1. Recent Innovations in Fluorosilicone
Rubber (FSR)
IRC 2009, Nuremberg
Dave Lawson, Dow Corning
co-authors:
Marco Pagliani, Emmanuel Bravais, Craig Gross, Lauren
Tonge, Fabien Virlogeux, Bruno Cuocci, Hans Peter Wolf

2. Objective of Today’s Presentation
• To review recent developments in fluorosilicone rubber (FSR)
and highlight the growing potential for this class of material
1. A multigenerational approach to upgrade our high consistency
FSR for use as high temperature turbocharger hose liner
• Temperature Resistance up to 200-225C
• Oil Resistance
• Interlayer Adhesion and Adhesion Stability
2. New family of liquid FSR (Silastic® F-LSR) that achieves typical
FSR chemical resistance in an injection moldable delivery form
• Fabrication of intricate parts
• Fast cycle time with low scrap rates

3. Introduction to Fluorosilicone and
Fluorosilicone Rubber (FSR)*
* FSR and FVMQ are used interchangeably

4. What is a Fluorosilicone
• Replacing one of a silicone’s methyl groups with trifluoropropyl results in
the following:
– Improved resistance to non-polar hydrocarbon fuels, oils, and solvents
– Increased specific gravity
– Lower refractive index
– Improved solubility in polar fluids such as esters and ketones
– Improved lubricity
– Lower use temperature by eliminating polymer Tm crystallization
-O-Si-O-
CH3
CH3
--
-O-Si-O-
CH3
CH2CH2CF3
--

5. Why Use a Fluorosilicone Rubber
• FSR maintains the extreme temperature resistance of conventional
silicone rubber (VMQ), now with additional levels of chemical resistance
• FSR is therefore uniquely suited to a variety of automotive applications
that require elastomeric components to survive increasingly harsh
conditions
Very HotVery Cold
Aggressive
Fluids


Very HotVery Cold
Aggressive
Fluids




6. Part 1
Recent Developments in High
Consistency FSR for Turbocharger
Hose Applications

7. High Consistency Silicone
Rubber (HCR) is now well
established to satisfy the high
temperature requirements for
“hot side” hoses
Hose liner can be either
Fluorosilicone Rubber (FSR) or
Fluorocarbon (FKM)
Liner needs to provide oil barrier
properties, resistance to extremes
of temperature, plus long lasting
functional performance & hose
integrity
Fluoroelastomer liner
(for oil resistance)
Aramid fabric
(reinforcement)
HCR
Medium
layer
HCR
Outer layer

8. Key Performance Requirements
• Temperature Resistance
• Oil Resistance
• Interlayer Adhesion and Adhesion Stability
• Processing Characteristics
 Calendering
 Co-extrusion

9. Temperature Resistance & Trends
• Under the bonnet temperatures are increasing
• Continuous use temperatures have increased from 175C
 200C  225C and higher
– Euro IV, V, VI …
– Small trucks in US market (US EPA 2007, 2010)
• Peak temperatures of 250C are now common
• Formulation expertise is very important in order to
achieve the highest levels of temperature resistance
• Our optimised FSR formulations show excellent property
retention after relevant heat ageing
• FSR in general shows superior property retention
compared to FKM when measured at typical service
temperatures

10. Heat Ageing - 42 Days @ 200C
• Under these conditions we have been able to reduce the loss in tensile
strength to around 10-25%
• Changes in elongation at break are in the range 35-45%
• Actual (retained) values of elongation after this heat exposure are
typically between 150% and 220%
Property Retention - 42 Days Heat Ageing @ 200C
0
10
20
30
40
50
60
HT1 HT2 HT3 HT4 HT5 HT6
Formulation
%ChangeinProperty
% loss in tensile
strength
% loss in elongation at
break

11. Heat Ageing – 7 Days @ 225C
• Similar trends are observed compared to continuous test at 200C;
stability in general is improved with this combination of higher
temperature/shorter time
• Tensile strength changes are typically ~ 10% or lower
• Elongation at break changes can be as low as 25% (especially
formulations HT1, 2 and 3)
Property Retention - 7 Days Heat Ageing @ 225C
0
10
20
30
40
HT1 HT2 HT3 HT4 HT5 HT6
Formulation
%ChangeinProperty
% loss in tensile
strength
% loss in elongation at
break

