High-performance Plastics for Aviation and Aerospace.

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1970 1980 1990 2000 2010

50

40

30

20

10

0

Properties of high-performance plastics

| High thermal and mechanical stability| Inherent flame resistance| Low degree of thermal expansion| High chemical resistance even at raised temperatures| Low level of outgassing in vacuum| Good electrical insulation

The dream of flying would quickly becomea thing of the past without today’s plastics. This is easily substantiated by a casual glance at the inside of a modern aeroplane. The use of plastics makes planes lighter, safer and more economical. This is by no means the case for just the interior, however, but also for sophisticated technical parts, structural elements and propulsion components, for example.

More recently, the significance of technical plastics and composites in aviation and aerospace applications has grown rapidly.

Advantages of plastics

| Every extra pound a plane weights costs energy to move it and thus money. The use of modern polymer materials and reinforcing fibres makes it possible to achieve lightweight constructions and hence fuel savings| Plastic components can normally be fabricated eco-

nomically| Plastics are approx. 50% lighter than aluminium| Compared to metals, plastics do not corrode| Plastics provide a high degree of freedom in design| Plastics with modified sliding properties are best suited for use in dry operation under extreme conditions| Transparent plastics serve as lighter and more impact resistant alternatives to glass

Plastics in aviation and aerospace applications.

Approvals

Before plastics are approved for applications in aviation and aerospace, they normally have to undergo testing which is specific for the components. ENSINGER processes special high-performance plastics to satisfy special needs, which meet the high standards and fulfil the requirements of QSFB, AS 9100, OSU, ABD 0031 or FAR 5.853. TECAPEEK® products are qualified according to IPS 04-06-004-01 specifically for interior Airbus applications.

Areas of application for plastics in aviation and aerospace

Interior components, technical parts, structural elements as well as components for navigation, propulsion engineering and satellite technology.

Development of the weight of technical plastics and com-posites [in %] used in commercial aeroplanes

33

ENSINGER Plastics for aviation and aerospace.

| SINTIMID

Materials with a continuous serv-ice temperature of 57 °F. High strength, rigidity and creep strength. Good chemical resistance and ex-cellent sliding properties for special types. Excellent electrical insulation properties and inherent flame resis-tance. May be used in cryogenic applications. High degree of purity and low out-gassing in vacuum.

| TORLON®

High mechanical strength and toughness. Very good creep resis-tance, low thermal expansion and high thermal resistance. Good mechanical values up to tempera-tures of 500 °F. Good frictional characteristics for special types. May be used in cryogenic appli-cations. Good chemical resistance and inherent flame resistance.

| TECAPEEK

Semi-crystalline plastic with high strength, rigidity and hardness. Continuous service temperature up to 500 °F. Resistant to many different types of hydraulic fluid (Skydrol) and chemicals, also at high temperatures. Excellent dimensional stability and very good sliding properties for special types. Inherent flame resistance. Extremely low smoke gas emiss-ion and density, as well as ex-tremely low toxicity of the smoke gases.

| TECATRON/TECATRON VF

Plastic with very high strength, rigidity and hardness. Continuous service temperature of 458° F. Excellent chemical resistance even at high temperatures. Excellent dimensional stability and low water absorption. Low degree of toughness and inherent flame resistance. Very good creep resistance.

| TECASON P VF

Very good creep strength and extremely impact resistant. Outstanding resistance to fluids used in the aerospace industry. Highly resistant to radiation (gamma, X-rays, etc.). Extremely low smoke gas emission and density. Inherent flame resistance.

| TECAPEI (Ultem®)

Amorphous plastic with high strength and continuous service temperature of 338 °F. Good chemical resistance to many substances, such as fully halo-genated hydrocarbons, alcohols and aqueous solutions. Excellent dimensional stability. Inherent flame resistance. Extremely low smoke gas emission and density, as well as extremely low toxicity of the smoke gases.

| TECAMAX SRP

Amorphous plastic with extremely high strength and hardness without the use of fillers. Continuous service temperature of 85 °F. Very good chemical resistance and outstanding cryogenic properties. Very good scratch resistance. Inherent flame resistance, extremely low smoke gas emission and density.

