Technical Information

Hytrel

Thermoplastic Polyester Elastomer

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DuPont
Engineering Polymers DuPont registered trademark
Module V
Design information

Table of contents
Introduction
1. Physical properties of HYTREL

1.1 Mechanical properties

1.1.1 Tensile properties
1.1.2 Compressive properties
1.1.3 Elastic modulus
1.1.4 Flexural modulus
1.1.5 Creep modulus
1.1.6 Compressive creep
1.1.7 Useful temperature range
1.1.8 Dynamic properties
1.1.9 Resistance to fatigue
1.1.10 Ross Flex (ASTMD 1052)
1.1.11 DeMattia Flex (ASTMD 813)
1.1.12 Friction and wear
1.1.13 Impact resistance
1.1.14 Notched Izod impact (ASTMD 256)
1.1.15 Instrumented impact (ASTMD 3763)
1.1.16 Brittleness temperature (ASTMD 746)
1.2 Thermal properties
1.3 Electrical properties
1.4 Physical properties
1.5 Other physical properties
2. Effect of environment
3. Regulatory compliance
4 Design concepts for HYTREL

4.1 General considerations

4.1.1 Defining the end-use requirements
4.1.2 Design checklist
4.1.3 Drafting the preliminary design
4.1.4 Prototyping the design
4.1.5 Testing the design
4.1.6 Taking a second look
4.1.7 Writing meaningful specifications
4.1.8 Setting up production
4.1.9 Controlling the quality
4.2 Multifunctional component integration
4.2.1 Hydraulic piston seal
4.2.2 Vacuum or pressure activated mechanism
4.2.3 Linkage suspension
4.2.4 Solenoid mount
4.3 Controlling shock, vibration and noise
4.3.1 Solenoid mount
4.3.2 Engineered footwear
4.3.3 Suspension system
4.3.4 Strut rebound bumper
5. Designing for specific applications
5.1 Bearings and seals
5.1.1 Unlubricated bearings
5.1.2 Lubricated bearings
5.1.3 Design considerations
5.2 Boots and bellows
5.3 Rollings diaphragms
5.4 Belts
5.5 Coiled tubing and cables
5.6 Reinforced hose
5.7 Seals, valves and pumps
Design principles for HYTREL

thermoplastic polyester elastomers

HYTREL

thermoplastic polyester elastomers are high per-

formance polymers characterized by:
Excellent flexibility at room and low temperatures.
Excellent flex crack resistance.
High resilience.
Excellent resistance to stress relaxation and creep.
Resistance to swell in oils and aliphatic and aromatic hydro-
carbons at moderate temperatures.
Conventional thermoplastic processing methods such as injec-
tion moulding, extrusion, melt casting and rotational moulding
can be utilized for producing tubing, rods, slabs, sheeting, film
or specific shapes. Machining operations like bandsawing,
turning, milling, drilling and tapping can be employed as fab-
rication or finishing techniques when necessary.
This brochure is intended to assist design engineers in the
successful and efficient design of parts of HYTREL

thermo-
plastic polyester elastomers. Many of the same design
considerations apply to HYTREL

as to metals and other engi-

neering materials of construction.
It is common practice to use standard engineering equations
for designing with HYTREL

. However, since all engineering

materials are affected to some extent by temperature, moisture
and other environmental service conditions, it is necessary to
determine the extreme operating conditions and to design a part
so that it will perform satisfactorily under all these conditions.
The selection of the best material for any application requires
a knowledge of the properties for all candidate materials and
how they satisfy the requirements of the application. HYTREL

may be chosen for a job because of one or a combination of its

properties.
Much of the engineering data needed in designing with
HYTREL

is given in the following pages and should be help-

ful to the designer. However, it is always important to test
prototypes of a proposed design and material under realistic
conditions before making production commitments.
Introduction
1. Physical properties of HYTREL

1.1 Mechanical properties

The hardness of HYTREL

thermoplastic polyester elastomers

spans the range from hard rubber at 40 durometer D to engi-
neering plastics with a hardness of 72 durometer D. Typical
properties for various types of HYTREL

are shown in Table 1.01.

1.1.1 Tensile properties
Tensile properties over a range of temperatures are shown in
Figures 1.01 through 1.05. Figures 1.06 through 1.10 show ten-
sile properties at low strain levels, which is the range most used
for design purposes. HYTREL

polyester elastomer will yield,

as most thermoplastic do, when strained and will take som
permanent set. Values of tensile set versus strain are shown in
Figures 1.11 and 1.11a.
1
Table 1.01 Typical mechanical properties
ASTM
HYTREL

thermoplastic polyester elastomer

Property Method Units 4056 G4074 5556 6356 7246
Hardness D 2240 Shore D 40 40 55 63 72
Specific gravity D 792 1,17 1,18 1,20 1,22 1,25
Melting point D 3418
Peak of endotherm C 150 170 203 211 217
Melt complete C 170 183 220 230 232
Tensile strength D 638 MPa 28,0 13,8 40,0 40,0 45,8
Elongation at break (23C) D 638 % 550 207 500 420 360
Flexural modulus D 790 MPa 62 65,5 207 330 570
Resilience, Bashore % 62 53 53 43 N.A.
Compression set, 22 hrs at 70C
1
Constant load (9,3 MPa) D 395A % 27 28 4 2 2
Tear strength D 624
Die B kN/m 110 102 164 185 238
Die C kN/m 122 70 158 149 200
Shear strength D 732 MPa 24 17 37 48 52
Resistance to flex cut growth
Ross (pierced) D 1052 cycles to failure >1 10
6
>1 10
6
>5 10
5
5 10
5
3 10
4
(unpierced) D 1052 cycles to failure >1 10
6
>1 10
6
>1 10
6
1 10
6
N.A.
DeMattia (pierced) D 813 cycles to failure >1 10
6
>1 10
6
>1 10
6
5 10
5
N.A.
Vicat softening point D 1525 C 108 112 180 195 207
Heat deflection temperature D 648
0,46 MPa C 54 50 90 115 130
1,82 MPa C N.A. N.A. 49 51 52
Water absorption, 24 hours D 570 % 0,6 2,1 0,5 0,3 0,3
Poissons ratio 0,45 0,45 0,45 0,45 0,45
1
Can be improved by annealing.
N.A. Not Applicable.
2
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
100 200 300 400 500 600 700 0
30
10
20
50
60
70
40
40C
20C
0C
23C
65C
100C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
100 200 300 400 500 600 700 800 900 0
50
60
60
60
60
60
60
40C
0C
65C
150C
20C
23C
100C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
500 200 100 300 400 0
20
0
10
40
30
40C
20C
0C
23C
65C
100C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
600 700 400 500 300 100 200 0
0
20
10
40
30
50
70
60
20C
23C
65C
100C
0C
150C
Dehnung (%)
Z
u
g
f
e
s
t
i
g
k
e
i
t

(
M
P
a
)
100 200 300 400 500 600 700 800 900 0
0
10
20
30
40
50
60
40C
20C
0C
23C
65C
150C
100C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
5 10 15 20 25 30 35 0
0
1
2
3
4
5
6
7
8
9
10
11
12
40C
20C
0C
23C
65C
100C
120C
Figure 1.01 Tensile properties of HYTREL

4056 ASTMD 638

Figure 1.02 Tensile properties of HYTREL

G4074 ASTMD 638

Figure 1.03 Tensile properties of HYTREL

5556 ASTMD 638

Figure 1.04 Tensile properties of HYTREL

6356 ASTMD 638

Figure 1.05 Tensile properties of HYTREL

7246 ASTMD 638

Figure 1.06 Tensile stress at low strain of HYTREL

4056 ASTMD 638

Strips: 6,35 mm wide Strain rate: 25,4 mm/min
3
Figure 1.07 Tensile stress at low strain of HYTREL

G4074 ASTMD 638

Strips: 6,35 mm wide Strain rate: 25,4 mm/min
Figure 1.08 Tensile stress at low strain of HYTREL

5556 ASTMD 638

Strips: 6,35 mm wide Strain rate: 25,4 mm/min
Figure 1.09 Tensile stress at low strain of HYTREL

6356 ASTMD 638

Strips: 6,35 mm wide Strain rate: 25,4 mm/min
Figure 1.10 Tensile stress at low strain of HYTREL

7246 ASTMD 638

Strips: 6,35 mm wide Strain rate: 25,4 mm/min
Figure 1.11 Tensile set ASTMD 412
Figure 1.11a Tensile set at low strain ASTMD 412
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
5 10 15 25 30 35 20 0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
40C
20C
0C
23C
65C
100C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
10 5 20 15 25 30 35 0
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
40C
20C
0C
23C
65C
100C
150C
120C
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
10 5 20 15 30 25 35 0
0
10
20
30
40
50
60
40C
20C
0C
23C
65C
120C
150C
100C
Strain (%)
T
e
n
s
i
l
e

s
e
t

(
%
)
3 5 1 6 8 4 2 9 7 11 12 10 0
0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
2,0
7246
6356
5556
4056
HYTREL
Strain (%)
T
e
n
s
i
l
e

s
e
t

(
%
)
60 20 100 140 200 160 120 80 40 180 0
0
20
40
60
80
100
120
140
7246
6356
5556
4056
See Figure 1.11a
HYTREL
Strain (%)
T
e
n
s
i
l
e

s
t
r
e
s
s

(
M
P
a
)
10 5 20 15 25 35 30 0
0
20
10
40
30
50
70
60
40C
20C
0C
23C
65C
100C
120C
150C
1.1.2 Compressive properties
Compressive stress/strain properties are shown in Figures 1.12
through 1.16. Typical values for compression set of HYTREL

under constant load and deflection are shown in Table 1.01.

