surface area. With care, a strong and held stationary while the mating part vibrates ~0.8 mm to
hermetic bond may be obtained using this method 1.5 mm (0.030 in. to 0.060 in.) in a linear fashion at 100 Hz
with Amodel® resins. to 400 Hz. Vibrational welding is limited to flat parts, but
has a relatively fast cycle time and a low tooling cost.

Amodel® PPA Design Guide / 79

 The machine used for these experiments was a Vinton Spin welded joints using Amodel® PPA should
Hydroweld Vibration welding machine. This machine incorporate a design known as a shear joint like that
operates at a nominal frequency of 240 Hz. The specimens shown in Figure 5.3. Details known as flash traps may be
used were 102 mm (4 in.) long, by 25 mm (1 in.) wide, incorporated to channel the localized flow of the material
by 6 mm (0.25 in.) thick, and they were welded in a 25 to one side of the part depending on requirements.
by 13 mm (1 by 0.5 in.) lap shear configuration as shown
in Figure 5.2. Figure 5.3 Shear joint configuration

Figure 5.2 Lap shear joint configuration

0.2 mm (0.008 in.)

Depth
of weld

30° - 45°

Interference

The spin welding machine used for these experiments

was a Mechasonic KLN Omega machine, model SPN-
063. Typically the important parameters for this welding
This method was very effective and welds as strong as
method are angular speed, in revolutions per minute,
the parent material were easily obtained. This technique
normal force, and welding time. Because this specific
proved relatively insensitive to welding conditions, giving
machine was an inertia- type, the energy available for
good results at weld times as short as 0.60 seconds and
spinning the sample was limited to that stored in the
pressures as low as 2.20 MPa (320 psi). Best results were
flywheel. Instead of adjustments per se to speed, the
obtained using specimens containing a normal (1.8 %)
energy stored in the flywheel was controlled. More
amount of moisture.
modern spin welding machines allow for the control of
Spin Welding speed, force, time, and in some cases, angular location.

The spin welding method uses frictional heat to join two The specimens used for the spin weld testing were
cylindrical or spherical mating parts. While one half is held injection molded cups with an interference joint design.
stationary in a nest fixture, the mating part is spun rapidly Excellent weld strength was obtained using this method.
against it. Friction at the interface raises the temperature
Because the welding condition settings were machine-
of the material until melting occurs. When the spinning
specific, they are not generally useful in setting a starting
action is stopped, the parts are held under pressure
point. Rather, it was observed that as forge pressure and
until cooled. Obviously, this welding method is limited to
angular velocity were increased, weld strength increased
parts with circular geometry at the joint. The advantage
up to a maximum and then decreased when an excessive
obtained through spin welding is the increased dispersion
amount of either pressure or velocity were applied. The
of material at the joint compared to other techniques. This
values for these parameters are strictly dependent on
allows for the development of hermetic seals and reduces
the part geometry and therefore they are not noted here.
the tolerance requirements on the joint geometry.
The explanation of the observed phenomena is that when
a weld was made with too high of a forge pressure, the
spinning motion was stopped too rapidly and not enough
polymer melted and 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.

Moisture content did not significantly affect weld strength.

