Using plastics instead of metal saves cost
and effort. These cost savings already begin with the manufacture of the molded
parts. Die casting alloys require melting temperatures of 400 to up to 600°C.
High-performance polyamides are generally processed at temperatures lower than
340° requiring significantly less energy.
The potential weight reduction of the molded parts is as high as 75%, an essential factor in improving ultimate energy efficiency, especially in the automotive and transportation areas. The shortening of work processes is an additional advantage. Finishing work on the molded parts can usually be completely eliminated.
Additionally, plastics offer more design freedom. In the conventional metal die casting processes, components with a wall thickness of approximately 0.9 mm and greater are produced. By contrast, the use of high-performance polyamides make very thin wall thicknesses possible. Wall thicknesses to be filled of only 0.2 mm are not unusual anymore. With the alternative use of plastics instead of metal, corrosion resistance, too, has become a non-issue, along with sustainability and recyclability.
An intensive examination of the requirement
profiles and product properties is always the first step for the right product
choice. Plastics that are suitable for metal replacement are, above all,
characterized by two essential properties: high strength and stiffness. The
dominant materials used here are polyamides, closely followed by polyesters
(PBT/PET). To achieve the described properties, a high reinforment material
content must be relied on. This is primarily achieved by a glass fiber filling
content of more than 50%.
The ultimate service temperature of the
work piece is an important criterium for the choice of materials, too. We
differentiate here between two material categories: materials that are suitable
for applications in the service temperature range of up to 150°C and those that
are used in the high temperature range. PA 6 , PA 66 , PBT and PET are
especially suitable as raw materials for the first category. For higher service
temperatures, high-performance products such as PA 4.6 and PPA are
desirable. The temperature gap between these groups can be bridged with
specially modified PA 66.
Our experts and product developers who specialize in metal replacement will be happy to advise you in detail on choice of product, processing and possibilities.
Please choose a brand or a producer or a generic product group!
Our product information and suggestions are based on analyses, empirical values, and data from the product manufacturer in question and are therefore provided with our best knowledge and accountability.
We do not, however, assume any liability or warranty, be it for defects in title, quality and suitability of the products for a specific purpose, or non-infringement of industrial property rights.
We do not warrant the use or processing of the products and information, or consequences of any kind arising from product descriptions, suggestions, and recommendations.
The responsibility for appropriate usage, as well as final suitability testing of the raw material is exclusively the responsibility of the customer as part of sampling/final qualification of a manufactured molded part.
The specified data are only indicative and are not to be interpreted as legally binding specifications.X