Method A (constant load) compression set values at different
test temperatures are given in Table 1.12.
Compression set can be significantly improved by annealing.
For best results, parts of HYTREL

4056 or G4074 should

be annealed for 24 to 48 hours at 100C. A temperature of
120C for the same time period should be used for all other
types.
Table 1.02 Compression set resistance
ASTMD 395, method A, 9,3 MPa load
Compression set, % after 22 hours at:
Type of HYTREL

23C 70C 100C

4056 11 27 33
G4074 10 28 51
5556 <1 4 8
6356 <1 2 4
7246 <1 2 5
4
Strain (%)
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
s
s

(
M
P
a
)
10 15 20 25 30 35 5 0
0
2
4
6
8
10
12
14
16
18
20
22
24
26
40C
20C
0C
23C
65C
100C
120C
150C
Strain (%)
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
s
s

(
M
P
a
)
10 5 15 30 35 20 25 0
10
20
30
40
50
60
0
40C
20C
0C
23C
65C
120C
150C
100C
Strain (%)
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
s
s

(
M
P
a
)
10 5 20 15 30 25 35 0
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
40C
20C
0C
23C
65C
100C
120C
150C
Strain (%)
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
s
s

(
M
P
a
)
15 10 25 20 35 30 5 0
20
10
40
30
60
50
80
90
70
0
40C
20C
0C
23C
65C
120C
150C
100C
Figure 1.12 Compressive properties of HYTREL

4056 ASTMD 575

Figure 1.13 Compressive properties of HYTREL

G4074 ASTMD 575

Figure 1.14 Compressive properties of HYTREL

5556 ASTMD 575

Figure 1.15 Compressive properties of HYTREL

6356 ASTMD 575

1.1.3 Elastic modulus
Figures 1.17 and 1.18 show values for elastic modulus in
tension and compression versus temperature. These numbers
are calculated from the linear portions of the stress-strain
curves, that is, below the elastic limit, which is approximately
seven to ten per cent for HYTREL

. Modulus changes with

time under load, however, and this factor must be included
in part design. See section entitled Creep Modulus for
additional information.
1.1.4 Flexural modulus
Variation of flexural modulus with temperature is shown in
Figure 1.19. Differences in modulus values for tension, com-
pression, and flexure will occur due to differences in strain
rates shapes of samples, etc. Also, flexure tests emphasize the
surface of the sample, which will have moulded-in stresses that
are different from those in the interior of the sample, which
cools more slowly in the moulding process.
1.1.5 Creep modulus
An important factor to consider when designing with thermo-
plastics is that the modulus of a given material will change due
to many factors including stress level, temperature, time and
environmental conditions. Figures 1.20 through 1.23 are plots
of creep or apparent modulus versus time at various stress lev-
els, all at room temperature. Generally, linear creep modulus
plots can be extrapolated one decade of time with reasonable
safety. This has been done on the creep modulus plots and is
signified by dashed lines. For critical applications, however,
testing for the full expected life of the part should be done to
verify these results. The highest stress level shown on each
plot is the maximum recommended stress level for each
material under long term loading. Higher stress levels may
result in catastrophic failure of the part. In all cases, testing
should be performed on the fabricated part to verify satisfac-
tory performance of the material in each application.
Figure 1.24 presents limited creep modulus data at 100C.
These plots are not extrapolated due to the unpredictable
effects that heat ageing under stress can have on materials.
5
Strain (%)
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
s
s

(
M
P
a
)
10 5 20 15 25 35 30 0
20
10
40
30
60
50
80
70
100
90
0
40C
20C
0C
23C
65C
100C
150C
120C
Temperature (C)
F
l
e
x
u
r
a
l

m
o
d
u
l
u
s

(
M
P
a
)
20 20 60 0 120 80 100 180 140 160 40 40
10
20
30
40
60
80
100
200
300
400
600
800
1000
2000
4056
HYTREL
7246
6356
5556
Figure 1.16 Compressive properties of HYTREL

7246 ASTMD 575

Figure 1.19 Flexural modulus versus temperature ASTMD 790
Figure 1.17 Elastic modulus in tension versus temperature ASTMD 638
Strips: 6,35 mm wide Strain rate: 25,4 mm/min
Figure 1.18 Elastic modulus in compression versus temperature ASTMD 575
Temperature (C)
E
l
a
s
t
i
c

m
o
d
u
l
u
s

(
M
P
a
)
20 60 100 140 180 80 120 0 40 20 160 40
200
300
400
600
800
1000
10
20
30
40
60
80
100
2000
4056
HYTREL
7246
6356
5556
G 4075
4056
G 4074
Temperature (C)
E
l
a
s
t
i
c

m
o
d
u
l
u
s

(
M
P
a
)
20 20 40 0 60 80 100 120 140 180 160 40
0
20
30
40
60
80
100
200
300
400
600
800
1000
4056
HYTREL
7246
6356
5556
G 4074
6
Time (hours)
C
r
e
e
p

m
o
d
u
l
u
s

(
M
P
a
)
0,2 0,5 1 2 5 10 50 100 20 500 1000 200 5000 10000 2000 0,1
1
2
3
4
6
8
10
20
30
40
60
80
100
1,4 MPa
3,4 MPa
3,8 MPa
4,3 MPa
4,8 MPa
5,5 MPa
5,9 MPa
Extrapolated
Applied Stress
Time (hours)
C
r
e
e
p

m
o
d
u
l
u
s

(
M
P
a
)
1
2
3
4
6
8
10
20
30
40
60
80
100
200
0,2 0,5 1 2 5 10 50 100 20 500 1000 200 5000 10000 2000 0,1
Extrapolated
5,5 MPa
9,7 MPa
11,0 MPa
8,3 MPa
3,4 MPa
Applied Stress
12,4 MPa
Time (hours)
C
r
e
e
p

m
o
d
u
l
u
s

(
M
P
a
)
10
20
30
40
60
80
100
200
300
400
600
800
1000
0,2 0,5 1 2 5 10 50 100 20 500 1000 200 5000 10000 2000 0,1
Extrapolated
Applied Stress
5,5 MPa
8,3 MPa
10,3 MPa
13,1 MPa
13,8 MPa
Figure 1.21 Tensile creep modulus of HYTREL

5556 ASTMD 2990, 23C

Figure 1.22 Tensile creep modulus of HYTREL

6356 ASTMD 2990, 23C

Figure 1.20 Tensile creep modulus of HYTREL

4056 ASTMD 2990, 23C

1.1.6 Compressive creep
Compressive creep results for a load of 6,9 MPa at 23C
and 50C are presented in Table 1.03. Creep in compression
is much less than in tension, as can be seen by comparing the
values for compressive creep with those for tensile creep
shown in the same table. Values for tensile creep were
obtained by converting creep modulus data to creep strain
with the formula:
Creep strain =
7
Time (hours)
C
r
e
e
p

m
o
d
u
l
u
s

(
M
P
a
)
50
0,2 0,5 1 2 5 10 50 100 20 500 1000 200 5000 10000 2000 0,1
20
30
40
60
80
100
200
300
400
600
800
1000
Extrapolated
Applied Stress
5,5 MPa
12,4 MPa
18,9 MPa
C
r
e
e
p

m
o
d
u
l
u
s

(
M
P
a
)
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
200
Time (hours)
0,2 0,5 1 2 5 10 50
HYTREL
100 20 500 200 1000 0,1
8,3 MPa
5,5 MPa
8,3 MPa
5,5 MPa
7246
7246
6356
6356
5556
Applied Stress
5,5 MPa
Figure 1.23 Tensile creep modulus of HYTREL

7246 ASTMD 2990, 23C

Figure 1.24 Tensile creep modulus at 100C ASTMD 2990
stress
creep modulus
Table 1.03 Creep strain
100 hours at 6,9 MPa stress
Compression creep, % Tensile creep, %
Type of HYTREL

23C 50C 23C

4056 5,4 8,9
G4074 6,0 11,5
5556 0,6 1,3 8,0
6356 0,5 0,7 5,8
7246 0,5 0,5 2,5
1.1.7 Useful temperature range
HYTREL

thermoplastic polyester elastomer exhibits excellent

physical properties over a broad temperature range. HYTREL

4056 remains quite flexible down to 40C. The harder grades

of HYTREL

retain good physical properties at temperatures as

high as 180C. Figure 1.25 presents information on dynamic
elastic modulus versus temperature and is valuable for esti-
mating the relative response characteristics of parts at various
temperatures. This is a short term test, however, and does
not consider the effects of heat ageing, so the information
in Figure 1.25 should not be used for estimating part life at a
given temperature.
1.1.8 Dynamic properties
Figures 1.25 and 1.26 present data on dynamic modulus and
damping factor (tan ) versus temperature. This data is useful
in the design of parts used in dynamic applications such as
motor mounts and couplings.
1.1.9 Resistance to fatigue
The fatigue resistance of HYTREL

is excellent. Table 1.04 gives

data on the temperature rise due to hysteresis after twenty min-
utes for two of the softer grades of HYTREL

when tested in a
Goodrich Flexometer. The temperature rises fairly quickly
and then remains roughly constant for the balance of the test.
Table 1.05 lists the fatigue limits of four types of HYTREL

