Ethan Clarke
While metals like nickel and stainless steel are often used for high-performance applications due to their heat resistance, there are many instances where heat-resistant plastics are a better choice. Heat-resistant plastics can be categorised as thermoplastics or thermosets. Thermoplastics, such as PEEK, become molten when heated and can be reshaped, while thermosets, such as Vespel, harden when exposed to heat and cannot be reshaped. Factors such as the glass transition temperature and melting point affect the structural integrity of thermoplastics. PTFE, also known as Teflon, is another example of a heat-resistant plastic with unique properties, making it ideal for various applications. Polyamide, or Nylon, is also a heat-resistant plastic with excellent properties when combined with additives.
| Characteristics | Values |
|---|---|
| Continuous-use temperature | 150°C (302°F) or above |
| Short-term exposure resistance | 250°C (482°F) or more |
| Operating temperature range | -200°C to +260°C |
| Corrosion resistance | Better than metals in some cases |
| Manufacturing flexibility | Can be manufactured using injection moulding |
| Weight | Lighter than metals |
| Electrical insulation | Good |
| Chemical resistance | Good |
| Mechanical properties | Exceptional |
| Types | Thermoplastics, thermosets, photopolymers |
| Examples | PTFE, PEEK, Polybenzimidazole (PBI), Polyphenylene sulfide (PPS), Polyetherimide (Ultem), Polycarbonate, Polysulfone (PSU) |
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PTFE/Teflon
PTFE, commonly known as Teflon, is a soft, heat-resistant, low-friction plastic with exceptional chemical resistance. PTFE has a wide range of applications due to its impressive characteristics. It has a high melting point of 327°C, one of the highest of any thermoplastic, and an operating temperature range of -200°C to +260°C.
PTFE is unique in that it is chemically inert and insoluble in most solvents, making it ideal for high-temperature applications. Its low friction and strong anti-adhesion properties make it perfect for non-stick pots and pans. PTFE is also used in the aerospace industry, as it is excellent at reducing friction and has good electrical insulating power in hot and wet environments. PTFE is also available in food-grade form, making it suitable for use in the food industry.
PTFE is also used in medical packaging, plumbing, and in the chemical industry, where its corrosion resistance is beneficial. It is also used in the production of carbon fibre composites and as a coating for magnetic stirrers in laboratories. PTFE is further used in the semiconductor industry, where its chemical resistance is critical.
PTFE's ability to withstand high temperatures in its virgin form, without additives or fillers, makes it one of the most versatile plastics. It can be continuously exposed to temperatures of 260°C without losing its mechanical properties. However, PTFE is sensitive to abrasion and radiation, and its fumes can be toxic. It is also relatively expensive to process.
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Polybenzimidazole (PBI)
PBI has an extraordinarily high decomposition temperature and stability, with a maximum continuous service temperature of 398°C in inert environments, 343°C in air, and short-term exposure potential up to 537°C. It does not exhibit a melting point, and its high stability at temperatures over 400°C makes it a highly heat-resistant plastic.
The PBI stock shapes have a glass transition temperature of about 425°C and a heat deflection temperature of about 435°C at 264 psi. PBI rods and sheets also show excellent thermal tolerance and chemical resilience to a wide range of compounds, including alcohols, hydrocarbons, chlorinated solvents, hydrogen sulfide, heavy acids, and bases.
The applications of PBI include demanding sealing in valve seats, stem seals, hydraulic seals, and backup rings. PBI resin is used in the aerospace industry due to its high strength and short-term high-temperature resistance. Its high dimensional stability and retention of electrical properties at high temperatures make it valuable as a thermal and electrical insulator.
PBI is also used in the fabrication of high-performance protective apparel, such as firefighters' gear, astronaut spacesuits, high-temperature protective gloves, welders' apparel, and aircraft wall fabrics. The moisture regain ability of PBI makes it comfortable for protective clothing, and its flame-resistant property further enhances its suitability for these applications.
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Vespel
The Vespel® SP Family grades are available in a number of formulations, including an unfilled grade (Vespel® SP-1) and filled grades with enhanced mechanical properties, dimensional stability, and friction and wear performance. The Vespel® SCP Family grades are stronger and stiffer and have superior long-term thermal stability compared to the SP grades.
