Halar ECTFE

Ethylene-Chlorotrifluoroethylene
Design and Processing Guide

TABLE OF CONTENTS
Introduction......................................................................................................................................... 3
The company......................................................................................................................................... 3
The Products......................................................................................................................................... 3
Halar ECTFE ....................................................................................................................................... 3
Chemistry ............................................................................................................................................... 4
Purity...................................................................................................................................................... 4
Typical Applications............................................................................................................................ 5
Product Range .................................................................................................................................... 6
Commercially available grades ............................................................................................................ 6
Packaging and Storage......................................................................................................................... 6
Typical properties ................................................................................................................................. 7
Physical Properties............................................................................................................................ 8
Thermal properties................................................................................................................................ 8
Coefficient of linear thermal expansion................................................................................................. 8
Stress cracking temperature ................................................................................................................ 9
Hardness............................................................................................................................................... 9
Surface properties............................................................................................................................... 10
Angle of contact and surface tension.................................................................................................. 10
Surface smoothness............................................................................................................................ 11
Optical properties Appearance........................................................................................................ 12
Mechanical properties.................................................................................................................... 14
Short term stresses.............................................................................................................................. 14
Long term static stress........................................................................................................................ 17
Electrical properties...................................................................................................................... 20
General characteristics....................................................................................................................... 20
Volume resistivity................................................................................................................................. 20
Dielectric constant............................................................................................................................... 21
Dissipation factor................................................................................................................................. 21
Halar grades for Wire & Cable applications....................................................................................... 21
Environmental resistance.............................................................................................................. 22
General chemical resistance properties............................................................................................. 22
Chemical resistance chart................................................................................................................... 23
Permeability ........................................................................................................................................ 24
Weathering resistance......................................................................................................................... 27
Resistance to high energy radiation.................................................................................................... 27
Fire resistance ................................................................................................................................... 28
UL Thermal Index (RTI)....................................................................................................................... 28
Limiting Oxygen Index LOI............................................................................................................... 29
Safety, Hygiene, Health Effects.................................................................................................... 30
Toxicity of decomposition products..................................................................................................... 30
Approvals............................................................................................................................................ 30
Processing .......................................................................................................................................... 31
Introduction.......................................................................................................................................... 31
Materials of c onstruction.................................................................................................................... 31
Extruder type....................................................................................................................................... 31
General considerations ...................................................................................................................... 31
Handling.............................................................................................................................................. 31
Regrind................................................................................................................................................ 31
Safety................................................................................................................................................... 31
Recommendations for extrusion.......................................................................................................... 32
Recommendations for injection moulding........................................................................................... 32
Recommendations for compression moulding.................................................................................... 33
Secondary Processing.................................................................................................................... 34
Welding . ............................................................................................................................................. 34
Machining............................................................................................................................................ 34

LIST OF TABLES
Table 1: Commercially available grades .............................................................................................................6
Table 2: Typical properties ..................................................................................................................................7
Table 3: Thermal properties..................................................................................................................................8
Table 4: Coefficient of Linear Thermal Expansion................................................................................................8
Table 5: Stress cracking temperature...................................................................................................................9
Table 6: Critical surface tension wetting.............................................................................................................10
Table 7: Contact angle........................................................................................................................................10
Table 8: Physical properties of Halar 650.........................................................................................................13
Table 9: Mechanical properties..........................................................................................................................14
Table 10: General electrical properties..............................................................................................................20
Table 11: Overview of the chemical resistance of Halar ECTFE.......................................................................23
Table 12: Fire resistance.....................................................................................................................................28
Table 13: Ignition resistance according to UL standard 746A...........................................................................28
Table 14: UL Thermal Index (RTI).......................................................................................................................29
Table 15: Limiting Oxygen Index........................................................................................................................29
Table 16: Halar ECTFE in compliance with NSF Standard 61...........................................................................30
Table 17: Typical extruder design.......................................................................................................................31
Table 18: Typical extruder operating conditions.................................................................................................32
Table 19: Typical injection moulding conditions ................................................................................................33
Table 20: Welding gun temperature...................................................................................................................34