.
Fatigue limit is defined by ASTM as the limiting value of stress
which will yield a very large number of cycles before failure.
Sample size and shape, frequency of flexing, ambient temper-
ature and heat transfer all have significant effects on fatigue.
For design purposes, tests simulating actual end use conditions
should be performed to determine the expected fatigue limit.
One of the outstanding properties of HYTREL

thermoplastic
polyester elastomer is its resistance to cut growth in flexure.
As can be seen from Table 1.01, HYTREL

can endure more than

a million cycles without failure in the Ross and DeMattia
pierced flex tests.
8
Temperature (C)
D
y
n
a
m
i
c

e
l
a
s
t
i
c

m
o
d
u
l
u
s

(
M
P
a
)
40 80 60 20 20 0 80 40 60 140 100 120 160 220 180 200 100
10
20
30
40
60
80
100
200
300
400
2000
3000
4000
600
800
1000
HYTREL
7246
6356
5556
4056
Figure 1.25 Dynamic modulus versus temperature ASTMD 2236
Figure 1.26 Damping factor versus temperature ASTMD 2236
T
a
n

(

)
40 80 60 20 20 0 80 40 60 140 100 120 160 220 180 200 100
Temperature (C)
0,02
0,01
0,2
0,3
0,03
0,04
0,05
0,06
0,08
0,1
HYTREL
4056
5556
6356
7246
1.1.10 Ross Flex (ASTM D 1052)
A pierced strip test specimen of 6,35 mm thick is bent freely
over a rod to a 90 angle and the cut length is measured at
frequent intervals to determine the cut growth rate. The cut is
initiated by a special shape piercing tool.
The test results are reported in Table 1.06 as the number of
cycles it took the specimen to grow five times the original
pierced length. These results are also reported in the brochure
General guide to products and properties of HYTREL

.
1.1.11 DeMattia Flex (ASTM D 813)
Apierced strip test specimen of 6,35 mm thick with a circular
groove restrained so that it becomes the outer surface of the
bend specimen, with 180 bend, and the cut length is measured
at frequent intervals to determine the cut growth rate.
The test results are reported in Table 1.07 as the number of
cycles it took for the specimen to reach failure.
1.1.12 Friction and wear
Values for coefficient of friction of HYTREL

measured by two
different methods are shown in Table 1.08. As can be seen from
the data, test conditions have a great influence on the results,
therefore, it is difficult to predict frictional forces unless test-
ing is performed under conditions that simulate the end use.
HYTREL

polyester elastomer has excellent wear properties in

many applications. Table 1.09 lists results from Taber and NBS
abrasion tests. For information on wear in bearing applications,
see Bearings and Seals, Chapter 3.
9
Table 1.04 Goodrich flexometer ASTM D 636
2,54 mm stroke, 1,0 MPa static load, 23C
Sample temperature after 20 minutes
Type of HYTREL

C
4056 48
5556 66
Table 1.05 Flex fatigue ASTM D 671
Fatigue limite
1
Type of HYTREL

MPa
4056 5,2
5556 6,9
6356 6,9
7246 11,0
1
Samples tested to 2,5 million cycles without failure.
Table 1.06 Resistance to flex cut growth, ross (pierced)
ASTM D 1052
Cycles to five times cut growth
Type of HYTREL

23C
G3548 L >1 10
6
G4074, G4078 W >1 10
6
G4774, G4778 >1 10
6
G5544 8 10
5
3078 >1 10
6
4056 >1 10
6
4068 >1 10
6
4556 >1 10
6
5526, 5556 5 10
5
6356 5 10
5
7246 3 10
4
8238
HTR4275 BK 5 10
4
5555HS 1 10
5
HTR5612 BK 6 10
5
HTR6108 6 10
5
HTR8068
HTR8139 LV >1 10
6
HTR8171 >1 10
6
HTR8206
Table 1.07 DeMattia flex life (pierced) ASTM D 813
Cycles to failure
Type of HYTREL

23C
G3548 L 3,6 10
4
G4074, G4078 W 3,6 10
4
G4774, G4778 1,6 10
5
G5544 7 10
3
4056 >1 10
6
4068 1,7 10
5
4556 3,6 10
3
5526, 5556 >1 10
6
HTR4275 BK 5,4 10
4
HTR5612 BK 1,1 10
5
HTR6108 5,4 10
3
Table 1.08 Coefficient of friction
HYTREL

on steel HYTREL

on steel
Moving sled Thrust washer
ASTM D 1894 ASTM D 3702
Type of HYTREL

Static Dynamic Dynamic

4056 0,32 0,29 0,85
5556 0,30 0,18 0,94
6356 0,30 0,21 0,90
7246 0,23 0,16 0,90
Table 1.09 Abrasion resistance ASTM D 1044 (mg/1000 rev)
Taber abrasion NBS abrasion
CS-17 H-18 ASTMD 1630
Type of HYTREL

Wheel Wheel (%)

4056 8 109 590
G4074 10 223 300
5556 6 97 2250
6356 15 109 2340
7246 15 75 2620
10
1.1.13 Impact resistance
The impact properties of polymeric materials are directly
related to their overall toughness, which is defined as the abil-
ity of the polymer to absorb applied energy. Impact resistance
is the ability of a material to resist breaking under shock load-
ing or the ability to resist the fracture under stress applied at
high speed.
Most polymers, when subjected to impact loading, seem to
fracture in a characteristic fashion. The crack is initiated on the
polymer surface by the impact loading. The energy to initiate
such a crack is called the crack-initiation energy. If the load
exceeds the crack-initiation energy, the crack continues to
propagate. Acomplete failure occurs when the load exceeds the
crack-propagation energy. Thus, both crack initiation and
crack propagation contribute to the measured impact strength.
The speed at which the specimen or part is struck with an
object has a significant effect on the behaviour of the polymer
under impact loading. At low rates of impact, relatively
stiff material can still have good impact strength; while at high
rates of impact, even highly elastomeric material like HYTREL

may exhibit brittle failure at low temperatures. All materials

have a critical velocity in which they behave as glassy, brittle
materials.
Impact properties are highly dependent on temperature.
Generally, plastics are tougher and exhibit ductile modes
of failure at temperatures above their glass transition tem-
perature (T
g
), and are brittle well below their T
g
.
A notch in a test specimen, which creates a localized stress
concentration, or a sharp corner in a moulded part drastically
lowers impact strength. Only the harder grades show evidence
of notch sensitivity as shown in Table 1.11.
1.1.14 Notched Izod Impact (ASTM D 256)
The objective of the Izod impact test is to measure the behav-
iour of a standard notched test specimen to a pendulum-type
impact load. The specimen is clamped vertically and the
swinging pendulum is released with the notch on the opposite
side. The results are expressed in terms of kinetic energy
consumed by the pendulum in order to break the specimen.
The energy required to break a standard specimen is actually
the sum of energies needed to deform it, to initiate its fracture,
and to propagate the fracture across it, and the energy needed
to throw the broken ends of the specimen.
1.1.15 Instrumented Impact (ASTM D 3763)
One of the drawbacks of the conventional impact test method
is that it provides only one value, the total impact energy; it
does not provide data on the type of fracture (ductile, brittle),
dynamic toughness, fracture, yield loads or fracture behaviour
based on the geometry of the specimen.
The falling weight instrumented impact tester provides a com-
plete load and energy history of specimen fracture mechanism.
Such a system monitors and precisely records the entire impact
event, starting from the rest position to initial impact, plastic
bending to fracture initiation and propagations to complete
failure.
Measurement is done by mounting the strain gauge into the
striking tup and an optical device triggers the microprocessor
just before striking the specimen. The output of the strain gauge
records the applied load variations to the specimen throughout
the entire fracturing process. A complete load-time history
(fracturing) of the entire specimen is obtained. The apparent
total energy absorbed by the specimen is calculated and plot-
ted against time.
Figures 1.27 to 1.31 show drop-weight-impact results for rep-
resentative grades of HYTREL

. The plots show energy dissi-

pated in rupturing the sample and the maximum force experi-
enced by the tup as it punches through the sample.
1.1.16 Brittleness temperature (ASTM D 746)
This test method establishes the temperature at which 50% of
the specimens tested fail when subjected to the test conditions.
The test evaluates long-term effects such as crystallization.
Thermoplastic elastomers are used in many applications
requiring low-temperature flexing with or without impact.
Data obtained by this test may be used to predict the behaviour
of elastomeric materials at low temperatures only in applica-
tions in which the conditions of deformation are similar to the
test conditions. Table 1.10 lists the brittleness temperatures for
representative grades of HYTREL

.
Table 1.10 Brittleness temperature ASTM 746
Brittleness temperature
Type of HYTREL

