This document appears to be from a forum on metal replacement that was held on June 6-7th, 2013 in Malpensa, Italy. It includes presentations on structural polyamides from Radici Plastics that can replace metals, including Radilon and Radistrong grades. Data shows the polyamides offer higher strength, stiffness, fatigue resistance, and lower density compared to aluminum and magnesium alloys. The document also discusses using coupled simulation and analysis tools to optimize plastic part design for requirements like burst pressure that consider fiber orientation from molding. Overall it promotes using structural polyamides from Radici Plastics to replace metals in applications.

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FORUM 2013METALMalpensa, 6th and 7th June 2013
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Erico SPINI, Radici Plastics MKT Director

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Stress(Mpa)
Strain (%)
Stress-Strain Curves Comparison
(23°C, DAM, ISO 527)
PA66-GF50
Radilon® ARV500RW
+ 12 % tensile strength at break
+ 20 % tensile deformation at break

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Stress(Mpa)
Strain (%)
Stress-Strain Curves Comparison
(23°C, DAM) ISO 527 Double Injection
Radilon® ARV500RW
PA66-GF50
+ 20 % tensile strength at break
+ 30 % tensile deformation at break

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Radilon® A RV500 RW blk 339 offers higher stress and strain at
break versus standard PA66-GF50 at high speed and therefore
absorbs more energy in case of impact.
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Stress(Mpa)
Strain (%)
Stress-Strain Curve Comparison at Different Speeds
(23°C, DAM, ISO 527)
Rad A RV500RW : 1 mm/sec
Rad A RV500RW : 100 mm/sec
PA66-GF50 : 1 mm/sec
PA66-GF50 : 100 mm/sec

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Smax(Mpa)
Cycles to Failure (Millions)
Fatigue Behaviour Wöhler Diagram - Sinusoidal
Displacement, 5hz, R= min stress/max stress =0.1
23°C - RH50 (water content 1.24 %)
PA66-GF50
Radilon® ARV500RW
Radilon® A RV500 RW blk 339 higher performances versus
standard grades are fully confirmed in case of long term dynamic
loading (fatigue)

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Tensile Strength at Break is not affected by a melt temperature
until 320°C. The material has been designed to withstand high
processing temperature.
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TensileStrength(Mpa)
Melt Temperature (°C)
Tensile Strength at Break at Different Melt
Temperatures (23°C, DAM, ISO 527)
Barrel residence
time 10 minutes

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Flow Length + 40%
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SpiralLength(mm)
Injection Pressure (Bar)
Spiral Length Comparison
High Flow
Radilon® S URV600LW
PA6-GF50
High Flow
Radilon® S URV600LW
PA6-GF50

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Stress(Mpa)
Strain (%)
Stress-Strain Curve Comparison ISO 527
(DAM) at 150 °C
Radistrong® A LGF50W
PA66-GF50
+ 25 % tensile strength at break

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Radistrong© LGF PA66 versus PA66-GF properties comparison
Charpy Notched Impact
Impact Energy Absorption
Tensile Strength at Break
(23 °C)
Tensile Strength at Break
(150 °C)
Elongation at BreakCreep
Heat resistance
Tensile Modulus (23 °C)
Tensile Modulus (150 °C)
PA66-GF Radistrong© LGF

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Metal Replacement
Structural Polyamides
show comparable
tensile strength at
break versus light
metal alloys
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Al Die Cast AlloyZn Die Cast Alloy Mg Die Cast
Alloy
Radilon A RV500
RW 339 Ner
Radilon S
URV600 100 Nat
TS(Mpa)
Tensile Strength at Break
Al Die Cast Alloy
Zn Die Cast Alloy
Mg Die Cast Alloy
Radilon A RV500 RW 339 Ner
Radilon S URV600 100 Nat
Radilon® versus metals properties comparison

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Metal Replacement
Structural Polyamides
show better fatigue
behaviour than light
metal alloys
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Al Die Cast Alloy Zn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW
339 Ner
Radilon S URV600 100
Nat
Mpa
Tensile Fatigue Limit at 7 million cycles
Radilon® versus metals properties comparison

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Metal Replacement
Structural Polyamides
show low density than
light metal alloys
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Al Die Cast Alloy Zn Die Cast Alloy Mg Die Cast Alloy Radilon A RV500 RW
339 Ner
Radilon S URV600 100
Nat
g/cm3
Density
Radilon® versus metals properties comparison

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Metal Replacement Typical Targets

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Metal Replacement Typical Targets

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Metal Replacement Typical Targets
Part name : Transmission Reaction Bracket
Parts/year : 150000
Life time : 6 years
Materials : Radilon® A RV500RW versus Aluminium
Cost (€) Radilon® A RV500RW
Tool cavities : 2
Aluminium
Tool cavities : 2
Material 1 0,8
Processing 0,3 1,1
Assembly &
Finishing
0,15
Machining 0,35
Tool
Amortization
0,1 0,28
Total cost 1,55 2,53

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Metal Replacement Typical Targets

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Metal Replacement Typical Targets
Virtual design from metal to plastics through optimization step.
Interactive collaboration with development partners in :
1- part design optimization
2- stress analysis
3- process analysis
STEP 1 STEP 2

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Metal Replacement Typical Targets
Part design approach comparison.
Part name : gas/water connector
Objective : burst pressure calculation at 23 °C
Material: Radilon A RV500RW (PA66-GF50, enhanced mech properties)
Hp 1 : isotropic material
Hp 2 : coupled process simulation + structural analysis
Type of analysis : non linear

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Metal Replacement Typical Targets
Part design approach comparison
Hp1 : isotropic behaviour
Stress and strain distribution, as expected, is the
same for the different part section
Calculated burst pressure is overestimated
Difference between calculated and measured burst pressure 20%

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Metal Replacement Typical Targets
Part design approach comparison
Hp2: coupled process simulation + structural analysis
First step : moldflow analysis
Welding line presence !
Part weakest section

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Metal Replacement Typical Targets
Part design approach comparison
Hp2: coupled process simulation + structural analysis
First step : moldflow analysis
Output : fibers orientation tensor to be used as input for structural
analysis

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FORUM 2013METALMalpensa, 6th and 7th June 2013
Metal Replacement Typical Targets
Part design approach comparison
Hp2 : coupled process simulation + structural analysis
Stress and strain distribution are not anymore simmetric since fiber
orientation is considered
Difference between calculated and measured burst pressure down to 5%

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Metal Replacement Typical Targets

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Erico SPINI, Radici Plastics MKT Director