Sensor plate TECAPEEK GF 30.

Attenuation tube TECAFORM AH

Twin Pulley TECAPEI GF 30 (Ultem®)

Output Pulley TECAPEI GF 30 (Ultem®)

S-frequency aerial for satellites TECAPEEK and VESPEL® SP1

4

0

1.000

2.000

3.000

4.000

5.000 TECAPEEK

VESPEL

TORLON

®

TECAPEI20.000

TECATRON

TECANAT

TECAFORM

Process engineering to match the highest demands.

ExtrusionENSINGER extrudes semi-finished goods from more than 100 different thermoplastics as rods, sheets and tubes in the dimensions the customer requires and as stock items. Many years of experience and the most modern equip-ment ensure the highest quality of all products, as well as individually adaptable material properties.

MachiningSmall parts and large volume components can be eco-nomically produced on the most modern CNC-controlled processing centres and cycle-controlled automatic turning lathes. Lot sizes are irrelevant. Complex geometries are possible with simultaneous four and five-axis processing.

Perfect products are the result of highly precise production processes and the most modern process technology.The comprehensive know-how of ENSINGER’s industrial specialists in conjunction with engineering expertise makes technically demanding and customised solutions possible.All processes are subject to continuous quality assurance. Thanks to the global sales network, our products reach you anywhere and on time every time.

Injection mouldingWe produce high-precision and demanding geometries for large volume production using injection moulding, which are used, for example, in holding fixtures or materials handling equipment.

Industrial profilesENSINGER demonstrates its high level of expertisein the production of special profiles and special tubes. Solid profiles, hollow chamber profiles and particularly thin-walled profiles are manufactured for this purpose from specially adapted materials.

Highest radiation resistance

Approximate values:Dosage in kGy, which reduce elongation by 25%.

(U

ltem

® )

55

Outstanding properties and top performance for your safety.

Chemical resistance according to different temperatures, residence times, concentrations and the geometry of the parts (possibly internal stress) ++ good resistance + resistant 0 limited resistance(1) Sales in Germany and Great Britain

Outstanding resistance to chemicals

High-performance plastics have to show special properties in their resistance to chemicals, in order to be used in the aviation and aerospace industry. This depends on the state of the part, the geometry and the internal stress of the materials. Our plastics satisfy these requirements. It is recommended that a test for suitability is carried out for definite applications, taking into account the resistance at different temperatures, concentrations, residence times and mechanical loads.

Safety through special fire protection properties

For certain plastic applications, high requirements are placed on flame retardant properties. ENSINGER plastics satisfy the current flammability ratings for aviation and aerospace purposes.

UL 94 FAR 25.853ABD

0031ATS 1000.001 Remarks

VESPEL® (1) PI V-0 No data No data No data

SINTIMID PI V-0 No data No data No data

TORLON® PAI V-0 No data No data No data only injection moulding

TECAPEEK PEEK V-0 Yes Yes Yes

TECATRON VF PPS V-0 No data No data No data

TECASON P VF PPSU V-0 Yes No data Yes R7700 series

TECAPEI PEI V-0 Yes Yes No data

TECAMAX SRP PPP V-0 No data Yes No data

Resistanceto acids

Resistanceto alkalis

Resistance tosolvents

Resistance tostress cracking

VESPEL® (1) PI + 0 ++ ++

SINTIMID PI + 0 ++ ++

TORLON® PAI + + ++ ++

TECAPEEK PEEK + ++ ++ ++

TECATRON VF PPS + ++ ++ ++

TECASON P VF PPSU + + 0 0

TECAPEI PEI 0 + + 0

TECAMAX SRP PPP ++ ++ + +

6

Victrex® PEEK™ Polymer Specifications and Approvals. Victrex® PEEK™ polymer and compounds are recognised or approved by the following bodies:

Aerospace/Military

FAR5-5853B Victrex® PEEK™ 381G & 450G meet the fire, smoke and toxicity standard FAR 5-5853 for aircraft cockpit use.