C
G3548 L 60
G4074,G4078 W 66
G4774 56
G4778 65
G5544 60
3078 <105
4056 <100
4068 <105
4556 <105
5526 <70
5556 100
6356, 7246 <70
8238 92
HTR4275 BK 100
5555HS <70
HTR5612 BK 100
HTR6108 98
HTR8068 48
HTR8139 LV <100
HTR8171 63
HTR8206 67
11
Temperature (C)
E
n
e
r
g
y

(
J
)
10
20
30
40
50
60
70
80
90
0
40 20 20 0 80 40 60 100
7246
6356
HYTREL
ductile failure
brittle failure
Temperature (C)
L
o
a
d

(
N
)
1000
2000
3000
4000
5000
6000
7000
0
40 20 20 0 80 40 60 100
5556
4056
HYTREL
Temperature (C)
L
o
a
d

(
N
)
1000
2000
3000
4000
5000
6000
7000
8000
0
40 20 20 0 80 40 60 100
ductile failure
brittle failure
7246
6356
HYTREL
Temperature (C)
B
r
i
t
t
l
e

f
a
i
l
u
r
e
s

(
%
)
30 40 10 20 10 0 50 60
0
10
20
30
40
50
60
70
80
90
100
7246
6356
HYTREL
Figure 1.28 Drop weight impact failure energy versus temperature
16 mm spherical tup 32 mm diameter support
Figure 1.30 Drop weight impact failure energy versus temperature
16 mm spherical tup 32 mm diameter support
Figure 1.29 Drop weight impact failure load versus temperature
16 mm spherical tup 32 mm diameter support
Figure 1.31 Pourcentage of brittle failures versus temperature
16 mm spherical tup 32 mm diameter support
Temperature (C)
E
n
e
r
g
y

(
J
)
10
20
30
40
50
60
70
0
40 20 20 0 80 40 60 100
5556
4056
HYTREL
Figure 1.27 Drop weight impact failure energy versus temperature
16 mm spherical tup 32 mm diameter support
Table 1.11 Izod impact ASTM D 256, method A (J/cm)
Unnotched Notched
Type of HYTREL

23C 40C 23C 40C

4056 >10,6 >10,6 >10,6 >10,6
No break No break No break No break
5556 >10,6 >10,6 >10,6 >10,6
No break No break No break No break
6356 >10,6 >10,6 >10,6 0,3
No break No break No break No break
7246 >10,6 >10,6 2,1 0,4
No break No break
12
1.2 Thermal properties
Thermal conductivity data are shown in Table 1.12 and coeffi-
cients of linear thermal expansion are presented in Table 1.13.
Figure 1.32 is a plot of specific heat versus temperature for four
types of HYTREL

.
Table 1.12 Thermal conductivity
Type of HYTREL

W/mC
4056 0,190
G4074 0,165
5556 0,156
6356 0,152
7246 0,149
Table 1.13 Coefficient of linear thermal expansion
Temperature range Coefficient
Type of HYTREL

C mm/mm/C 10
5
4056 50 to 20 51
20 to +120 19
5556 50 to 10 21
10 to +60 10
+60 to +120 13
6356 50 to 30 9
30 to +40 10
+40 to +120 13
7246 50 to +10 4
+10 to +60 9
+60 to +120 10
1.3 Electrical properties
Electrical measurements show that HYTREL

polyester elas-
tomers are suitable for low-voltage applications. High
mechanical strength, coupled with excellent resistance to
oils, solvents and chemicals, also makes HYTREL

suitable
for many jacketing applications. The properties shown in
Table 1.14 were measured on injection moulded plaques
with the dimensions 76 127 1,9 mm.
1.4 Physical properties
For flow analysis, simulating mould filling, the physical prop-
erties as shown in Table 1.15 are applicable. Viscosity data of
several HYTREL

grades is available in figures 1.33 to 1.36.

Table 1.15 Physical properties of HYTREL

HYTREL

grade
4056 5526 G5544 7246
Density kg/m
3
1160 1200 1220 1250
Melt density kg/m
3
1000 1020 1020 1050
Specific heat J/kgC 2144 2186 2186 2152
No-flow
temperature C 107 162 182 176
Freezing
temperature C 50 122 152 130
Thermal
conductivity melt W/mC 0,16 0,15 0,15 0,12
Temperature (C)
S
p
e
c
i
f
i
c

h
e
a
t

(
k
J
/
k
g

C
)
20 40 20 0 60 80 100 120 130 40
0
1
2
4056
5556
7246
6356
HYTREL
Figure 1.32 Specific heat versus temperature
Table 1.14 Electrical properties at room temperature and 50% R.H.
ASTM HYTREL

HYTREL

HYTREL

HYTREL

HYTREL

Property Method 4056 5526 5556 6356 7246

Volume resistivity, ohmm D 257 8,2 10
10
1,2 10
11
1,1 10
10
9,7 10
11
1,8 10
12
Dielectric strength, kV/mm D 149 16,1 17,3 15,7 16,1 18,1
Dielectric constant D 150
100 Hz 5,1 4,5 4,6 4,4 4,0
1 kHz 5,1 4,5 4,5 4,2 3,9
1 MHz 4,7 4,2 4,2 3,7 3,8
Dissipation factor D 150
100 Hz 0,005 0,006 0,006 0,018 0,016
1 kHz 0,008 0,009 0,009 0,02 0,019
1 MHz 0,06 0,04 0,04 0,04 0,036
13
1.5 Other physical properties
In special cases, properties other than those discussed above
may be of interest in designing parts of HYTREL

. Asample of
the kinds of subjects covered by bulletins available from
DuPont are shown here.
Figure 1.34 Viscosity of HYTREL

5526 vs. shear rate for three temperatures

Figure 1.35 Viscosity of HYTREL

G5544 vs. shear rate for three temperatures

Figure 1.36 Viscosity of HYTREL

7246 vs. shear rate for three temperatures

V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
10
Shear rate (s
-1
)
10
2
10
3
10
4
100
1000
215
235
255
V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
1000
10
100
Shear rate (s
-1
)
10
2
10
3
10
4
210
230
250
V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
1000
10
100
Shear rate (s
-1
)
10
2
10
3
10
4
220
240
260
Figure 1.33 Viscosity of HYTREL

4056 vs. shear rate for three temperatures

Shear rate (s
-1
)
V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
10
2
10
3
10
4
10
100
1000
190
210
230
Shear rate (s
1
) Shear rate (s
1
)
Shear rate (s
1
) Shear rate (s
1
)
Bulletin Subject
HYT-402 Injection moulding guide
HYT-403 HYTREL

extrusion manual
General Design Principles
(Module I) Machining of HYTREL

, design rules
2.2 Radiation resistance
The increasing use of nuclear energy, for example in power
plants, military areas, and medicine, places new requirements
on many rubber compounds as well as other materials. Some
factors of importance to market development of nuclear energy
include, for example: the maximum dosage to which the mate-
rial can be subjected without damaging effects, the possible use
of additives to provide additional stabilization to radiation, and
the effect of radiation on physical properties.
Three uncompounded grades of HYTREL

thermoplastic poly-
ester elastomers show excellent retention of physical proper-
ties after irradiation at 23C in air. (The combined effect of
heat-ageing or steamageing concurrent with radiation exposure
was not studied.)
Injection-moulded slabs of HYTREL

4056, HYTREL

5556,
and HYTREL

7246, 2 mm thick, were exposed to a 1,5 MeV

electron beam at Radiation Dynamics Ltd., Swindon, Wiltshire,
U.K. The slabs were then tested by ASTM test methods.
For the most part, the radiation of prime interest from the stand-
point of insulation damage has energy of the order of 1 MeV,
which is principally gamma photons and fast neutrons. Damage
is caused by collisions of this radiation with electrons and nuclei
in the elastomer where the energy input from such collisions
may be greater than the bond energies in the elastomer.
Most elastomers are embrittled by radiation exposure, which
induces cross-links between molecules. This eventually gives
a three-dimensional network, such as is seen in hard rubber or
phenolic resins. Afew polymers, notably butyl rubber, degrade
by reversion to low-molecular-weight tars and oils.
Although upgrading changes can occur under controlled low
dosage (radiation cross-linked polyolefins), long exposure
normally produces degradation. Thus, the amount of change is
dependent on radiation flux rate, total radiation dose, energy of
radiation, chemical composition of the polymer, environment
(ambient temperature, air versus inert gas, steam exposure,
etc.), and the initial properties of the elastomeric compound.
The amount of change is independent of the type of radiation
at equal energy*, whether alpha, beta, or gamma rays, or neu-
trons. This is known as the equal-energy, equal-damage
concept.
Table 2.02 summarizes the effect of radiation on three hardness
grades of HYTREL