80 \ Amodel® PPA Design Guide

Ultrasonic Welding Adhesive Bonding
In the ultrasonic welding of thermoplastic materials, Injection molded samples of Amodel® A-1133 HS resin
high-frequency (10 to 40 KHz) mechanical vibrations were bonded with both an epoxy and a urethane adhesive.
are transmitted through one of the mating parts to the Both adhesives were supplied by Lord Corporation. The
joint interface while the other half of the assembly is held epoxy was a two-part adhesive sold under the trade
stationary. The combination of friction and an applied name Lord® 305-1/305-2 and the urethane was a two-
force causes the temperature at the joint interface part system known as Lord® 7500 A/C.
to increase to the melting temperature of the material.
Normal force is held after the ultrasonic energy input To prepare the test specimens for the Lord® 305-1/305-2,
is removed to achieve a mechanical bond or weld. a cure cycle of 30 minutes at 120 °C (250 °F) followed
by conditioning at room temperature for 72 hours was
Ultrasonic welding has the advantage of being very high employed. The cure cycle for the Lord® 7500 A/C
speed and is well-suited to high-volume production. Weld adhesive was 10 minutes at 90 °C (200 °F) followed
consistency and quality are high using this method; even by a 72-hour room temperature conditioning step.
hermetic seals may be obtained with close tolerance parts.
The bond strength for both materials was tested at
Aside from the ultrasonic weld equipment, a customized low temperature, room temperature, and an elevated
horn must be employed for each assembly to focus the temperature. To evaluate the effect of humid aging,
ultrasonic energy for the given part configuration. specimens were conditioned for 14 days at 38 °C (100 °F)
and 100 % relative humidity. Some specimens were
An energy-directing joint design is recommended for use
tested immediately after conditioning; others were tested
with Amodel® materials to ensure that there is localized
24 hours after conditioning.
melting at the joint. A typical joint design is shown in
Figure 5.4. The recommended interference using a shear Impact performance was determined with a side impact
joint design is a minimum of 0.2 mm (0.008 in.). tester according to GM specification #9751P. Lap shear
values were measured on an Instron testing machine
Figure 5.4 Typical energy-directing using a pull rate of 13 mm/min (0.5 in./min) according
joint configuration to ASTM D1002.
W The results are shown in Figures 5.5 and 5.6. In general,
the epoxy adhesive performed slightly better than the
W/12 urethane. Acrylic adhesives are not recommended for
W/2 use with Amodel® resins.
W/3 Figure 5.5 Lap shear bond strength
Draft angle
3° to 5°
7 1,000
302 1/2
6 7500 A/C 900
W/10 800
5
Lap shear [ MPa ]

700
Lap shear [ psi ]
W/5 4 600
500
3 400
The ultrasonic welding machine used for this testing 2 300
was a Branson Model 910 M microprocessor-controlled 200
1
machine. With this unit, it is possible to adjust the amount 100
of ultrasonic energy that is applied to the sample. For 0 0
23 °C -34 °C 82 °C Promptly After
testing, the output from the booster was fed to near and ( 73 °F ) ( -30 °F ) ( 180 °F ) 24 hours
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] were excellent. Welds made using the far field horn
position 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).

Amodel® PPA Design Guide / 81

 Figure 5.6 Side impact bond strength Laser Marking
8 70 It is possible to obtain a durable, high contrast mark on
302 1/2 Amodel® resins using commercially available laser marking
7 7500 A/C 60 systems. Depending upon the wavelength and intensity
6 of the laser system used, the appearance of the mark

Side impact [ in-lb ]

50
Side impact [ J ]

5 can range from a bleached surface to an engraved mark.

40
4 No one set of conditions can be specified for laser
30 marking all Amodel® PPA resins. Operating parameters
3
20 must be adjusted depending upon the particular
2 application and part being marked.
1 10
The manufacturers in Table 5.1 have equipment that
0 0 should be suitable for marking Amodel® PPA resins.
23 °C -34 °C Promptly After
( 73 °F ) ( -30 °F ) 24 hours
Table 5.1 Suppliers of laser marking equipment
Coatings and Surface Finishes Company Website
Vacuum Metallizing Videojet Systems www.videojet.com
International, Inc.
Vacuum metallization involves the evaporation, and
Panasonic Electric www.panasonic-electric-works.co.uk
subsequent condensation, of a metal onto a substrate Works Corporation
in a vacuum chamber. The metal used in most industrial ID Technology www.idtechnology.com
applications is aluminum. When the end-use requirement
is primarily decorative, the substrate is usually processed Inkjet Printing
with two organic coatings called the basecoat and the
Inkjet printing can be used to provide a highly visible
topcoat with the metal layer deposited in between. The
mark on Amodel® PPA resin substrates of any color. The
primary function of the basecoat is to produce a smooth
durability of marks made using an inkjet system depends
surface on molded plastic parts so that the metal layer
upon the environment to which the marked part will be
will have maximum luster. A secondary function of the
exposed and the type of ink used to make the mark. In
basecoat is to maximize adhesion of the metal layer to the
many cases the durability of the mark will be satisfactory.
substrate. On substrates that tend to outgas in a vacuum,
the basecoat also provides a barrier layer. The function Equipment needs vary depending upon the type of ink
of the topcoat is to protect the metal layer from physical, used, the speed at which the mark is made, and size
oxidative, or chemical deterioration. of the desired mark. A wide variety of equipment and inks
are commercially available. Two sources are shown in
Basecoats that are compatible with Amodel® resins
Table 5.2.
include #VB-4315, #VB-4774, and #VB-4836-1 from
Pearl Paints, http://www.pearlpaints.com. Topcoats that Table 5.2 Suppliers of inkjet printing equipment
are compatible with Amodel® resin include #VT 4316-2,
also from Pearl Paints. Company Website
Videojet Systems www.videojet.com
Because of the need to vaporize the metal materials International, Inc.
during this process, an elevated temperature may be ID Technology www.idtechnology.com
expected in the vacuum chamber. The rate at which parts
may be coated is controlled by the thermal characteristics
of the substrate material. For this reason, Amodel® resin,
with its high heat deflection temperature, is an excellent
candidate material when metallization is required as
comparatively rapid cycle times may be obtained.