ATS 1000.001 Victrex® PEEK™ 381G & 450G meet the fire, smoke and toxicity standard ATS 1000.001 for optical density and toxicity of fumes from burning.

SP-R-00A Victrex® PEEK™ 450G meets the NASA standard SP-R-00A for vacuum stability of polymeric materials in spacecraft applications.

BMS 8-317A Victrex® PEEK™ unfilled glass and carbon filled polymers can be supplied to Boeing specification BMS 8-317A for use in aircraft applications.

MIL-P-46183 Victrex® PEEK™ polymer and compounds can be supplied to the military specification MIL-P-46183.

Staining Test Victrex® PEEK™ 381G complies with the Boeing Aircraft staining test.

#DMSRR 1018 Victrex® PEEK™ CA30 complies with the Rolls Royce standard #DMSRR 1018.

75-T--3007-4-1 Victrex® PEEK™ CA30 meets the Deutsche Aerospace/Airbus standard 75-T--3007-4-1.

MS9.0.03 Victrex® PEEK™ 450GL30 complies with the Sundstran Aerospace materials specification MS9.0.03.

JAR 5.853 Victrex® PEEK™ 381G meets the fire, smok and toxicity standard JAR 5.853 for flame resistance.

S6 465 Victrex® PEEK™ 381G meets the fire, smoke and toxicity standard S6 465 for non-flaming smoke generation.

VPRM85-10A Victrex® PEEK™ 381G meets the fire, smoke and toxicity standard VPRM85-10A for peak and total heat release when heated.

99-947-36 All grades of Victrex® PEEK™ polymer meet Bell Helicopter specification 99-947-36.

P640 All grades of Victrex® PEEK™ polymer meet General Dynamics specification P640.

HS13534 Victrex® PEEK™ 450FC30 meets Hamilton Standard (United Technologies) specification HS13534.

Flammability Rating

Underwriters Laboratories V-0 Victrex® PEEK™ 450G and compounds 450GL30 and 450CA30 have an Underwriters Laboratories V-0 rating at .057 in. (1.45mm) thickness

ENSINGER High-temperature plastics.Material reference values.

Mechanical Values

Tradename

DIN-abbreviation

Additives and/orcolour

Long TermService Temp°F

ρ σSpsi

σRpsi

εR%

EZksi

EBksi

HK anft-lb/in

σB/1000psi

σ1/1000psi

µ V

VESPEL® (6) SP1 PI brown 300 1,43 86

(a)7,5

(a) 375 3100 0,35

VESPEL® (6) SP21 PI CS 15 black 300 1,51 66

(a)4,5

(a) 3790 0,3

SINTIMID PUR HT PI black 57 1,35 1680 9 580 580 M10 0.6 1740

TORLON® (5) 4203 PAI 500 1,4 000 7,6 650 5000 E86 ,7

TORLON® (5) 4301 PAI CS TF 500 1,46 16400 3,3 990 6900 E7 1,

TORLON® (5) 5030 PAI GF 30 500 1,61 3100 ,3 110 11700 E94 1,5

TECAPEEK PEEKnatural, also black(1)

grey500 1,30 13700 5 435 594 M99

R16 1.6 0.5 00

TECAPEEK GF 30 PEEK GF 30 30% glass fibre 500 1,51 6100 ,5 1377 1450 M103 50

TECAPEEK CF 30 PEEK CF 30 30% carbon fibre,

black 500 1,40 31000 1,5 1718 900 170

TECAPEEK PVX PEEK CF CS TF 10% carbon fibre,

graphite, PTFE, black 500 1,48 18800 1,5 1377 1174 0,0 150

TECATRON PPS natural 446 1,35 10800 1500 4 536 5 M93 0,5 0.4 540

TECATRON GF 40 PPS GF 40 40% glass fibre, natural 446 1,64 685 1,9 030 1885

TECATRON GF 15 VF PPS GF 15 15% glass fibre, black 1,44 17400 1116 1087

TECATRON GF 30 VF PPS GF 30 30% glass fibre, black 1,58 300 1595 1508

TECATRON GF 40 VF PPS GF 40 40% glass fibre, black 1,65 685 1,9 030 030

TECASON P VF PPSU coloured, black (1) 338 1,9 10100 > 50 340 377 R13 13

TECAPEI1000 (ULTEM)