. It will be seen that the exposure to 150

kJ/kg (15 Mrad) produces very little change in the properties of
HYTREL

.
* R. B. Blodgett and R. G. Fisher, IEEE Transactions on power apparatus and systems, Vol. 88, No. 5,
p. 529, (May 1969).
2. Effort of environment
Table 2.01 Permeability
a
of HYTREL

to gases
Gas HYTREL

4056 HYTREL

5556 HYTREL

6356 HYTREL

7246
Air 2,4 10
8
1, 8 10
8

Nitrogen 1,7 10
8
1,4 10
8

Carbon dioxide 3,5 10
7
1,8 10
7

Helium 15,7 10
8
9,9 10
8
3,2 10
8
Propane <0,2 10
8
<0,2 10
8
<0,2 10
8

Water
b
3,1 10
5
2,4 10
5

a
Units of permeability: cm
3
(at standard temperature and pressure, STP)mm/Pasm
2
at 21,5C and P = 34,5 kPa or cm
3
.
b
Values obtained at 90% RH, 25C, assuming that permeability laws hold for water.
2.1 Gas permeability
HYTREL

thermoplastic polyester elastomers have an unusual

combination of polarity, crystallinity, and morphology.
As a result, they have a high degree of permeability to polar
molecules, such as water, but are resistant to permeation by non-
polar hydrocarbons and refrigerant gases (see Table 2.01).
In permeability to moisture, HYTREL

is comparable to the
polyether-based urethanes and, therefore, is useful as a fabric
coating for apparel. Its low permeability to refrigerant gases
and hydrocarbons, such as propane, makes HYTREL

of inter-
est for use in refrigerant hose or in flexible hose or tubing to
transmit gas for heating and cooking.
15
2.3 Resistance to mildew and fungus
The resistance of a high-performance 40 durometer D hardness
grade of HYTREL

to certain fungi was determined according to

ASTM D 1924-63, using the following cultures.
Culture Observed growth
Aspergillus niger None
Aspergillus flavus None
Aspergillus versicolor Very slight, sparse
Penicillin funiculosum None
Pullularia pullulans None
Trichloderma sp. None
Samples of the same grade HYTREL

were also buried for one

year in Panama. Instron test results were as follows.
Original
Durometer D hardness 40
Tensile strength, MPa 25,5
Elongation at break, % 450
100% modulus, MPa 6,9
300% modulus, MPa 8,8
Retention after 1 year soil burial in Panama, %
Durometer hardness 98
Tensile strength 82
Elongation at break 82
100% modulus 99
300% modulus 98
The harder grades of HYTREL

were not included in these tests

but should show at least equivalent resistance, because they are
based on the same raw materials.
Table 2.02 Stability of HYTREL

thermoplastic polyester elastomer to radiation

Electron Beam, 1,5 MeV, 23C, 70% RH, radiation dosage in J/kg (rad)
ASTM test method HYTREL

4056 HYTREL

5556 HYTREL

7246
Original
Tensile strength, MPa D 638 24,1 27,2 35,7
Elongation at break, % D 638 550 390 430
100% modulus, MPa D 638 6,8 14,4 22,0
Hardness, durometer D D 2240 40 55 72
Exposure 5 Mrad, kJ/kg 50 50 50
Tensile strength, MPa 22,8 28,3 36,6
Elongation at break, % 510 470 410
100% modulus, MPa 7,3 14,5 23,6
Hardness, durometer D 40 55 72
Exposure 10 Mrad, kJ/kg 100 100 100
Tensile strength, MPa 22,8 28,9 37,4
Elongation at break, % 500 470 370
100% modulus, MPa 6,2 14,5 23,9
Hardness, durometer D 40 55 72
Exposure 15 Mrad, kJ/kg 150 150 150
Tensile strength, MPa 22,1 30,3 38,6
Elongation at break, % 490 490 390
100% modulus, MPa 6,1 14,2 24,6
Hardness, durometer D 40 55 72
16
For use in many applications, a material has either to be
approved or must meet the requirements of various govern-
mental or private agencies. This is mainly to protect the user,
the general public or the environment.
Besides meeting such regulations, all products and/or their
constituents have to be listed in the different chemical inven-
tories. Specific regulations exist for certain areas like electri-
cal applications or applications in contact with food.
DuPont makes sure that all materials supplied to its customer
are in compliance with applicable regulations for the material
itself.
As a subscriber to the RESPONSIBLE CARE initiative,
DuPont also has accepted to share information and help the
product users to handle, process, use, recycle and dispose of its
materials safely and in an environmentally sound manner.
For selected specific application areas, DuPont has developed
information which will enable the product user to obtain appro-
vals from authorities or to certify compliance with regu-
lations.
These areas are:
Compliance statements with European and non-European food
contact regulations
Europe:
The EU (European Union) Directive 90/128 and its subsequent
amendments plus country specific regulations where applicable.
USA:
FDA (Food and Drug Administration).
The following grades of HYTREL

meet Food and Drug Admi-

nistration (FDA) guidelines for food contact use in the U.S.
The stabilizer system used in these grades is in full compliance
with FDAregulations.
The following grades of HYTREL

may be used in compliance

with the Federal Food, Drug, and Cosmetic Act, specifically:
Essentially all High Performance grades meet FDAguideline
for bulk dry food contact use in the U.S. If the customer uses
compliant additives and follows the temperature and alcohol
content requirements of the application, then the application
should be in compliance with the repeated use regulation.
None of the High Productivity grades have FDA approval in
the U.S. not because of the presence of toxic extractable
material, but rather because they have not been tested due to
the enormous expense of extraction and animal feeding tests
required by the FDA.
Canada:
HPB (Health Protection Branch of Health and Welfare).
Other countries:
Compliance statements can be established on request.
Compliance statements with European and non-European
drinking water regulations
Germany:
The KTW (Kunststoff-Trinkwasser-Empfehlungen) recom-
mandation.
Italy:
The circular on plastics materials for pipes and auxiliaries
intended to be used in contact with potable water.
The Netherlands:
The Guideline: Quality of materials and chemicals for drink-
ing water supply and KIWA (Keuringsinstituut voor Water-
leidingartikelen) certification.
UK:
The WRC (Water Research Council).
Support information for approval of application under
European and nonEuropean pharmaceutical
regulations.
Statements on the content of certain regulated chemicals
as required e.g. by the Deutsche Dioxinverbotsverordnung
or the Clean Air Act in the USA.
Regulations are constantly adapted to new information avail-
able, new test methods and also issues of concern developing
in the public.
DuPont will adapt its products to the changing market needs
or develop new products to satisfy new requirements. The
same is true for information needed to support customers for
regulatory compliance of their applications.
It is impossible in the frame of this bulletin to provide up-to-
date information on all grades of HYTREL

meeting the various

specifications. Our recommendation is therefore to consult
with your DuPont representative on the best material selection
for a given application in an early stage of a development.
Repeated use contact
Contact with dry bulk food with fatty or wet food
HYTREL

(regulation 21CFR177.1590) (regulation 21CFR177.2600)

3078
4056
4069
4556
5526
5556
6356
7246
8238
HTR6108
3. Regulatory compliance
17
19
4.1 General considerations
Although the material properties of strength (stiffness) and
flexibility (elasticity) are seemingly mutually exclusive,
they do cohabit in a class of plastics that combines the
strength of engineering resins with the useful elasticity of rub-
ber. They are known as Thermoplastic Polyester Elastomers
(TPEs), produced by DuPont under the trademark HYTREL

.
TPEs display an unusual combination of strength and flexi-
bility. The resins are load bearing under conditions that also
require flexing, sealing, shock absorption or elastic recovery
from deformation.
Figure 4.01 illustrates the point graphically. Steel performs well
as a spring, provided the deformation is limited to a fraction of
one per cent (beyond this, the steel will yield). Engineering
plastics such as DELRIN

acetal resin retain spring characteris-

tics to a strain of a few per cent. At the other end of the scale,
rubber has very high elasticity, but minimal load bearing
capacity.
Replacing traditional concepts
HYTREL

thermoplastic polyester elastomer performs both

functions. It behaves as a spring up to 25 per cent strain
(depending on the grade) and is 2 to 15 times stronger than rub-
ber. This unique position defines HYTREL

as a high strength
plastic with a high capacity for flexing. Used in a thin section,
therefore, HYTREL

can behave like rubber. In thick or ribbed

sections, it provides structural functions similar to engineering
plastics or metals.
TPE resins close the circle of component integration by com-
bining parts across the spectrum of functionality into single
units.
A new design strategy
For innovative designers and engineers, this broad portfolio of
properties defines a new degree of design freedom in compo-
nent integration. Asingle part designed with HYTREL

can per-
form tasks conventionally performed by separate components
made from different materials, and save considerable costs by
eliminating or reducing multicomponent assemblies. Sepa-
rate structural and flexible elements in hinges, springs, seals,
fasteners, power transmission and shock absorption can occur
simultaneously in one part. New design strategies for multi-
functional component integration are now possible with the use
of HYTREL

.
The following general stepwise procedure is intended to help
minimize problems during the growth of a design, and to aid
in the rapid development of a successful commercial product.
For design rules, see Module I General Design Principles.
4.1.1 Defining the end-use requirements
As an initial step, the designer should list the anticipated con-
ditions of use and the performance requirements of the article
to be designed. He may then determine the limiting design fac-
tors and, by doing so realistically, avoid pitfalls which can
cause loss of time and expense at later stages of development.
Use of the check list (below) will be helpful in defining design
factors.
4. Design concepts for HYTREL

Useful elasticity (% strain)

