Ivano-Frankivsk caprolon, fluoroplastic circle, sheet, textolite, fiberglass

Ivano-Frankivsk caprolon, fluoroplastic circle, sheet, textolite, fiberglass

Caprolon (polyamide-6 block, PA-6 block) is a structural polymer obtained in the process of anionic polymerization of caprolactam, carried out directly in the mold in the presence of alkaline catalysts and activators.[1]
It is supplied in the form of sheets, rods, blocks or blanks of complex shape. It is used for the manufacture of parts by machining blanks.
Physical and mechanical properties
Caprolon is resistant to hydrocarbons, oils, alcohols, ketones, esters, alkalis and weak acids, soluble in phenols, concentrated mineral acids, formic and acetic acids. The material has good anti-friction properties and high wear resistance.
Caprolon under normal conditions is non-toxic, does not have a harmful effect on the human body [2].
During the mechanical processing of caprolon in the product, the decomposition of the material does not occur, and harmful substances are not released.
At temperatures above 300 ° C, caprolon decomposes with the release of carbon monoxide and ammonia.
Caprolon, whose technical characteristics are quite unique, is used instead of metals. The material is 6 or even 7 times lighter than steel, which indicates that the products are lightweight and high strength. Caprolon is used for the manufacture of bearings that are resistant to corrosion, wear-resistant, low coefficient of friction, among other things, these parts have a self-lubricating effect. Caprolon is used to produce gears, pump blades, impellers, various housings, as well as rollers that form the basis of conveyor belts. Sometimes cutting boards are also made from this material, which are convenient to use in the meat industry.
Types and grades of material

The main types of caprolon:

     Casting. The most popular and widespread, simple and cheap to manufacture.
     extruded. Polymer with reduced heat resistance, suitable for operation at temperatures up to 100 °C.
     Heat resistant. It has increased resistance to heat, the maximum allowable temperature for the operation of such products is 259 ° C.
     Food. An environmentally friendly material that undergoes stricter control in terms of hygiene. Suitable for food contact.
     With the addition of solid lubricants (most often graphite). Differs in the increased wear resistance. Used for the manufacture of industrial equipment parts. Such elements work quietly, do not need lubrication and are not erased during operation. This is due to graphite dust that protrudes to the surface of the part when friction occurs. Graphite immediately reduces friction.
     With the addition of polyethylene or fiberglass. Caprolon, reinforced by the inclusion of PE or fiberglass filler in the production of parts or blanks.

The most popular grades of polymer:

     A. For the aircraft industry. Material of small weight and high durability, maintains serious dynamic loadings.
     B. For the production of parts for industrial equipment, automobiles, etc. Strong and durable polymer, the most common on the market.
     MG (with graphite). Possesses the increased antifrictional properties. The coefficient of friction of such a material is lower than that of products made of conventional caprolon with oil lubrication. The material is more expensive than usual and is used in a narrower field.
     MDM (with molybdenum). Polymer with enhanced dielectric properties. It is used where there is a high probability of ignition of an explosive gas mixture (mainly in the gas production and gas processing industry).

Release forms
Raw caprolon is produced in the form of a powder for further casting or extrusion. It enters the market in the form of finished cast parts or blanks. As a rule, this is:

     Sheets with a thickness of 6–250 mm and a size of 1 × 1 m (rings and liners are made from them).
     Rods up to 150–300 mm in diameter and up to 2 m long.
     Bars of different sizes (usually the size is set for a specific part that will be machined from a bar).
     Blanks of certain, non-standard shapes for further milling.

The material is recyclable, but virgin parts are stronger and more durable.
Due to its high chemical resistance, caprolon can be used even in difficult conditions and difficult environments. It is widely used in industries such as:

     food industry;
     aircraft, automobile and mechanical engineering;
     energy.

The material is perfect for making:

     bearings and other sliding parts;
     bushings, guide liners, facings;
     valves, rings, flanges;
     wheel hubs in carts, trolleys;
     pulleys, blocks, rollers, wheels of hoisting mechanisms for heavy loads (with a maximum load of up to 30 tons);
     brackets;
     sealing elements in separators;
     drives in gearboxes;
     sprockets, gears, parts of the worm gear;
     cutting boards and rotating parts of conveyors for meat and fish processing (for examplefood industry enterprises);
     elements of mechanisms for dressing leather at tanneries (reagents working there do not dissolve caprolon);
     details of mechanisms for cutting products at confectionery enterprises;
     fittings;
     electrical insulating parts.

Kaprolon is suitable for use in friction units with loads up to 20 MPa (here they work with a safety margin of 250%).
In many cases, PTFE can be replaced with caprolon and vice versa. But the interchangeability of these materials is limited. Caprolon is more wear-resistant and durable, while fluoroplastic is easier to process and withstands extreme temperatures (for example, the melting point of fluoroplast is 327 °C, caprolon is 225 °C). Therefore, in mass production, the use of these two materials is almost completely separated.