82 \ Amodel® PPA Design Guide

Painting Overmolding
Several grades of Amodel® PPA resin were evaluated for A process developed by the Bryant Rubber Corporation
their compatibility with various automotive paint systems. allows for the overmolding of Amodel® materials with soft
Representative glass-reinforced, mineral-reinforced, and touch silicone rubber. The silicone rubber materials are
mineral/ glass-reinforced compounds were evaluated. ideal for the creation of sealing surfaces, tactile grips, and
sound/noise dampening details. While overmolding with
As with all plastic substrates, the primer system is silicone rubber is not a new idea, these design details are
critical. The test specimens were cleaned with isopropyl typically characterized as having poor adhesion to the
alcohol then coated with primers and cured as per the rigid substrates even if primers, or priming processes,
manufacturer’s instructions. The plaques were tested for are employed. The adhesion and peel strength achieved
tape adhesion (GM9071P, method A) and cross-hatch through the use of Bryant’s Select Primerless Adhesion
adhesion (GM9071P, method B) and gravelometer chip Polymer System (SPAPS™ Technology) is uniquely better
resistance (GM9508P and SAEJ400) as coated and after than anything that has previously been achieved. In fact,
conditioning for 96 hours with water/fog/humidity per cohesive failure of the silicone rubber is typical of the
GM4465P specification. Table 5.3 lists primers that meet SPAPS™ Technology process.
or exceed all test requirements and represent adequate
coating performance for most painted automotive Amodel® resins are particularly well-suited for use in
applications. conjunction with SPAPS™ silicone rubbers due to their
excellent properties at high temperatures. This allows
Table 5.3 Suitable automotive primers for reduced cycle times for the silicone cure process,
improving overall economics. The silicone materials match
Supplier Primer Description the long-term thermal stability of Amodel® resin, more
BASF U04KD004 Solvent, flexible so than other elastomeric materials, ensuring long-term
U04AD041 Solvent, rigid performance in difficult environments.
U36AD001 Water based
The SPAPS™ silicone rubbers are offered in the full
PPG RPP9870 Solvent, high solids range of property options available in other common
AHAP9470R Solvent, one coat silicone rubbers. The materials are naturally transparent
Red Spot AE146 Solvent, lacquer and colorable using liquid colorants during the molding
Siebert-Oxidermo UBP9604 Solvent, high solids process, offering excellent color fastness even with
BP2024 Solvent prolonged ultraviolet light exposure. They are available
with durometer ratings of 10 to 85 on the Shore A scale.
Sherwin-Williams E75BC2301 Solvent
Their chemical resistance is similar to that of other silicone
E75AC6 Solvent
rubber materials. The unreactive character 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 http://www.bryantrubber.com/.