PEI (Ultem®) translucent 338 1,7 155 > 50 464 478 M109 1. 0.17 4000

TECAPEI2300 (ULTEM)

PEI GF 30(Ultem®) 30% glass fibre

338 1,51 3900 1377 1305 0.4 130

TECAMAX SRP PPP black 90 1, 30000 100000 100000 B80 1.0

TECAMID 66 PA 66 1 1,14 11600/8700

40/ 150*

449/ 90 410 R11

M80 1. 7975 1160 0.8 00

TECANAT PC transparent 48 1,0 8700 333 R118/M70 17 6960 610 0,38 500

TECAFORM AH POM-C opaque, also in

black (1) 1 1,41 945 30 391 M75 5800 1885 0,1 65

This data represents the current state of our knowledge and is meantto provide information about our products and their possible applications. It thus does not represent any legally binding guarantee of particular properties of the products or their suitability for a definite purpose.All existing industrial property rights are to be observed.

We ensure the perfect quality of our products within our General Terms and Conditions of Sale. Norm tests are carried out under standard climatic conditions 3/50 according to DIN 50 014.The right is reserved to make technical changes. Unless otherwise specified, the values are average values obtained from many different single measurements from tests on injection moulded specimens.

Specifications

Densit

y

(ASTM

D 79

2, DIN

EN IS

O 1183

)

Tensil

e stre

ngth at

yield

(ASTM

D 63

8, DIN

EN IS

O 527)

Tensil

e stre

ngth at

bre

ak (A

STM D

638,

DIN E

N ISO 52

7, ASTM

D 17

08 (a

))

Elongat

ion at

bre

ak (A

STM D

638,

DIN E

N ISO 52

7, ASTM

D 17

08 (a

))

Modulu

s of e

lastic

ity af

ter t

ensil

e tes

t

(ASTM

D 63

8, DIN

EN IS

O 527)

Modulu

s of e

lastic

ity af

ter f

lexura

l tes

t

(ASTM

D 79

0, DIN

EN IS

O 178)

Hardnes

s: Ball

-pre

ssure

ISO 20

39/1

, Shore

D A

STM D

2240

,

DIN E

N ISO 86

8(d),

Rockw

ell A

STM D

785 ,

ISO 20

39/2

(r)

Impac

t stre

ngth: F

or det

ailed

info

rmat

ion

see f

ootnote

(4)

Creep

-ruptu

re st

rength

afte

r 100

0 h

with

stat

ic lo

ad

Time y

ield lim

it fo

r 1%

elongat

ion af

ter 1

000 h

Coeffic

ient o

f fric

tion o

= 0.

05 n

/mm

2 v =

0.6m

/s

on stee

l, har

dened

and g

round

Wea

r

(conditi

ons as p

revi

ous)

77

0

100

200

300

400

500

600

700

800

900

Electrical ValuesThermal Values Misc. Data

TmOF

TgOF

HDT/AOF

HDT/BOF OF

λBTU-

in/hr-ft2 °F

cBTU/lb · °F

α x 105

in/in/°F

εr–

tan δ–

ρD

Ω·cmRO

Ω/SQ

EdkV/mmv/mil

grade W(H2O)%

WS% – – – Trade

name

360 360 360 0,35 1,13 5,4 3,55 0,0034 1014 - 1015

1015 - 1016 1,3 V0 1,91) 0,001) VESPEL® (6)

SP1

360 360 360 0,87 4,9 13,4 0,01 101 - 1013 9,84 1,1 V0 0,51) 0,01 VESPEL® (6)