S
t
r
e
n
g
t
h
5 25 100 3
Metal
Rubber
Engineering
plastic
HYTREL
Figure 4.01 Strength and elasticity of materials
4.1.2 Design checklist
General information
What is the function of the part?
How does the assembly operate?
Can the assembly be simplified by using HYTREL

?
Can it be made and assembled more economically?
What tolerances are necessary?
Can a number of functions be combined in a single moulding
to eliminate future assembly operations and simplify design?
What space limitations exist?
What service life is required?
Is wear resistance required?
Can weight be saved?
Is light weight desirable?
Are there acceptance codes and specifications
such as SAE, UL?
Do analogous applications exist?
Structural considerations
How is the part stressed in service?
What is the magnitude of stress?
What is the stress vs time relationship?
How much deflection can be tolerated in service?
Environment
Operating temperature?
Chemicals, solvents?
Humidity?
Service life in the environment?
Appearance
Style?
Shape?
Colour?
Surface finish?
Decoration?
Economic factors
Cost of present part?
Cost estimate of part in HYTREL

?
Are faster assemblies and elimination of finishing operations
possible?
Will redesign of the part simplify the assembled product and
thus give rise to savings in installed cost?
Manufacturing options
Should the proposed design be machined, blow moulded, melt
cast, injection moulded or extruded considering the number
of parts to be made, design geometry and tolerances?
If injection moulding is chosen, how can mould design con-
tribute to part design?
In subsequent assembly operations, can the properties of the cho-
sen material be used further; e.g., spin welding, snap fits, etc.?
After preliminary study, several steps remain to convert design
ideas into production.
4.1.3 Drafting the preliminary design
After considering end-use requirements, the designer is ready
to define the part geometry. This may be done in several
stages with preliminary drawings indicating the basic design
and functions. More detailed sketches provide information on
thickness, radii and other structures, as worked out from end-
use considerations.
4.1.4 Prototyping the design
Prototypes can be prepared by several techniques. Acommon
approach is to machine the part from rod or slab stock.
(See Module I, General Design Principles, Machining
HYTREL

.) If machining operations are expected to be elabo-

rate or expensive, it is sometimes advisable to x-ray the part to
avoid using material with voids. A medical type unit will
show voids as small as 1,58 mm diameter and even greater res-
olution can be obtained with some industrial units.
The melt stability of HYTREL

permits production of prototypes

by melt casting, which is a process using an extruder to fill an
inexpensive aluminium mould. This method can also be
advantageous for short production runs because set-up costs are
low. In any large and important development, the preparation
of prototypes using the fabrication method intended for pro-
duction can provide added assurance against failure in use.
For injection-moulded parts, the use of an inexpensive alu-
minium, brass or copper beryllium mould is frequently con-
sidered an important step between conception and production.
In addition, moulded prototypes provide information on gate
location and on mould shrinkage.
Additional reasons why the moulded prototype is preferred
to the machined prototype are:
Machine marks may result in variable behaviour.
Orientation effects in the moulded parts resulting from gate
location or knockout pins may influence toughness.
4.1.5 Testing the design
Every design should be subjected to some form of testing while
in the prototype stage to check the accuracy of calculations and
basic assumptions.
Actual end-use-testing of a part in service is the most mean-
ingful kind of prototype testing. Here, all of the performance
requirements are encountered, and a complete assessment of
the design can be made.
Simulated service tests are often conducted with prototype
parts. The value of this type of testing depends on how
closely the end-use conditions are duplicated. An automobile
engine part might be given temperature, vibration and
hydrocarbon resistance tests; a luggage fixture could be
subjected to impact and abrasion tests, and a radio compo-
nent might undergo tests for electrical and thermal insulation.
Standard test procedures such as those developed by the
ISO/ASTM generally are useful as a design guide but,
normally, cannot be drawn upon to predict accurately the
performance of a part in service. Again, representative field
testing may be indispensable.
Long-term performance must sometimes be predicted on the
basis of severe short-term tests. This form of accelerated test-
ing is widely used but should be used with discretion because
the relationship between the long-term service and the accel-
erated condition is not always known.
4.1.6 Taking a second look
Asecond look at the design helps to answer the basic question:
Will the product do the right job at the right price? Even at
this point, most products can be improved by redesigning for
production economies or for important functional and aesthetic
changes.
20
Weak sections can be strengthened, new features added and
colours changed. Substantial and vital changes in design may
necessitate complete evaluation of the new design. If the
design has held up under this close scrutiny, specifications and
details of production can be established.
4.1.7 Writing meaningful specifications
The purpose of a specification is to eliminate any variations in
the product that would prevent it from satisfying the functional,
aesthetic or economic requirements. The specification is a com-
plete set of written requirements which the part must meet.
It should include such things as: generic name, brand and grade
of material, finish, parting line location, flash, gating, locations
where voids are intolerable, warpage, colour, decorating and
performance specifications.
4.1.8 Setting up production
Once the specifications have been carefully and realistically
written, moulds can be designed and built to fit the process-
ing equipment. Tool design for injection moulding should
be left to a specialist or able consultant in the field, because
inefficient and unnecessarily expensive production can result
from improper design of tools or selection of manufacturing
equipment.
4.1.9 Controlling the quality
It is good inspection practice to schedule regular checking of
production parts against a given standard. An inspection check
list should include all the items which are pertinent to satis-
factory performance of the part in actual service at its assem-
bled cost. The end-user and moulder should jointly establish
the quality control procedures that will facilitate production of
parts within specifications.
4.2 Multifunctional component integration
4.2.1 Hydraulic piston seal
The standard design for a piston seal used in hydraulic cylin-
ders, valves, transmissions, etc., is a multipiece assembly.
The piston is usually metal or structural plastic. Arubber seal
with supporting washer is used at each end of the piston. Some
designs feature concentric outer grooves for O-ring seals or
V-shaped seals with back-up rings. Figure 4.02 demonstrates
redesign of this assembly as a single part in HYTREL

. Incor-
porating ribbed and thick sections allows the resin to meet the
structural requirements of the piston. The sealing function is
achieved by thin sections (see inset), which provide functional
elasticity equivalent to rubber. This design is commercial in
hydraulic cylinders rated to 3,45 MPa. Designs for operation
at 6,9 MPa are possible.
4.2.2 Vacuum or pressure actuated mechanism
Vacuum actuated diaphragm mechanisms are used in industrial
plants and automotive design. Atypical application is opening
and closing doors in heating and air conditioning systems.
The traditional mechanism is made from two welded steel
or plastic halves. A metal bracket connects the door to the
spring/diaphragm assembly. When vacuum is applied to the
diaphragm, it flexes and opens the door. Release of the vacuum
allows the spring to return to its unstressed position.
Former designs (Figure 2.03) used eight separate pieces of
metal, rubber and plastic. Since all of these materials can be
replaced by HYTREL

, a single blow-moulded part can be

designed to replace the multipiece assembly. The TPE provides
longterm dynamic performance, spring action over a wide tem-
perature range and it resists creep, ensuring long life of the part.
This design reduces part cost between 50 and 75 per cent.
21
Figure 4.02 Hydraulic piston seal
Figure 4.03 Automotive vacuum motor
Multipiece design
One-piece design in HYTREL

One-piece design in HYTREL

Normal position Under vacuum

Multipiece design (8 pieces)
4.2.3 Linkage suspension
Electronic and computer equipment often use linkage sus-
pension designs to control movement of recording and play-
back heads. The function of the linkage is to keep two objects
in parallel planes. The traditional approach in metal or plastic
involves a multipiece assembly with lubricated pivot points.
Figure 4.04 illustrates a new one-piece design in HYTREL

that replaces the former twelve-piece design in metal. The key

to successful use of TPEs is to mould integral hinges at the six
flex points. In addition to the significant cost savings from
reduced assembly labour, the new design offers these additional
features:

silent mechanism

electrical insulation

use without lubrication.

4.2.4 Solenoid mount
Solenoid relays must be protected from vibration to avoid arc-
ing of the contacts and failure by burnout. The traditional
design assembles the solenoid to a plastic wire connector,
which then snaps into a mounting box supported by rubber
vibration mounts. This has required a five-piece assembly as
shown in Figure 4.05.
Now, a single moulding of HYTREL

replaces wire connectors,

the mounting box and the rubber vibration mounts. This inte-
grates a five-piece assembly into a single moulding. In addi-
tion, the superior spring quality of this design protects the sole-
noids well enough for a 300 per cent improvement in solenoid
life!
22
Figure 4.04 Movement control linkage
Figure 4.05 Solenoid mount, vibration control
Multipiece metal or plastic
with pin hinges
One-piece moulding of
HYTREL

with integral hinges

Solenoids
Nylon connectors
Nylon mounting box
Rubber vibration mounts
Snap-in moulding HYTREL