Amodel® PPA Design Guide / 83

84 \ Amodel® PPA Design Guide
 Index E
Effect of Moisture on Strength and Stiffness . . . . . 40
Electrical Properties . . . . . . . . . . . . . . . . . 51
A Environmental Resistance . . . . . . . . . . . . . . 56
Absorption Amount . . . . . . . . . . . . . . . . . 39
F
Accelerated Moisture Conditioning . . . . . . . . . . 8
Adding Ribs to Maintain Stiffness . . . . . . . . . . .66 Falling weight impact properties . . . . . . . . . . . 31
Adhesive Bonding . . . . . . . . . . . . . . . . . .81 Fatigue strength of Amodel® resin . . . . . . . . . .37
Amodel Polyphthalamide (PPA) Resins . . . . . . . . 3 Flexural Properties . . . . . . . . . . . . . . . . . .24
Amodel® Resin Property Tables . . . . . . . . . . . 6 Flexural properties at elevated temperatures . . . . .26
Flexural property comparison . . . . . . . . . . . . .25
B
G
Bosses . . . . . . . . . . . . . . . . . . . . . . . .77
Gamma Radiation . . . . . . . . . . . . . . . . . . 60
C Glow Wire Testing . . . . . . . . . . . . . . . . . . 49
Calculating Allowable Stress - Creep Rupture . . . . 68
H
Calculating Deflection . . . . . . . . . . . . . . . . 67
Calculating the Allowable Interference . . . . . . . . 71 Heat Deflection Temperature – HDT . . . . . . . . . 42
Changing Section Thickness . . . . . . . . . . . . .66 High-Current Arc Ignition (HAI) . . . . . . . . . . . .54
Charpy (supported beam) impact . . . . . . . . . . 30 High-Voltage Arc Resistance to Ignition . . . . . . . 55
Chemical Compatibility . . . . . . . . . . . . . . . .60 High-Voltage Arc-Tracking-Rate (HVTR) . . . . . . . 54
Chemical Resistance . . . . . . . . . . . . . . . . .56 High-Voltage, Low-Current, Dry Arc Resistance –
Chemistry . . . . . . . . . . . . . . . . . . . . . . . 3 ASTM D495 . . . . . . . . . . . . . . . . . . . 54
Coatings and Surface Finishes . . . . . . . . . . . .82 Horizontal burning test . . . . . . . . . . . . . . . .50
Coefficient of Linear Thermal Expansion . . . . . . .43 Hot Plate Welding . . . . . . . . . . . . . . . . . . 79
Comparative Tracking Index (CTI) –ASTM D3638 . . . 54 Hot Wire Ignition (HWI) - ASTM D3874 . . . . . . . .54
Compressive creep . . . . . . . . . . . . . . . . . .36
Compressive Strength and Modulus . . . . . . . . .28 I
Considering Stress Concentrations . . . . . . . . . .69
Impact Strength . . . . . . . . . . . . . . . . . . . 28
Considering Thermal Stresses . . . . . . . . . . . .69
Improving torque retention . . . . . . . . . . . . . .72
Coring . . . . . . . . . . . . . . . . . . . . . . . .77
Inkjet Printing . . . . . . . . . . . . . . . . . . . . .82
Creep . . . . . . . . . . . . . . . . . . . . . . . . 32
Interference or Press Fits . . . . . . . . . . . . . . .71
Crystallinity . . . . . . . . . . . . . . . . . . . . . . 4
Introduction and Typical Properties . . . . . . . . . . 3
D Isochronous Stress/Strain Curves . . . . . . . . . . 35
Izod (Cantilevered Beam) Impact . . . . . . . . . . .29
Deflection Calculations . . . . . . . . . . . . . . . .65 Izod impact property comparison . . . . . . . . . . 29
Deflection Temperature Values for Amodel Resins . . 43
Design Information . . . . . . . . . . . . . . . . . .61 L
Designing for Assembly . . . . . . . . . . . . . . . 71
Laser Marking . . . . . . . . . . . . . . . . . . . . 82
Designing for Equivalent Part Stiffness . . . . . . . .66
Limitations of Design Calculations . . . . . . . . . . 65
Designing for Injection Molding . . . . . . . . . . . .76
Long-term Mechanical Properties . . . . . . . . . . 32
Designing for Sustained Load . . . . . . . . . . . . 67
Loss of Bolt Tightness Due to Creep . . . . . . . . .70
Designing with Snap Fits . . . . . . . . . . . . . . .74
Dielectric Breakdown Voltage and Strength -
ASTM D149 . . . . . . . . . . . . . . . . . . . 51
Dielectric Constant - ASTM D150 . . . . . . . . . . 52
Dimensional Change Compared to PA 6,6 . . . . . .41
Dimensional Change due to Moisture . . . . . . . . 40
Dissipation Factor - ASTM D150 . . . . . . . . . . .53
Draft Angle . . . . . . . . . . . . . . . . . . . . . .76