SP21

680-707 694 66 1.53 0.5 .44 3,1 0,003 1017 1016 304 ,6 3,6 (+) V0 (+) SINTIMID

PUR HT

545 53 518 1,8 17 3,9 0,031 x1015 8x1018 580 ,5 5,5 (+) V0 + TORLON® (5) 4203

545 534 518 3,7 14 5,4 0,04 8x1013 8x1017 1,9 4,5 (+) V0 + TORLON® (5) 4301

545 539 518 ,5 9 4, 0,05 x1015 1018 840 1,8 4,0 (+) V0 + TORLON® (5) 5030

649 89 84 360 570 1.73 0.08 .8 3,-3,3 0,001- 0,004 1016 1015 480 0,1 0,5 + V0 - TECAPEEK

649 89 599 570 .98 1.1 0,004 1015 1015 609 0,1 0,1 + V0 - TECAPEEK GF 30

649 89 599 570 0,6.38 0.8 105-107()

105-107() 0,1 0,1 + V0 + TECAPEEK

CF 30

649 89 530 570 1.66 1. 3x105 5x106 0,1 0,1 + V0 + TECAPEEK PVX

536 194 30 400 500 .08 .8 1013 1015 450 0,01 + V0 - TECATRON

536 194 500 500 1.73 0.8 . 4 0,004 1013 1015 304 KC 175 0,0 1 + V0 - TECATRON GF 40

536 194 48 1015 0,0 V0 TECATRON GF 15 VF

536 194 491 1015 1015 0,0 V0 TECATRON GF 30 VF

80 90 60 60 0,5 ca. 3 1013 1015 304 KC 175 0,0 1 V0 TECATRON GF 40 VF

44* 40 48 360 0.7 1.7 3,45 1015 1013 360 0,37 1,1 + V0 + TECASON P VF

4 356 39 39 1.53 1.1 3,15 0,001 1015 1015 0,7 1,5 + V0 - TECAPEI1000 (ULTEM)

4 410 40 39 1.60 .9 3.7 0.007 1015 1015 770 0.5 0.9 + V0 - TECAPEI 2300 (ULTEM)

311 30 300(3) .3 3.11 6x1015 x1016 6,44 CTI 150 0,5 0,3 V0 TECAMAX

SRP

500 161/41 1 39 356 1.60 1.60 4.4 3.6-5 0,06- 0,00 101 1010 350 CTI

600 ,8 8,5 (+) HB - TECAMID 66

356 75 84 84 1.3 0.9 3.9 3 0,006 1013 1015 380 KA 1 0,15 0,36 - HB - TECANAT

39 140 30 30 84 0.36 5.5 3,5 0,003 1014 1014 500 KA 3c <0,3 0,5 (+) HB - TECAFORM AH

Vespel® is a registered trade mark of DuPont de Nemours and Company.

Remarks: With polyamides, values are strongly dependent upon moisture content. * wet, after storage in standard climate 3 /50 (DIN 50 014) to saturation. + = resistant (+) = limited resistance – = not resistant (dependent upon concentration, time and temperature)(1)

(1) For plastics, which under “Additives or Colour“ are also quoted alternatively in black, the electrical values do not apply for the black version.() Tested on semi-finished goods.(3) Estimated values.(4) Impact strength is measured according to various methods. The values in the following table are marked with letters according to the method used (c) Charpy: DIN EN ISO 179: an kJ/m

(ai) Izod: ASTM D 56: an J/m (di) Izod: DIN EN ISO 180, an kJ/m

(k) Notch impact strength DIN EN ISO 179: an kJ/m

(5) Only injection moulding (6) Sales in Germany and Great Britain

Source1) NASA, ASTM E-595-90) ESA, ESA PSS-01-703) ESA, ECSS-Q-70-0A

Sp

ecif

ic o

pti

cal d

ensi

ty D

M (

corr

.)