LIST OF FIGURES
Fig. 1: Linear thermal expansion of Halar resin..................................................................................................9
Fig. 2: Shore D....................................................................................................................................................10
Fig. 3: Average direct cell count/cm.................................................................................................................11
Fig. 4: Highest direct cell count/cm...................................................................................................................12
Fig. 5: Light transmission vs. wavelength...........................................................................................................12
Fig. 6: Light transmission vs. wavelength...........................................................................................................13
Fig. 7: Light transmission of Halar 650.............................................................................................................13
Fig. 8: Tensile curve for Halar ECTFE...............................................................................................................14
Fig. 9: Tensile modulus vs. temperature.............................................................................................................15
Fig. 10: Tensile stress vs. temperature...............................................................................................................15
Fig. 11: Flexural modulus vs. temperature (ASTM D-790)..................................................................................16
Fig. 12: Tensile creep of Halar ECTFE @ 23C.................................................................................................17
Fig. 13: Tensile creep of Halar ECTFE @ 75C.................................................................................................17
Fig. 14: Tensile creep of Halar ECTFE @ 125C...............................................................................................18
Fig. 15: Tensile creep of Halar ECTFE @ 150C...............................................................................................18
Fig. 16: Stress relaxation of Halar ECTFE after 1000 hours..............................................................................19
Fig. 17: Volume resistivity...................................................................................................................................20
Fig. 18: Dielectric constant.................................................................................................................................21
Fig. 19: Dissipation factor...................................................................................................................................21
Fig. 20: Gas permeability in Halar ECTFE* .....................................................................................................24
Fig. 21: Chlorine permeability of Halar ECTFE compared with other polymers...............................................24
Fig. 22: Hydrogen sulfide permeability of Halar ECTFE compared with other polymers.................................25
Fig .23: Water vapor at 23C..............................................................................................................................25
Fig. 24: Water Vapor at 90C..............................................................................................................................26
Fig. 25: Permeabilities of HCl and HNO3 molecules in fluoropolymers .
from aqueous solutions.................................................................................................................................26
Fig. 26: Liquid permeabilities of a few common chemicals in Halar ECTFE, .
compared with PVDF and PFA......................................................................................................................26
Fig. 27: Florida exposure 45 South...................................................................................................................27
Fig. 28: QUV weatherometer..............................................................................................................................27

Introduction
The company
Solvay Solexis results from the acquisition of Ausimont
by the Solvay Group in 2002. The merger of both
Ausimont and Solvay activities in fluorinated materials
into the new company Solvay Solexis created a
new leader on the market, totally dedicated to the
development of fluoromaterials and their applications.
Solvay Solexis is part of the Strategic Business
Unit Specialty Polymers of the Solvay Group, and
contributes to the group strategy by being a leader in
specialty materials.
Solvay Solexis is an international group focused
on socially sustainable and constantly growing
businesses, based on the fluorine chemistry and
benefits from a unique integrated value chain, from
the Fluorspar to the ultimate fluorinated materials.
It is operating worldwide through five companies
in Italy, France, Japan, Brazil and the USA. Solvay
Solexis is headquartered in Bollate (Milano, Italy),
which is also its main R&D facility. Local R&D support
is also provided from Thorofare NJ for the NAFTA
area.

The Products
Solvay Solexis is organized in four Business units:
Fluids
these sophisticated perfluoropolyethers
commercialized under the brands Fomblin,
Fluorolink, Solvera and Galden are used as high
performance lubricants and heat transfer agents
offering unmatched chemical resistance and excellent
thermal stability.
Fluoroelastomers
Tecnoflon covers a wide range of elastomers
offering excellent chemical and thermal resistance to
atmospheric agents, especially to oxygen and ozone,
which are notably used in automotive, aerospace,
chemical, mining, oil and semi-conductors industries
PTFE and coatings
Algoflon PTFE and Polymist PTFE exhibit
outstanding physical, electric and non-stick
characteristics, and particularly excellent resistance
in aggressive environment, in a wide range of
temperatures. They are notably used for producing
gaskets, seals, pipes, fittings, to impregnate fabrics,
as additives for plastics compounds, elastomers and
inks.

Halar ECTFE in powder forms allows the production

of particularly smooth and weather-resistant coatings,
combined with extremely good chemical and flame
resistance.
Melt processable fluoropolymers
Solvay Solexis offers a wide range of fluoropolymers
easily processed by injection, extrusion, and all
conventional processing techniques:
Solef and Hylar PVDF (polyvinylidene fluoride)
Halar ECTFE (copolymer of ethylene and
chlorotrifluoethylene)
Hyflon PFA (copolymer of tetrafluoroethylene and
perfuoroalkoxyvinylethers).