12. Peak Temperature Testing from 225C-250C
• Trends are very clear as the severity of this test increases
• Even at 250C we retain around 60% of our starting tensile strength
and 55% of original elongation at break
• 250C peak temperature represents continuous exposure to 225C
• Materials are competitive for continuous hose temperatures of ~ 225C
Property Retention - 7 Day Testing at Peak
Temperatures (Formulation HT2)
0
10
20
30
40
50
225C 230C 240C 250C
Peak Temperature
%Changein
Property
% loss in tensile
strength
% loss in elongation
at break

13. Alternative View: Measure Properties @
Service Temperature
• Room temperature values of > 400% EB are achievable with FSR
• FSR @ 180C can still maintain 200-300% EB
• FKM @ 180C shows < 100% EB
Elongation at Break as Measured @ 180C
0
100
200
300
400
500FSR
#
1
FSR
#
5
FSR
#
6
FSR
#
7
FKM
Ref
AEM
Ref
Material
%Elongation@Break
E.B. @ Room Temp
E.B. @ 180C

14. Oil Resistance
• Hose liner must act as a barrier layer to prevent oil weep
into subsequent layers and degradation of the hose
• Typical testing involves immersion in hot oil and
measurement of change in mechanical properties
• Test temperatures are trending upwards (150C  175C
 200C)
• Oils are becoming more aggressive due to their fully
synthetic nature and additive packages
– Engine wear is reduced
– Service intervals are increased
– Elastomeric components are challenged to survive!
• Our preferred test oil has been LUB MA4 5w30

15. Oil Resistance – 7 Days @ 175C
• This latest range of optimised formulations demonstrates exceptionally
low property changes in this oil immersion test
• Loss in tensile strength can be controlled down to 10-15%
• Best materials exhibit loss in elongation at break of 10-20%
Property Retention - 7 Days Oil Ageing @ 175C in
pre-aged MA4
0
10
20
30
40
50
HT1 HT2 HT3 HT4 HT5 HT6
Formulation
%Changein
Property % loss in tensile
strength
% loss in elongation at
break

16. Interlayer Adhesion and Heat Stability
• We have developed novel adhesion promoter chemistry that achieves
good initial adhesion, but also excellent stability
• Initial peel strength of 2 N/mm is considered acceptable
• Ageing of an FVMQ-VMQ composite @ 200C shows 5% loss in initial
bond strength after 24 hours and just 50% loss after 1 month
• FKM-VMQ composite shows much higher adhesion loss
Adhesion Stability @ 200C
0
1
2
3
4
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Days
PeelStrength(N/mm)
FSR-HCR
FKM-HCR

17. Processing Characteristics
• FSR has many attributes that are well matched with the
needs in this application
• Wide range of hardness  both calendering and co-
extrusion are possible to yield thin and therefore cost
effective layers
 Co-extrusion  simpler and more compact hose designs
 Calendering  more complex, convoluted and larger
diameter hoses
• Similarity between FSR and HCR (chemical nature of
siloxane backbone, cure chemistry, cure speed)

18. Conclusions from PART 1
• We have been able to deliver multigenerational FSR improvements
to meet the increasing challenges of turbocharger hose applications
• We strongly believe in the all round superiority and sustainability of
an FSR-HCR solution for this fast growing segment, given the
established and/or upgraded performance in the following areas:
 Resistance to increasing temperatures
 Resistance to modern, synthetic, aggressive engine oils
 Interlayer adhesion and adhesion stability
 Low temperature performance and flexibility
 Chemical and physical compatibility between FSR and HCR
 Processing efficiencies  fast throughput & low levels of waste
 Wide range of hardness  materials are compatible with fabrication
via both calendering and co-extrusion techniques

19. Part 2
A New Product Line of Liquid FSR
(Silastic® F-LSR)

20. Overview
• We are commercializing a new product line of liquid F-
LSR, including our first 100 mol% F-LSR materials
• These products offer similar chemical resistance to
traditional high consistency FSR, combined with lower
viscosity and processability of an LSR
• An upgraded range of 40 mol% F-LSR copolymers is also
available; this copolymer approach already offers
enhanced performance compared to a silicone rubber
• New design possibilities are now enabled thanks to the
existence of FSR in a genuinely liquid form