Built-up assembly of plastic rubber

4.3 Controlling shock, vibration and noise
4.3.1 Solenoid mount (see also 4.2.4)
Other applications: computer motherboards
and disk drives
4.3.2 Engineered footwear for running,
walking and team sports
Characteristics:
High load capacity
Conforms to body shape; can be designed for localized
load.
Applications, see figures 4.06 and 4.07.
Benefits:
Shock absorption
Consistent properties over life of product avoids the
break-in required by foam
Breathing action air circulation
Thermal insulation
Longer life than foam resistant to creep
Lighter weight than rubber
Consistent properties over a broad temperature range.
4.3.3 Suspension system for offroad equipment (heavy
mining truck)
The real job of a shock absorbing system is managing energy.
Atypical system consists of damper and spring, where

the damper absorbs mechanical energy, converting it to heat

excess mechanical energy is stored in the spring and metered

to the damper.
Spring design is critical for effective storage and metering of
energy. With a unique combination of elastic properties and
injection mouldability, HYTREL

allows custom design of

spring characteristics into a part.
Application, see figure 4.08.
Other applications:
Railroad car bumpers; crane bumpers.
23
Figure 4.06 Heel spring insert for walking shoe
Figure 4.08 Solid state strut
Figure 4.07 Cushion innersole for dress and golf shoes
Pads of HYTREL thermoplastic
polyester elastomer, separated
by steel plates.
Friction damping... no fluids to leak
Commercial on heavy-duty
170-ton mining trucks.
4.3.4 MacPherson strut rebound bumper
Rebound bumper cushions are activated when uneven road sur-
faces cause full suspension travel of the wheel. The part
is tested in the laboratory at 2,5 m/s entry rates with shock
loads as high as 1120 kg. Vehicle durability tests require
160000 km without failure.
U.S. automakers have adopted HYTREL

thermoplastic poly-
ester elastomer on 1987 vehicles. Benefits of new system:
33% improvement in rebound damping and entry noise
rating over previous materials
Improved life
Improved ride quality.
24
Figure 4.09 Mac Pherson strut rebund bumper
5.1 Bearings
HYTREL

thermoplastic polyester elastomer has been used in a

number of bearing and seal applications where flexibility,
chemical resistance, or useful temperature range not found in
other elastomers or plastics are required. In addition, HYTREL

is suitable for use in handling of dry food and in potable water

applications requiring approval by the FDA, National Sanita-
tion Foundation, and National Water Council (U.K.).
Aconvenient way for assessing the suitability of a material for
use in unlubricated bearing applications is by determining
whether the PV of the proposed bearing is lower than the PV
limit for the material under the operating conditions foreseen.
The PV limit for a material is the product of limiting bearing
pressure MPa and peripheral velocity m/min, or bearing
pressure and limiting velocity, in a given dynamic system.
It describes a critical, easily recognizable change in the bear-
ing performance of the material in the given system. When the
PV limit is exceeded, one of the following manifestations
may occur:
1. melting;
2. cold flow or creep;
3. unstable friction;
4. transition from mild to severe wear.
PV limit is generally related to rubbing surface temperature
limit. As such, PV limit decreases with increasing ambient
temperature. The PVlimits determined on any given tester geo-
metry and ambient temperature can rank materials, but trans-
lation of test PV limits to other geometries is difficult.
For a given bearing application, the product of pressure and
velocity (PV) is independent of the bearing material. Wear is
dependent on PV for any material.
The use of experimentally determined PV limits in specific
applications should be considered approximate, since all per-
tinent factors are not easily defined. This means that a gener-
ous safety factor is an important consideration in bearing
design. Some factors known to affect PV limits are:
1. absolute pressure;
2. velocity;
3. lubrication;
4. ambient temperature;
5. clearances;
6. type of mating materials and
7. surface roughness.
5.1.1 Unlubricated bearings
Plastic materials frequently show a wide range for the coeffi-
cient of friction depending upon test conditions such as velo-
city, temperature and humidity. Static coefficients of friction
are usually, although not always higher than dynamic coeffi-
cients. Friction values for HYTREL

under two test conditions

are shown in Table 1.08 on page 9.
The following equation can be useful in interpreting wear test
results in terms of specific wear rate or wear factor. With cau-
tion, experimentally determined wear factors can be used to
estimate wear in a particular application.
W= KFVt
where:
W= Volume of wear particles, mm
3
F = Load supported, N
V = Sliding velocity, m/min
t = time, h
K = Wear factor, mm
3
min/m N h
For two flat rubbing surfaces, the equations can be written:
w = KPVt
with w = W/A
and P = L/A
w = Wear, mm
P = Pressure, MPa
A= Contact area, mm
2
Unlubricated bearings operating below the PV limit will
exhibit mild wear.
PVlimits and wear factors for HYTREL

are shown in Table 5.01.

5.1.2 Lubricated bearings
Lubrication can increase the PV limit by reducing the coeffi-
cient of friction, and providing cooling and washing away of
wear debris.
Lubrication of bearings can be considered to be of two types:
1. thick-film (hydrodynamic or hydrostatic);
2. thin-film (boundary).
Thick-film lubrication describes lubrication by a fluid-film of
thickness sufficient to prevent contact between the solid slid-
ing surfaces. Thus, if the lubricant is clean, neither surface will
wear and friction coefficient will depend on lubricant proper-
ties, bearing geometry and bearing PV.
In thin-film lubrication, contact can occur between the sliding
surfaces because the lubricant film is not sufficiently thick
to prevent contact. Consequently, both lubricant properties
and properties of the solid bearing surfaces are important.
An effective boundary lubricant must wet the solid surfaces.
5.1.3 Design considerations
As indicated previously, the PVlimit will be decreased by any
change which results in increase of the coefficient of friction
or reduced heat dissipation from the bearing zone. This obser-
vation and industrial experience leads to the following sug-
gestions for bearing design.
25
Table 5.01 PV limit and wear factor ASTM D 3702
PV limit Wear factor, K
MPa 10
3
Type of HYTREL

4056 2,1 22
G4074 1,1 39
5556 2,1 2,0
6356 6,3 2,1
7246 8,4 0,48
m
min
mm
3
min
m N h
5 Designing for specific applications
1. Design bearing sections as thin as consistent with applica-
tion requirements. This maximizes heat conduction through
the plastic material adjacent to the bearing surface and
reduces thermal expansion.
2. Metal/plastic bearing interfaces run cooler than plastic/plas-
tic interfaces, because heat is conducted from the interface
more rapidly by metal than plastic. Metal/plastic bearings
have higher PV limits than plastic/plastic bearings.
3. Provision for air circulation about the bearing can bring
about cooler operation.
4. Lubrication can greatly increase the PV limit depending on
type and quantity of lubrication. Where lubricants are used,
these must be stable at the bearing temperature.
5. For unlubricated bearings of HYTREL

on metal, the metal

should be as hard and smooth as consistent with bearing life
requirements and bearing cost.
6. Bearing clearance is essential to allow for thermal expansion
or contraction and other effects.
7. Surface grooves should be provided in the bearing so
that wear debris may be cleared from the bearing area.
For lubricated bearings, the grooves can increase the supply
of lubricant. Bearing pressure will increase with grooving.
8. For the bearing applications in dirty environments, use of
seals or felt rings can increase bearing life if they are effec-
tive in preventing penetration of dirt into the bearing.
5.2 Boots and bellows
Figure 5.01 shows a blow-moulded automotive CVJ-boot.
HYTREL

is replacing vulcanized rubber in boot and bellows

applications because:
1. higher modulus permits a thinner wall with equivalent
strength and less weight and;
2. processing costs are much less for a blow moulded boot than
an injection moulded rubber boot.
The best design for a plastic boot differs from many existing
rubber boots. The convolutes should be designed with nearly
flat sides and small radii at the peaks, as shown in Figure 5.02.
It is very important that the boot does not buckle as it is flexed,
as this will usually result in early failure. Excessive extension
of a boot of this type will cause it to buckle inward. If the
application requires extension of the boot from some neutral
position, the boot should be designed so that its length, as
moulded, is equal to the maximum extension length in service.
The boot will then experience only compression and buckling
will not occur.
Flexing of the boot results in bending stresses at the peaks of
the convolutes. In any bending situation in which total deflec-
tion is determined by the geometry of the application, stress in
the outermost layers of the material will increase as thickness
increases. Flex life, therefore, will be maximized if material
thickness is kept to a minimum. HYTREL