Test conditions:Smoke chamber of the American National Bureau of StandardsSample thickness 3.2 mm flamed

(Source: Victrex® plc.)

Smoke gas density of plastics

ABS

Polyest

er la

min

ate

PVC

Polysty

rene

Polysulfo

ne

Polycar

bonate

PTFE

Phenoplas

ts

Polyet

herim

ide

PEEK 450

Densit

y

(ASTM

D 79

2, DIN

EN IS

O 1183

)

Tensil

e stre

ngth at

yield

(ASTM

D 63

8, DIN

EN IS

O 527)

Tensil

e stre

ngth at

bre

ak (A

STM D

638,

DIN E

N ISO 52

7, ASTM

D 17

08 (a

))

Elongat

ion at

bre

ak (A

STM D

638,

DIN E

N ISO 52

7, ASTM

D 17

08 (a

))

Modulu

s of e

lastic

ity af

ter t

ensil

e tes

t

(ASTM

D 63

8, DIN

EN IS

O 527)

Modulu

s of e

lastic

ity af

ter f

lexura

l tes

t

(ASTM

D 79

0, DIN

EN IS

O 178)

Hardnes

s: Ball

-pre

ssure

ISO 20

39/1

, Shore

D A

STM D

2240

,

DIN E

N ISO 86

8(d),

Rockw

ell A

STM D

785 ,

ISO 20

39/2

(r)

Impac

t stre

ngth: F

or det

ailed

info

rmat

ion

see f

ootnote

(4)

Creep

-ruptu

re st

rength

afte

r 100

0 h

with

stat

ic lo

ad

Time y

ield lim

it fo

r 1%

elongat

ion af

ter 1

000 h

Coeffic

ient o

f fric

tion o

= 0.

05 n

/mm

2 v =

0.6m

/s

on stee

l, har

dened

and g

round

Wea

r

(conditi

ons as p

revi

ous)

Melt

ing p

oint

(DIN

53 76

5, DIN

EN IS

O 3146

)

Glass

tran

sitio

n tem

perat

ure

(DIN

53 76

5, DIN

EN IS

O 3146

)

Heat d

istorti

on tem

perat

ure

DIN E

N ISO 7

5 pro

cedure

A

Heat d

istorti

on tem

perat

ure

DIN E

N ISO 7

5 pro

cedure

B

Servi

ce te

mper

ature

short

term

Therm

al co

nductiv

ity (2

3°C)

Specifi

c

heat (

23°C

)

Coeffic

ient o

f lin

ear t

herm

al e

xpan

sion

(23°

C, ASTM

D 69

6, DIN

ISO 79

91, A

STM E

831)

Diele

ctric

const

ant

(106

Hz,

ASTM D

150,

DIN 53

483,

IE-2

50)

Diele

ctric

loss

fact

or

(106

Hz,

ASTM D

150,

DIN 53

483,

IE-2

50)

Specifi

c volu

me

resis

tance

(ASTM

D 25

7, EC 93

, DIN

IEC 60

093)

Surface

resis

tance

(ASTM

D 25

7, EC 93

, DIN

IEC 60

093)

Diele

ctric

stre

ngth

(ASTM

D 14

9, DIN

EN 60

093)

Resist

ance

to tr

acki

ng

(DIN

EN 6

0112

, VDE 0

303

Part 1

)

Moist

ure a

bsorp

tion to

equili

brium

23 °C

/50%

rel.

air h

umid

ity (D

IN E

N ISO 6

2)

Wat

er a

bsorp

tion a

t sat

uratio

n

(DIN

EN IS

O 62)

Resist

ance

to h

ot wat

er,

was

hin so

da

Flam

mab

ility

acc

. to

UL st

andar

d 94

Resist

ance

to w

eath

erin

g (5

)

Outgas

sing T

ML [

%]

Tota

l Mas

s Loss

Outgas

sing C

VCM.

Collecte

d volat

ile co

ndensa

ble m

ater

ial

Your specialist dealer:

ASK. THINK. SUCCEED. 01/0

7 11

7

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