21. Product Line
• Copolymers (40 mol%) are available in 45 Shore and 65 Shore
• 100 mol% materials are currently available in 30 Shore and 40 Shore
versions
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100
Mol % Trifluoropropyl Methyl
Durometer
FL 65-9001
FL 45-9001
FL 40-9201
FL 30-9201
DimethylLSRs
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100
Mol % Trifluoropropyl Methyl
Durometer
FL 65-9001
FL 45-9001
FL 40-9201
FL 30-9201
DimethylLSRs
Copolymers (40 mol%) 100 mol%
F-LSRs
Silicone
Rubber

22. General Characteristics
 All these F-LSR materials offer the following capabilities:
 No post cure potential
 Lower use temperature by elimination of polymer melt point
 Wide range of temperature stability
 Good mechanical properties for excellent performance
 The new Silastic® 100 mol% F-LSRs offer further significant benefits:
 Excellent resistance to non-polar hydrocarbon fuels, oils, and
solvents
 Improved solubility in polar fluids such as esters and ketones
 Same fluid resistance as standard high consistency FSR grades

23. Volume Swell Performance
• Data shows the very good swell resistances achieved over extended
testing times
• Note particularly the performance in aggressive diesel type fluids
• Good mechanical properties were retained throughout the ageing tests,
especially for the two Silastic® 100 mol% F-LSRs
• The effect of fluorine substitution is evident in the lower swell for the
100 mol% materials
-2
0
2
4
6
8
10
FL 30-9201 FL 40-9201 FL 45-9001 FL 65-9001
VolumeSwell
MA4 7d/175C SLX 0W30 3d/150C SLX 0W30 500hrs/150C
IRM 903 72hrs/150C FAME Biodiesel 3d/40C Diesel 3d/40C

24. Uncompressed Permeation in CE10 @ 60C
• Data shows results from permeation cup testing
• Test used CE10 (Reference Fuel C with 10% Ethanol) at 60C
• The performance of the copolymer is already significantly better than
the dimethyl HCR
• Silastic® 100 mol% liquid F-LSR and a traditional high consistency
FSR give very similar results (and dramatically lower than the
copolymer offerings)
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
HCR
(VMQ)
Copolymer
F-LSR
FSR
(FVMQ)
FL 40-9201
PermeationRate(gm*mm/m2*day)

25. Blow By Testing using FL 30-9201
BMW Specification GS 97018 : 2001-11
Fluid 1
72 h 120°C Drying : 2 h 23°C + 24 h 60°C + 24 h 80°C + 24 h 120°C
Test Unit Norm Value Change Value Change
Wet status After drying
Hardness Shore A DIN 53505-A 21 -12pts 44 +11 pts
Tensile N/mm2 DIN 53504 S2 3.5 -49% 6.8 0%
Elongation % DIN 53504 S2 290 -25% 298 -23%
50 % modulus N/mm2 DIN 53504 S2 0.33 -30% 0.76 +62%
100% modulus N/mm2 DIN 53504 S2 0.71 -26% 1.54 +60%
weight change % 7.5 -2.3
volume change % 14.8 -2.2
•Very good retention of elastomeric properties with 100 mol% F-LSR
•Elongation at break still ~ 300%
•Relatively low volume swell, even at wet stage

26. Blow By Testing using FL 30-9201
BMW Specification GS 97018 : 2001-11
Fluid 2
72 h 120°C
Drying : 2 h 23°C + 24 h
60°C + 24 h 80°C + 24 h
120°C
Test Unit Norm Value Change Value Change
Wet status After drying
Hardness Shore A DIN 53505-A 34 1pts 37 +4 pts
Tensile N/mm2 DIN 53504 S2 6.7 -1.5% 7.4 9%
Elongation % DIN 53504 S2 402 +4.4% 382 -0.8%
50 % modulus N/mm2 DIN 53504 S2 0.5 +6.4% 0.55 +17%
100% modulus N/mm2 DIN 53504 S2 0.97 1% 1.11 +16%
weight change % 1.8 -0.5
volume change % 2.6 -0.5
•Exceptional stability to aqueous/acidic environment
•Volume changes very low
•Elongation at break virtually unaffected