CVJ boots have,

compared to rubber boots, the advantage of higher impact
resistance. HYTREL

also has higher fatigue resistance and bet-

ter shape stability at high speed. At low temperatures, the prop-
erties of HYTREL

remain outstanding.
5.3 Rolling Diaphragms
Because of its flexibility and fatigue resistance, HYTREL

is
suitable for use in many diaphragm applications. Its high
modulus compared to vulcanized rubber allows a thinner
cross-section and possible elimination of fabric reinforce-
ment, which, combined with thermoplastic processing, often
result in a lower cost part.
Pictured in Figure 5.03 is a rolling type diaphragm, which
provides a longer stroke than a flat diaphragm. A plastic
diaphragm of this type must be designed so that there is no cir-
cumferential compression of the diaphragm as it rolls from the
cylinder wall to the piston, which would cause wrinkling or
buckling and results in early failure. There are two ways to
accomplish this:
1. Use a piston with a tapered skirt to keep the compression to
a minimum, as shown in Figure 5.03.
2. Design the system so that the piston moves only in the direc-
tion that will roll the diaphragm from the piston to the
cylinder wall, as related to the moulded shape of the
diaphragm.
26
Figure 5.01 Automotive CVJ-boot
Figure 5.02 Boot design
5.4 Belts
HYTREL

has proven to be an excellent material for power

transmission and conveyor belting. It can be made in V,
round, flat and other configurations. Its high tensile modulus
compared to rubber eliminates the need for reinforcing cord in
many applications which means that belting can be extruded in
long lengths and stocked in rolls. When a belt is needed, a
length is cut off and heat spliced to make a finished belt.
Belts of HYTREL

should be made to the same dimensions as

the belts being replaced. In applications involving large diam-
eter pulleys and moderate speeds, belts of HYTREL

have out-
lasted vulcanized rubber belts by a wide margin. Small diam-
eter pulleys and high speeds should be avoided, as these result
in excessive heat buildup and failure of the belt.
Heat splicing of the belt is a simple process, but must be done
properly for best results. A45 bias cut will generally give the
best splice. After cutting, the ends to be spliced are heated
above the melting point of the material with a heating paddle
and then joined together. Two important points are:
1. The belt ends must not be pushed so tightly together that the
melt is squeezed from between the ends;
2. The ends must be held motionless until the melt has solidi-
fied. A fixture which will hold the belt ends properly will
help insure a good splice. Flash is trimmed from the splice
with a knife or clippers.
Excessive moisture content will cause degradation of the melt
in the splice as it does during any other processing operation.
For best results, the ends of the belt should be dried before
splicing or the belting should be stored in a dry atmosphere,
such as a heated cabinet.
5.5 Coiled tubing and cables
Table 5.02 Heat setting temperature
Type of HYTREL

Temperature C
4056 107
5556 125
6356 125
7246 150
Products such as coiled pneumatic tubing and coiled electrical
cables are made from HYTREL

by winding an extruded profile

around a mandrel and heat setting. The coil will spring back to
some extent when released so the mandrel must be smaller than
the desired final diameter of the coil. Exact mandrel size must
be determined for each application by trial and error.
Recommended temperatures for heat setting are shown in
Table 5.02. Parts must be held at the setting temperature only
long enough to heat the entire cross section of the part to the
setting temperature. Parts may be cooled in room temperature
air and should remain on the mandrel until cool.
5.6 Reinforced hose
In the design of reinforced hose, three important factors to con-
sider in the choice of the tube and cover materials are: resistance
to the environment in which the hose must operate, strength, and
flexibility of the material. Based on these factors and others,
HYTREL

thermoplastic polyester elastomer has been chosen for

several hose applications such as hydraulic and paint spray hose.
As a cover, HYTREL

offers excellent resistance to abrasion and

weathering. HYTREL

20UVshould be added to the cover mate-

rial if it will be exposed to sunlight. Similarly, thin-walled hose
linings of HYTREL

must be protected from ultraviolet (UV) light

that passes through the cover. Carbon black is an effective
screen.
In fire hose and other lay-flat hoses, it is possible to use a tube
of HYTREL

which is thinner than a vulcanized rubber tube,

making the hoses lighter and easier to handle. It can be used in
SAE100R7 and R8 thermoplastic hydraulic hoses, which offer
the advantages of lighter weight and a wider colour selection
than steel reinforced rubber hose.
In the design of thin-walled tubing of HYTREL

care must be
taken that the expansion of the lining against the cover does not
exceed the elastic limit of HYTREL

.
If the finished hose is to be coupled, creep, thermal expansion,
and cut and/or notch sensitivity must be considered in the fit-
ting design. If the possibility exists that the hose fittings are
subjected to corrosion in service, the use of steel as the fitting
material should be avoided and brass should be used instead.
Creep data for HYTREL

may be calculated from the creep mod-

ulus plots appearing elsewhere in this handbook. Sharp edges
and burrs should be avoided when designing fittings for hoses
based on HYTREL

. In all cases, the final fitting design should

be tested under actual or closely simulated service conditions
to insure satisfactory performance.
If the possibility exists that the hose fittings are subjected to
corrosion in service, the use of steel as the fittings material
should be avoided and brass should be used instead.
27
Figure 5.03 Rolling type diaphragm
Figure 5.04 Tapered piston skirt
Dp + Convolution Width
Dp
Reprinted with permission from Bellofram Corp.
Reprinted with permission from Bellofram Corp.
28
5.7 Seals, valves and pumps
Specific designs for seals and valve actuators are already
shown in Figures 4.02 and 4.03 (page 21).
It can be seen that it is not always possible to achieve full com-
ponent integration as shown in Figure 4.03. There might be cir-
cumstances when, for example, the housing must be stiffer,
therefore glass-fibre reinforced plastic (or metal) is needed.
Figure 5.05 shows a typical design for a diaphragm piston
pump, including the previous metal-rubber solution. Such
pumps are used in the following sectors:
Automotive
Industrial
Medical/health
Nuclear energy
Sports/recreation (volleyballs, scuba tanks)
Other applications requiring clean, oil free operation
Requirements for such design solutions are:
Heat resistance comparable to epichlorohydrin rubber
Dimensional stability equivalent to fabric reinforced rubber
Strength and stiffness to replace metal or structural plastic
connecting rod
Thinner areas to replace rubber (Akey design feature is a thin
convolution to allow flexing without overstraining the
resin.) Cost savings with this design can be substantial.
Other design examples of seals are shown
in Figures 5.06 5.08
Figure 5.05 Diaphragm piston pump design
Figure 5.06 Snap-together vacuum fitting
Figure 5.07 Crush seal with over-torque protection
Figure 5.08 Rotary shaft seals
Assembly
Metal-rubber solution
HYTREL

solution
Interference fit membrane
Built-in wear surface prevents
overstrain of seals
Wipes lubricant two directions
for low wear
09.98 Printed in Switzerland
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Schweiz / Suisse / Svizzera
Dolder AG
Immengasse 9
Postfach 14695
CH-4004 Basel
Tel. (061) 326 66 00
Telex 962 306 DOL CH
Telefax (061) 326 62 04
Slovenija
Serviced by Interowa.
See under sterreich.
Suomi / Finland
Du Pont Suomi Oy
PL 199
FIN-02201 Espoo
Tel. 09-725 66 100
Telefax 09-725 66 166
Sverige
DuPont Sverige AB
Box 23
S-164 93 Kista (Stockholm)
Tel. +46 8-750 40 20
Telefax +46 8-750 97 97
Trkiye
Du Pont Products S.A.
Turkish Branch Office
Sakir Kesebir cad. Plaza 4
No 36 / 7, Balmumcu
TR-80700 Istanbul
Tel. (212) 275 33 83
Telex 26541 DPIS TR
Telefax (212) 211 66 38
Ukraine
Du Pont de Nemours
International S.A.
Representative Office
3, Glazunova Street
Kyiv 252042
Tel. (044) 294 9633 / 269 1302
Telefax (044) 269 1181
United Kingdom
Du Pont (U.K.) Limited
Maylands Avenue
GB-Hemel Hempstead
Herts. HP2 7DP
Tel. (01442) 34 65 00
Telefax (01442) 24 94 63
Argentina
Du Pont Argentina S.A.
Avda. Mitre y Calle 5
(1884) Berazategui-Bs.As.
Tel. (541) 319-4484 / 85 / 86
Telefax (541) 319-4417
Brasil
Du Pont do Brasil S.A.
Al. Itapecuru, 506 Alphaville
06454-080 Barueri-So Polo
Tel . (5511) 421-8468 / 8556
Asia Pacific
Du Pont Kabushiki Kaisha
Arco Tower, 14th Fl.
8-1, Shimomeguro 1-chome
Meguro-ku, Tokyo 153
Tel. (03) 5424 6100
South Africa
Plastamid
P.O. Box 59
Elsies River 59
Cape Town
Tel. 27 (21) 592 12 00
Telefax 27 (21) 592 14 09
USA
DuPont Engineering Polymers
Barley Mill Plaza, Building #22
P.O. Box 80022
Wilmington, Delaware 19880
Tel. (302) 892 0541
Telefax (302) 892 0737
Requests for further information
from countries not listed above
should be sent to:
Du Pont de Nemours
International S.A.
2, chemin du Pavillon
CH-1218 Le Grand-Saconnex
Geneva
Tel. (022) 717 51 11
Telex 415 777 DUP CH
Telefax (022) 717 52 00
Internet location:
http://www.dupont.com/
enggpolymers/europe
For further information on Engineering Polymers contact:
The information provided in this documentation corresponds to our knowledge on the subject at the date
of its publication. This information may be subject to revision as new knowledge and experience becomes
available. The data provided fall within the normal range of product properties and relate only to the spe-
cific material designated; these data may not be valid for such material used in combination with any other
materials or additives or in any process, unless expressly indicated otherwise. The data provided should
not be used to establish specification limits nor used alone as the basis of design; they are not intended
to substitute for any testing you may need to conduct to determine for yourself the suitability of a spe-
cific material for your particular purposes. Since DuPont cannot anticipate all variations in actual end-
use conditions DuPont makes no warranties and assumes no liability in connection with any use of this
information. Nothing in this publication is to be considered as a license to operate under or a recom-
mendation to infringe any patent rights.
Caution: Do not use this product in medical applications involving permanent implantation in the human
body. For other medical applications see DuPont Medical Caution Statement , H-50102.