Maya Ellison
Heat-resistant plastics are polymeric materials that can withstand continuous operating temperatures exceeding 150°C without compromising their mechanical properties. They are lightweight, versatile alternatives to metal, ceramics, and older-generation polymers. The most heat-resistant plastics include Polyetherimide (PEI), Polyether Ether Ketone (PEEK), Politetrafluoroethylene (PTFE), Polyamide-imide (PAI), Polyphenylene Sulfide (PPS), and Vespel. Each of these plastics has unique characteristics, such as high strength, stiffness, thermal stability, and chemical resistance, making them suitable for various applications in industries like aerospace, automotive, electrical, and biomedical.
| Characteristics | Values |
|---|---|
| Permanent operating temperature | 150° C and above |
| Reinforcing materials | Glass fiber, glass beads, carbon fiber |
| Additives | PTFE, graphite, aramid fibers, metal fibers |
| Applications | Aerospace, automotive, biomedical, electrical, solar panels, photovoltaic panels, wire and cable industry |
| Examples | Vespel, PEEK, PTFE, PAI, PPS, PVDF, PEI, Torlon, Noryl |
| PEEK characteristics | Semi-crystalline thermoplastic, high strength, stiffness, wear resistance |
| PTFE characteristics | High thermal stability, non-stick, thermal conductivity, chemically inert |
| PAI characteristics | Mechanical strength, thermal stability, excellent strength, stiffness, wear resistance |
| PPS characteristics | Dimensional stability, small degree of shrinkage during molding, good electrical insulation |
| PVDF characteristics | Electrical insulation |
| PEI characteristics | Strength, stability, flame resistance, dielectric strength |
| Torlon characteristics | Long-term strength, stiffness, wear resistance, creep resistance, chemical resistance |
| Noryl characteristics | Stable in boiling water, excellent electrical insulation |
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What You'll Learn
Polyetherimide (PEI)
Polyetherimide was first developed in 1982 by the General Electric Company (now known as SABIC) under the trade name Ultem. It is one of a handful of commercially available amorphous thermoplastics. It is strong, chemical-resistant, and flame-resistant, and has the highest dielectric strength of any high-performance thermoplastic. It is suitable for continuous service at temperatures up to 338°F.
Polyetherimide's polymeric structure includes ether (E) linkages to the polyimide (PI) molecular structure. This modification allows PEI to be melt-processed by injection moulding and extrusion, a limitation of traditional polyimide materials. Its high aromatic content also makes it radiation-stable.
Polyetherimide is used in a wide range of industries, including aerospace, automotive, glass, electrical, semiconductor, and medical devices. It is also used in food processing equipment due to its ability to retain its properties after extended exposure to steam and hot water.
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Vespel
Unlike most plastics, Vespel does not produce significant outgassing even at high temperatures, which makes it useful for lightweight heat shields and crucible support. It also performs well in vacuum applications, down to extremely low cryogenic temperatures. However, Vespel tends to absorb a small amount of water, resulting in longer pump time while placed in a vacuum. Although there are polymers surpassing polyimide in each of these properties, the combination of them is the main advantage of Vespel. Vespel is commonly used as a thermal conductivity reference material for testing thermal insulators, because of the high reproducibility and consistency of its thermophysical properties. For example, it can withstand repeated heating up to 300 °C without altering its thermal and mechanical properties.
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Polyether Ether Ketone (PEEK)
PEEK exhibits excellent thermal stability and is highly resistant to thermal degradation. It has a low thermal conductivity, making it suitable for fused filament fabrication (FFF) printing to thermally separate the hot and cold ends. PEEK is also used in fused deposition modelling (FDM) and can be processed into filament form for 3D printing medical devices.
In its solid state, PEEK is readily machinable and is commonly used to produce high-quality plastic parts that are thermostable and electrically and thermally insulating. PEEK plastics maintain their structural integrity even when repeatedly subjected to heavy loads, stress, and impact, exhibiting excellent tensile strength and resilience.
The complex production process of PEEK results in a high price, restricting its use to demanding applications. PEEK is available in various grades, such as unfilled, carbon fiber-reinforced, and glass fiber-reinforced, each offering different properties like improved stiffness, dimensional stability, and mechanical strength.
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Polyamide-imide (PAI)
PAI is recognized as the highest-performing melt-processable polymer available. It is part of the imide family of resins and is closely related to two other high-temperature aromatic imide polymers: polyetherimide (PEI) and polyimide (PI). However, PAI differs from polyimide in that it can be melt-processed into extruded shapes and injection-molded parts, while polyimide cannot. PAI offers impressive strength under load at high temperatures and maintains its rigidity even as it approaches its glass transition temperature (Tg) or softening point of 537°F (280°C). It also resists deformation under static load over time due to its superior compressive strength and creep resistance.
PAI has a wide range of applications due to its exceptional performance characteristics. It is used in industrial machines, cars, and aerospace technology. For example, PAI is used as a magnet wire enamel, which is made by dissolving PAI powder in a strong, aprotic solvent. PAI is also used in decorative, corrosion-resistant coatings for industrial uses and in non-stick cookware coatings. PAI formulations with additives enhance their bearing and wear properties, making them ideal for moving and rotating components under load.
The ability to melt-process PAI through extrusion and injection molding has led to numerous applications for this ultra-high-performance polymer. PAI is available in various forms, such as rods, plates, tubes, and precision components, to meet the diverse needs of different industries. Overall, PAI's heat resistance, strength, and versatility make it a valuable material for high-temperature and demanding applications.
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Polyphenylene Sulfide (PPS)
PPS is an engineering plastic commonly used as a high-performance thermoplastic. It can be moulded, machined, or extruded to tight tolerances. PPS has excellent dimensional stability, unmatched chemical resistance, and inherent electrical insulation. It also has high tensile strength, making it capable of withstanding high levels of stress before breaking. PPS is flame-resistant and can achieve UL 94 V-0 flammability ratings without any additional fillers or additives.
The maximum service temperature of PPS is 240°C (464°F), and it has a melting temperature of 280°C (540°F). PPS has a high heat deflection temperature (HDT), only deforming at 115°C (250°F) under a load of 1.8 MPa (264 PSI). PPS parts can withstand a continuous service temperature of 220°C (425°F) for 20,000 hours in air.
PPS is an excellent lower-cost alternative to pricier materials like PEEK and PAI in applications requiring great dimensional stability at moderate-to-high temperatures. It is often used as a lower-cost alternative to PEEK when metal would be too heavy. PPS is suitable for automotive parts, appliances, electronics, and other applications requiring high-temperature exposure.
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