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Engineering Materials

Injection-Moldable Composite Beats Metal Specs

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Dave Wilkinson
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Iron
Re: What about the heads?
Dave Wilkinson   9/3/2014 2:16:48 PM
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Mr Wirtel,

All of the fasteners we have been asked to produce to date have been hex head screws without internal features.  We have a program in the works right now with a large Aerospace OEM that wants to develop a NAS bolt geometry which using a Phillips head internal feature so we hope to have better results in the coming months.

to date, all the tested fasteners are breaking at the firs few tread engagements across the minor diameter which is the expected location.

This OEM also recognizes that this is a obviously a completely different material of construction so they are expecting to potentially alter the NAS geometry to suit the application and our material.

The fasteners have such great performance that the majority of our customers are willing to make minor geometry changes to achieve the weight reduction and other obvious benefits that the KyronMAX materials offer.

We also employ a great team of Design and Application Engineers to assist our customers with the transition from metal to plastic and ensure the design is robust and cost effective.  We then test samples from 100% of every lot and batch of product we product in our analytical lab to confirm expected performance.

Keep the great questions coming...!

Dave Wilkinson

Ann R. Thryft
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Blogger
Re: What about the heads?
Ann R. Thryft   9/3/2014 1:59:10 PM
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Glad this was useful to you, Mr. Wirtel. That's an interesting question about head strength. I've asked Dave Wilkinson to reply.



Mr. Wirtel
User Rank
Gold
What about the heads?
Mr. Wirtel   9/2/2014 9:19:18 PM
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@Anne: Good story and very interesting product. It would be great in an application where it had to be "Non-sparking". In munitions plants for example. My question is in head strength. I have used various non-metallic fasteners and to my knowledge, have never had the thread fail. However, I have twisted screw driver slots to an unusable configuration and have turned the corners off hexhead screws. How do these fare?

Dave Wilkinson
User Rank
Iron
Re: INJECTION-MOLDABLE COMPOSITE
Dave Wilkinson   8/27/2014 5:59:49 PM
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Dave,

Great question in terms of the K-Factor and frictional characteristics.  We have not completed the full characterization of the materials yet because we are so early on in the commercial process.  Although, the material has great bearing properties and low friction and wear.  There is a large name race team that is using the KyronMAX in such an application with great results.  The company needed high flex modulus but also good bearing properties for a high speed wear part.  The incumbent material was being changed out after one days' cycling and so far the KyronMAX has been in test for over 3 weeks with virtually no wear!  We are hoping they will let us quote them in a future press release.

Now to clarify we did not design it specifically for bearing applications but it will absolutely blow away metallics in friction and wear conditions.  Let me know if you have any other questions and let us know if you have any potential applications.

Dave

Ann R. Thryft
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Blogger
Re: INJECTION-MOLDABLE COMPOSITE
Ann R. Thryft   8/27/2014 5:18:01 PM
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Good point bobjengr, about the corrosion-free characteristics of composite fasteners. There's a whole bunch of plastic and titanium/other material fasteners being developed for use with aerospace composites, for example. Yet, as you point out, shear and tensile strength haven't always measured up. So composite fasteners for composite parts--what a concept!

Ann R. Thryft
User Rank
Blogger
Re: More materials innovators and providers?
Ann R. Thryft   8/27/2014 5:16:26 PM
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Dave, I've asked Dave Wilkinson to answer your question.



bobjengr
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Platinum
INJECTION-MOLDABLE COMPOSITE
bobjengr   8/27/2014 4:42:27 PM
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Once again Ann--news we can use.  Great post.  One additional advantage a moldable composite has over metal fasteners, excellent corrosion resistance.  There are also fewer tendencies toward galling.  The big problem has been, prior to composites and this process, no ability to withstand the tensile and shear stresses.  From the data, it looks as though this has been overcome.  When used for aircraft structures, the weight reduction can be significant. Excellent post. 

Dave Palmer
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Platinum
Re: More materials innovators and providers?
Dave Palmer   8/26/2014 2:19:59 PM
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Thanks, Dave -- very impressive video.  These are clearly very high strength fasteners.  What about thread friction? What's a typical K-factor?

Ann R. Thryft
User Rank
Blogger
Re: No creep in the deep, or in the bolt
Ann R. Thryft   8/25/2014 2:23:55 PM
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William, I agree, it would have been interesting to find out more about the process and how it differs from more standard molding processes. It's proprietary, though, so the company understandably didn't go into detail about it.

William K.
User Rank
Platinum
Re: No creep in the deep, or in the bolt
William K.   8/22/2014 5:30:24 PM
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From the initial description it was not clear just howw "non-standard" the molding process was. My guess is that there will not be much competition in that area for a while. To popularize the product they could sell nut and bolt sets at some of the bigger trade gatherings, since my guess is that they are way to expensive to give away.

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