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Polyetherimide/Ultem
Polyetherimide, also known as Ultem®, is a semi-transparent, high-strength plastic with excellent electrical insulation and high-temperature performance. It is a popular choice for applications requiring high heat resistance, such as in the automotive and aerospace industries. Ultem® is also FDA-compliant, making it suitable for use in food-related contexts.
One of the key advantages of Ultem® is its ability to maintain stable electrical properties over a wide range of frequencies while resisting high temperatures. This makes it ideal for electrical insulation parts, connectors, and other components requiring high electrical performance in elevated temperature environments.
In addition to its heat and electrical resistance, Ultem® offers good chemical resistance and ductile properties. It can withstand repeated cycles in a steam autoclave, making it suitable for applications involving steam exposure. However, it is important to note that Ultem® is less durable than other engineering plastics such as acetal and nylon, and it has relatively low tensile elongation and impact strength.
Ultem® is available in different grades and sizes to meet specific requirements. For example, Ultem® 1000, an unfilled or unreinforced plastic, combines exceptional mechanical, thermal, and electrical properties. It is translucent amber in colour and is FDA-compliant. SABIC, a manufacturer of Ultem®, also offers a portfolio of ISCC+ certified renewable bio-based Ultem® resins that deliver the same high performance while providing sustainability benefits.
Overall, Polyetherimide/Ultem® is a versatile high-performance plastic with excellent heat resistance, electrical properties, and chemical resistance, making it suitable for a wide range of applications, including those in the medical, scientific, and semiconductor equipment industries.
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Polysulfone (PSU)
Polysulfone, also known as PSU, is a semi-transparent, high-temperature plastic with good strength and rigidity. PSU has a continuous service temperature of over 300°F (148.8°C), classifying it as a heat-resistant plastic.
PSU is resistant to degradation from hot water and steam, making it ideal for applications requiring repeated sterilization, such as medical and food preparation equipment. It has better chemical resistance than polycarbonate and is dimensionally stable over 300°F. Its high-temperature capabilities and strength make it suitable for use in autoclaves.
PSU is also available in FDA-compliant grades, making it safe for use in food-contact applications. It is a low-cost plastic with excellent aesthetic qualities, making it a versatile choice for various applications.
The use of PSU in high-temperature applications offers several advantages over metals. Firstly, plastics are generally lighter than metals, making them ideal for industries such as automotive and aerospace, where lightweight components are crucial for efficiency. Secondly, PSU offers better corrosion resistance than metals when exposed to a wide range of chemicals, which is particularly advantageous in corrosive environments. Finally, plastic components offer more manufacturing flexibility, as they can be produced using high-volume technologies like injection moulding.
Overall, PSU is a strong and rigid high-temperature plastic with excellent chemical and corrosion resistance, making it a versatile choice for applications requiring repeated sterilization and high-temperature performance.
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Frequently asked questions
A heat-resistant plastic is any plastic that has a continuous-use temperature of above 150°C (302°F) or a short-term exposure resistance of 250°C (482°F) or more.
Some plastics with high heat resistance include Polyetheretherketone (PEEK), Polyetherimide (Ultem), Polyphenylene sulfide (PPS), Polybenzimidazole (PBI), Vespel, and Polytetrafluoroethylene (PTFE or Teflon).
When choosing a heat-resistant plastic, it is important to consider the load conditions, corrosive environments, duration of high-temperature exposure, and the material's thermal expansion properties. Additionally, the specific application and budget may also influence the selection of a particular plastic.
Heat-resistant plastics offer several advantages over metals, including lower weight, corrosion resistance, and manufacturing flexibility. Plastics are lighter than metals, making them ideal for industries that require lightweight components, such as automotive and aerospace. Some plastics also exhibit better corrosion resistance than metals when exposed to a wide range of chemicals. Plastics can also be manufactured using high-volume production technologies, offering greater flexibility in the production process.
Heat-resistant plastics are suitable for a wide range of applications, including automotive, aerospace, electrical equipment, medical technology, and chemical industries. They can be used for piston components, cable conduits, subsea connectors, circuit boards, lighting, and medical devices, among others.
