To maintain functionality of gear sets over their lifetime, the occurring wear and temperature development must be considered. Surface structure is one of the most important factors on the run-in behavior. In this paper, the effects of different process-induced surface structures of steel pinions on the thermal and tribological run-in behavior of a steel-polyamide gear set is investigated.

Initial morphology of the PA66 wheel and area for localizing wear

Polyamide

Kunststoff Werkstoffe

Thermoplaste

Tribologie

Betriebsausrüstung / Betriebsmittel

Getriebe

Maschinenelemente

Effect of Surface Structure on Run-in Wear in Steel-Polyamide Gear Sets

This paper presents a new method for in situ deformation and wear measurement of polymer gears under operating loads. This new approach is based on the highly accurate measurement and tracking of time differences in the index pulses of encoders on the driving and driven side of a gear test rig.

Example pairing of two gears for the determination of elastic, plastic and wear deformation components

Zahnräder

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verschleißprüfgeräte

Messtechnik

Werkstoffprüfung

Test Rig for the In Situ Measurement of the Deformation Characteristics of Polymer Gears

Major trends in the leading fields of application are driving sales of PA6 and 66 – for instance industry 4.0 in the electrical/electronics segment, or e-mobility and lightweight design in automobile manufacturing. China is able to supply itself in the meantime with both plastics as well as important preliminary products such as caprolactam. Capacities for base resins and compounds are increasingly being expanded in the country. Ongoing high prices for PA66 compounds are leading to substitution with PA6 in many applications.  

Improved Material Properties Pave the Way to New Fields of Application  

Polyamide 6 and 66 (PA6 and PA66) 

Polykemi AB, Ystad, Sweden, has the automotive sector firmly in its sights and is positioning itself with innovations in blends, high-performance plastics, and lightweight design and recycling applications at Fakuma 2017. 

Polykemi 

Polycarbonat

Verstärkungsstoffe

Fasern

Novelties for Exterior and Interior Applications 

For a specially good combination of toughness and stiffness, even in high-temperature applications, the TER Plastics Polymer Group, Herten, Germany, is exhibiting its Terez LFT range of grades with good fiber adhesion at the Fakuma trade show. A new product in the range, which usefully complements existing long fiber compounds, is Terez GT3 HLG40 with reduced water absorption. Tribological requirements, even at high temperatures, can be fulfilled with the newly developed grade Terez HT 100 H G30 TF15. According to the manufacturer, special chemical coupling of the lubricating component allows maintenance-free use over long periods. With standard polyamides, glass fiber contents of up to 65 % are now available, which enable high stiffness and strength as well as good surface quality to be achieved. 

TER Plastics Polymer 

Polyethylen

Compound

Range of LFT Compounds Expanded 

High-quality appearance and lightweight design feature prominently on the booth run by Akro-Plastic GmbH, Niederzissen, Germany. The company has developed Akroloy Para ICF 40, an aromatic polyamide with very good flowability (PA MXD 6). Even with 40 % carbon fiber reinforcement, high surface quality with strength values similar to that of metal can be achieved. According to the manufacturer, the surface quality is so high that components can be fitted unpainted in the BMW 7 series. 

Citos seat module produced from Akromid B3 GF 25 9 (6360) by Franz Kiel (© Akro-Plastic) 

Akro-Plastic 

Glasfasern / -matten

Kohlenstofffasern / -matten

New and Extended Product Portfolios 

Besides distributing partner products, Velox GmbH, Hamburg, Germany, has expanded its business activities and is now also offering its own development services under the brand name PrimeTec. According to information from the company, these services include both new individual developments as well as modifications covering a wide product range. In addition, Velox is extending the range of PPA products it sells from its partner Pentac Polymer GmbH, Gross-Umstadt, Germany. These products are suitable for high service temperatures and can be customized for specific applications. Besides Pentamid AHT1 and AHT2, the expanded product range now also includes Pentamid AHS, a blend of PA66 + PPA. With a glass fiber content of 30 to 60 %, AHS offers high mechanical strength and is a suitable metal replacement for service temperatures up to 235 °C, while AHT1 (310 °C) and AHT2 (300 °C) are formulated for higher temperatures. 

Velox 

Additive

Improving Processing and Flame-Retardant Properties 

BASF SE, Ludwigshafen, Germany, has now succeeded in developing a semi-crystalline polyamide that allows light to pass through largely unhindered. Ultramid Vision combines very high light transmission with low light scattering. 