Amodel® PPA Design Guide / 85

 M T
Mechanical Design . . . . . . . . . . . . . . . . . .62 Tapered Cantilever Beam Equation . . . . . . . . . .75
Mechanical Fasteners . . . . . . . . . . . . . . . . 72 Tensile Creep . . . . . . . . . . . . . . . . . . . . .33
Mechanical Properties . . . . . . . . . . . . . . . 21 Tensile Creep Rupture . . . . . . . . . . . . . . . .35
Moisture Absorption and Glass Transition Tensile Properties . . . . . . . . . . . . . . . . . . 21
Temperature (Tg) . . . . . . . . . . . . . . . . .39 Tensile properties for GR PPA vs. temperature . . . .23
Moisture Effects . . . . . . . . . . . . . . . . . . 5, 38 Tensile properties of A-1000 GR grades at
Molded-In Threads . . . . . . . . . . . . . . . . . .74 elevated temperatures . . . . . . . . . . . . . . 24
Tensile property comparison . . . . . . . . . . . . .23
N Tensile Property Comparison . . . . . . . . . . . . .22
Nomenclature . . . . . . . . . . . . . . . . . . . . . 7 Test Methods . . . . . . . . . . . . . . . . . . . . .21
Thermal Aging . . . . . . . . . . . . . . . . . . . .47
O Thermal Conductivity . . . . . . . . . . . . . . . . .44
Thermal Properties . . . . . . . . . . . . . . . . . .42
Overmolding . . . . . . . . . . . . . . . . . . . . .83 Thermal Stability . . . . . . . . . . . . . . . . . . .47
Thermogravimetric Analysis (TGA) . . . . . . . . . .47
P Threaded Inserts . . . . . . . . . . . . . . . . . . .73
Poisson’s Ratio . . . . . . . . . . . . . . . . . . . .31 Tightening torque . . . . . . . . . . . . . . . . . . 73
Product Data . . . . . . . . . . . . . . . . . . . . . 6 Typical Properties . . . . . . . . . . . . . . . . . . . 8
Product Selection . . . . . . . . . . . . . . . . . . . 7
Property Data . . . . . . . . . . . . . . . . . . . . . 8 U
Pull Out Force Calculation . . . . . . . . . . . . . . 73 UL 746A Short-Term Properties . . . . . . . . . . . 53
UL Relative Thermal Indices . . . . . . . . . . . . . 55
R Ultrasonic Welding . . . . . . . . . . . . . . . . . .81
Reinforcing Fiber Orientation Considerations . . . . .65 Using Classical Stress/Strain Equations . . . . . . . 65
Relative Thermal Index (UL) . . . . . . . . . . . . . 48
Ribs . . . . . . . . . . . . . . . . . . . . . . . . . 77 V
Vacuum Metallizing . . . . . . . . . . . . . . . . . .82
S Vertical Burn Test . . . . . . . . . . . . . . . . . . .50
Secondary Operations . . . . . . . . . . . . . . . .79 Vertical Flammability per UL 94 . . . . . . . . . . . .50
Self-Tapping Screws . . . . . . . . . . . . . . . . .72 Vibrational Welding . . . . . . . . . . . . . . . . . .79
Shear Properties . . . . . . . . . . . . . . . . . . .27 Volume Resistivity - ASTM D257 . . . . . . . . . . .52
Short-Term Mechanical Properties . . . . . . . . . .21
Significance of Moisture Absorption . . . . . . . . . 38 W
Smoke Density Test (NBS) . . . . . . . . . . . . . .50 Wall Thickness . . . . . . . . . . . . . . . . . . . .76
Specific Heat . . . . . . . . . . . . . . . . . . . . .46 Wall Thickness Variation . . . . . . . . . . . . . . . 76
Spin Welding . . . . . . . . . . . . . . . . . . . . .80 Welding . . . . . . . . . . . . . . . . . . . . . . . 79
Straight Cantilever Beam Equation . . . . . . . . . .74
Stress Calculations . . . . . . . . . . . . . . . . . .65
Surface Resistivity - ASTM D257 . . . . . . . . . . .52

86 \ Amodel® PPA Design Guide

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