27. Selected Features/Benefits
• Processable via Injection Molding
• Low Viscosity/Extended Pot Life
• Fast Cycle Time
• Overmolding Capabilities
• Pigmentable
• Etc

28. Processable via Injection Molding
• Silastic® F-LSR processes like conventional dimethyl silicone LSR
• Fabrication of intricate fuel resistant parts is now possible
• No special equipment or tooling is necessary
• Pot life > 3 days is typical
BA
Injection Molding Machine
•Standard Injection Molding Machine
•Special LSR Screw and Barrel
•Spring loaded Non-Return-Valve
•Cooled Barrel to 23°C
Mold
•Heated Mold up to 125 - 175°C
•Cold Runners
•Hardened Steel
•Exact Finishing 1/1000 mm
•Vacuum
Pump / Mixer
•Hydraulic or Pneumatic
•Pressure 180 - 220 bar
•Trough Static Mixer
•Plus Color Additive
Silastic LSR
•Pourable to Paste
•2-Component
•1:1 Mixing Ratio
•Supply in 20 l pails
or 200 l Drums
Injection Molding Equipment
BA BA
Injection Molding Machine
•Standard Injection Molding Machine
•Special LSR Screw and Barrel
•Spring loaded Non-Return-Valve
•Cooled Barrel to 23°C
Mold
•Heated Mold up to 125 - 175°C
•Cold Runners
•Hardened Steel
•Exact Finishing 1/1000 mm
•Vacuum
Pump / Mixer
•Hydraulic or Pneumatic
•Pressure 180 - 220 bar
•Trough Static Mixer
•Plus Color Additive
Silastic LSR
•Pourable to Paste
•2-Component
•1:1 Mixing Ratio
•Supply in 20 l pails
or 200 l Drums
Injection Molding Equipment

29. Fast Cycle Time
• Short cycle times enhance process productivity and production flexibility
• Mold temperatures can be reduced whilst retaining short molding cycles
• Temperature dependence for platinum cured F-LSR is much less than
for peroxide cured high consistency FSR
0
1
2
3
4
5
6
7
8
9
10
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0
Time, min
Torque,lb-in
F-LSR 120°C F-LSR 140°C F-LSR 160°C
FSR 160°C FSR 180°C FSR 200°C

30. Overmolding Capabilities
• Fast cycle times can still be achieved at reduced molding
temperatures  it is therefore possible to overmold Silastic® F-LSR
onto temperature sensitive plastic parts
• This capability offers scope for supply chain efficiencies since
multiple operations can be integrated (either by the silicone or the
plastic molder)
• Key benefits include:
– Saving time
– Saving costs on shipment and stock of intermediate parts
– Reducing quality assurance issues of incoming parts made
elsewhere
– Removing the cost of assembling parts
• F-LSR can enable efficiency improvements through innovative
design possibilities and flexibility in the fabrication of multi-
component parts (rubber-plastic composites)

31. Conclusions from PART 2
• This new class of F-LSR materials unites FSR and LSR
technologies with a new range of 100 mol% Liquid Fluorosilicone
Rubber (Silastic® F-LSR)
• This product line is further complemented with an expanded
range of 40 mol% copolymer offerings
• Materials can be processed with standard liquid injection molding
machines to achieve fabrication of intricate parts with a high level
of chemical resistance
• New design possibilities are now available with this unique
technology
• We are now in the position to offer the market a family of
materials that combines the best properties of high consistency
FSR with the processing efficiencies of an LSR

32. Final Summary
• We have described 2 areas of recent innovation in the field of
FLUOROSILICONE RUBBER
 In traditional high consistency form, optimised FSR hose liners
facilitate the continued growth in turbocharging, with its associated
benefits (reduced CO2 emissions, improved fuel economy etc)
 We have demonstrated performance to continuous temperatures
of 200-225C, exceptional oil resistance and a unique, patented
solution that achieves high and stable interlayer adhesion
 In liquid form, our Silastic® F-LSR materials offer new design
possibilities with both copolymer & 100 mole% fluorinated offerings
 Their combination of chemical/temperature resistance,
processability and fast cycle times make these new materials
unique to designers, fabricators and OEMs who are looking for
innovative and differentiated solutions
 The opportunity now exists to fabricate small, intricate parts that
withstand contact with aggressive fuels/oils over a wide range of
operating temperatures

33. Thank you for Listening!