BASF has succeeded in developing a semi-crystalline polyamide that allows light to pass through largely unhindered (© BASF) 

Exceptional Visual Properties 

First Semi-Transparent Polyamide 

If plastics are insufficiently or incorrectly dried, the result is processing problems and rejects. The amount of moisture polymers can absorb, and how quickly they can be dried varies greatly. Studies on PA6, PET, PLA and PHB help us to understand what influence the material properties and the drying parameters have on the drying rate. 

Gentle and Efficient Drying of Moisture-Sensitive Polymers 

Polyethylenterephthalat

Trockner

Debunking the Myths about Drying 

In cast polyamides, the catalyst is retained and remains active, causing the material to degrade during processing in the molten state. To preserve the high-value properties of the material after recycling, specific additives are required. Trials show that it is possible to produce high-viscosity polyamides that can find future use in, for example, thermoforming. 

High-Viscosity Recyclates from Cast Polyamide 6 

Gusswerkstoffe

Kunststoff-Aufbereitung

Wiederaufbereitung

Kunststoff-Recycling

Long-Chained and High-Viscous 

At the beginning of May, Jürgen Becky took over the helm of BASF’s European plastics business. He is steering the ship in the direction of polyamides, 3D printing, and digitalization. In the interview, he explains why BASF is not just a material supplier, why business could not be going better, and why the company will not get everything it would have liked from Solvay. 

Interview with Jürgen Becky on Goals, Markets, and Trends for BASF Plastics 

Industrie 4.0

Additive Fertigung

"Service Requires Trust" 

Evonik Industries AG, Essen, Germany, has developed a new base polymer for the plastics industry. Vestamid HTplus TGP3717 is distinguished by stable mechanical properties at sustained high temperatures. 

Vestamid HTplus TGP3717 

Replacement for Metals 

The change in drive-train technology from the conventional combustion engine to the electric drive poses a big challenge for car manufacturers and suppliers alike. Engineering plastics have versatile properties that offer a wide potential for applications in electric vehicles.  

From the Prototype of the First Lithium-Ion Battery to Thermoplastics for Electrification 

Elektromobilität

Energiemanagement / Ladetechnik

Polypropylen

Synergies from the Far East 

Lightweight is no longer just a matter of replacing metal. More and more often, plastics already in use are substituted by lighter weight polymers. New low-density compounds exhibit not only good materials and processing properties. On top of that, they offer various secondary advantages, such as are illustrated by an engine room bulkhead cover and a car door sill.  

Reducing Density and Part Weight via the Material without Altering Existing Processes 

Strong Flyweights 

Grilamid TR 50 is the latest addition to Ems-Grivory¿s amorphous polyamide product range. The new material combines properties such as high stiffness, optical quality, and chemical resistance with high ductility and toughness.  

Material for Applications in Cell Phones, Cars, Toys, and Beverage Bottles 

Transparent and Safe 

Systematic Use of the Chemical Transformation of Magnesium Hydroxide — a New Approach for Polymer Tribology

Driven by necessary energy and cost savings, plastics are increasingly applied as primary components in tribological systems. The trend is marked by research and development regarding the effectiveness of different material compositions in reducing friction and wear, in which friction induced heat is one of the main challenges.

The contact temperatures have a negative impact on the system’s performance, particularly during variable loading profiles or when using engineering thermoplastics. The systematic use of chemical transformation processes by incorporating reactive fillers like magnesium hydroxide promises a solution. The thesis examines the influence of this filler on the mechanical and thermal properties of a polyamide 66 and, through extensive tribological and surface analytical methods, illuminates the fundamental modes of action. The chemical transformation, initiated by friction induced heat, was confirmed. It introduced a weak spot in low load segments due to a temporary unfavourable interaction between tribochemical and abrasive effects. Compared to an unfilled reference and two control materials, a significant and stable performance increase was achieved over a wide load spectrum. By impeding damage on the integrated fibres and by a reaction turnover dependant scarring effect, the released reaction particles have the highest impact. The use of substances like magnesium hydroxide presents a new approach in polymer tribology and could potentially establish smart materials that are able to dynamically react to changing circumstances via a load-dependant manipulation of the tribological contact.

Polymer; Polymer technology; Magnesium hydroxide; Polyamide 66; Friction; Tribology; Wear; Wear testing; Polymer tribology; Flash temperature

Dissertation Sebastian Kamerling.pdf

20211206 Dissertation Sebastian Kamerling

issue 02/2023

issue 01/2023

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