Halar ECTFE
At a glance, the key properties of Halar ECTFE are
excellent chemical resistance to acids and strong
bases, up to pH 14,
excellent barrier properties to oxygen, carbon
dioxide, chlorine gas, hydrochloric acid,
very good electrical properties,
excellent abrasion resistance,
broad use temperature range from cryogenic to
+150C (depending on the grade and stresses
applied),
good weathering resistance,
excellent intrinsic fire resistance,.
UL class 94 V-0 at 0.18mm.
LOI >52 %.
Low flame spread, low smoke generation
exceptional surface smoothness,
very good impact strength,
good mechanical properties.
Properties and processing techniques of Halar
ECTFE are detailed in this brochure.

Hylar 5000 PVDF serves as the base resin for

durable architectural coating.
Hyflon PFA powders are used for very high
temperature, harsh environment resistant coatings, in
electronic, semi-conductors and processing fields.

Chemistry
Halar ECTFE is a semi-crystalline and meltprocessable fluoropolymer from Solvay Solexis
manufactured at its ISO-certified plant in Orange,
Texas.
Because of its chemical structure -a 1:1 alternating
copolymer of ethylene and chlorotrifluoroethyleneHalar ECTFE offers a unique combination of
properties.
One of the principal advantages of Halar
fluoropolymer is the ease with which it can be
processed. Halar fluorocarbon resin is a true
thermoplastic that can be handled by conventional
techniques of extrusion as well as by blow,
compression, injection, roto and transfer molding.
Powder coating methods are also applicable. Halar
resin is available in various melt viscosities to suit
virtually every processing technique.

Chemical structure of Halar ECTFE

Purity
Static soak testing in ultra-pure water and high purity
chemicals show extremely low levels of metallic
and organic extractables. Additional dynamic rinse
data validates Halar ECTFE as suitable for high
purity systems in the semiconductor, biotech, and
pharmaceutical industries. Halar exhibits very low
fluoride ion leachout.
Halar ECTFE is used as a lining and coating for ultrapure water systems in the semiconductor industry.
FM Global 4922 complete exhaust duct systems use
Halar ECTFE coated stainless steel.

Typical Applications
Chemical
Halar ECTFE is used extensively in CPI due to
excellent chemical resistance properties, even at
elevated temperatures, and mechanical properties.
Halar ECTFE is used in pulp and paper applications
due to its resistance to harsh acids, bases and
halogens. Specific applications include: containers,
diaphragms, protective linings/coatings for tanks,
pumps, valves, pipes, scrubbing towers, reactors,
thermocouple wells, centrifuge components, heat
exchangers, unsupported pipe and tubing, tower
packing, valve seats, filters, dust collectors, mist
eliminators, closures, filter fabric, fittings, process
system components.
Coatings
Halar ECTFE electrostatic powder coatings possess
excellent chemical resistance and good processability
making it well-suited for the following: agitators;
centrifuges; containers; hoods; membranes; filters;
pumps; vessels; reactors; piping systems; caustic
collectors; semiconductor chemical storage tanks;
electroplating equipment. Contact Solvay Solexis for
a copy of the Halar ECTFE Powder Coating manual
and/or the Halar ECTFE Ductwork brochure for more
detailed information.
Cryogenic and Aerospace
The excellent low temperature properties of Halar
ECTFE and wide temperature use range make it well
suited for Cryogenic and Aerospace applications.
Specific examples include: wire and cable insulation
and jacketing; pump liners; seals; gaskets; valve
seats; fittings; gaskets for liquid oxygen and other
propellants; components for manned space vehicles
and aircraft cabins, space suits; convoluted tubing
and hose for conduit; expandable abrasion-resistant
braid.

Halar High Purity Piping

(Courtesy of Asahi
America, Malden, MA)

Halar Powder Coated Tank

Head
(Courtesy of Sermatech,
Limerick)

Electrical
The low dielectric constant and low loss factor for
Halar ECTFE makes it well suited for electrical
applications. Specific examples include: wire and
cable insulation and jacketing; foamed insulation
in coaxial cable constructions; hook-up and other
computer wire insulation; oil-well wire and cable
insulation; jacketing for logging wire and cathodic
protection; aircraft, mass transit, automotive wire;
battery cases; fuel cell membranes; flexible printed
circuitry and flat cable.
Filtration
Halar Melt Blown Fiber is a fluoropolymer nonwoven web that offers improve d chemical resistance
(all acids and bases) and temperature resistance
properties (up to 150C / 300F) versus polypropylene,
nylon and polyester melt blown webs. Halar melt
blown webs also exhibit excellent radiation resistance
and will not support combustion.
Food and Pharmaceutical
Halar stabilized DA grades comply with the FDAs
Register of Food Additive Regulations, Use B
described at 21 C.F.R. 176.170(c), Table 2. Halar
unstabilized grades are suitable for repeated use
applications at temperatures up to 100C (212F)
in contact with non-fatty foods, under FDA 21 CFR
177.1380. Halar is particularly suited for use with
acidic food, fruit and juice processing.
Note: These are typical applications of Halar
ECTFE as at the date of publication. Solvay Solexis
fluoropolymer products are gaining increasing
acceptance in many industries. For further information
on your specific application, please contact Solvay
Solexis.

Mixed Polishing Bed

Powder Coated
(Courtesy of GDS
Manufacturing (Komstuff)
Wilkinston, Vermont)

Ozone-Resistant Filter
Cartridge made with
pleated media of Halar Melt
Blown Fiber.
(Courtesy of U.S. Filter,
Timonium, MD)

Various moulded parts

used in high purity
processing.

Product Range
Halar resins are available in a range of viscosities for extrusion and molding applications. Halar powders are
available in different particle sizes optimized for specific coating processes.

Commercially available grades

Table 1: Commercially available grades
Grade

Viscosity

Typical Melt Index

@ 275C and 2.16kg

Typical Use

Product form

Extrusion of sheet, pipe, and rod.

pellets

Standard Copolymer Series

901

High

0.8 1.3

Compression molding.
300

Med.

1.5 - 3

Film and rod extrusion.

pellets

350

Med.

3-6

Tube extrusion and injection molding

pellets

of large parts.
930

Med.

3-6

Cable jacketing.

pellets

500

Low

15 - 22

Primary wire insulation and standard

pellets

injection molding.
513

Low

18 - 20

Monofilament extrusion.

pellets

1450

very low

40 - 60

Injection molding of extremely small parts

pellets

Improved stress crack resistant grade

pellets

Improved Thermal Stress Crack Resistant Series

902

high

0.8 1.3*

for extrusion of sheet and rod.

Compression molding
Specialty Wire & Cable Series
558

Low

18 - 20

Foamable grade for wire coating.

pellets

Terpolymer Series
600

Med.

10 15

Thick rod extrusion

pellets

650

Med.

59

Transparent grade for specialty

pellets

applications
Powder Coating Series
6014

Low

12

Electrostatic powder coating. Top coat.

powder

6514

Low

12

Electrostatic powder coating. Primer.

powder

6614

Low

12

Electrostatic powder coating. Primer.

powder

8014

Low

12

Electrostatic powder coating. Top coat,

powder

improvements in high-temperature
stress cracking over 6014
* melt index @ 275C and 5kg

Specialty Formulations
All standard Halar extrusion and molding grades
are formulated to minimize Halar fluoropolymers
corrosivity to materials of construction and are
denoted LC or DA.
Halar LC grades offer the best corrosion
resistance to process machinery,
Halar DA grades are available and meet the
FDAs condition of Use B, as described under 21
C.F.R. 176-170(c).

Contact Solvay Solexis for further information.

Packaging and Storage

Halar resins are available in the following packaging:
55 lb (25 kg) drums,
175 lb (79,4 kg) drums,
500 kg big boxes,
2000 lb (907,4 kg) octabins.
Though they have an indefinite shelf life, it is
recommended to store them in a clean area, protected
from direct sunlight and possible contamination.

Typical properties
Table 2: Typical properties
Test Method

Unit

Standard
Copolymers

Terpolymer (Halar
600)

Halar 902

Density @ 23C (73F)

ASTM D792

g/cm (lb/ft)

1.68 (105)

1.68 (105)

1.71 (107)

Water absorption

ASTM D570

<0.1

<0.1

<0.1

Property
PHYSICAL

MECHANICAL (23C)
MPa (psi)

30-32 (4300-4600)

30-32 (4300-4600)

30-32 (4300-4600)

Tensile stress at break

Tensile stress at yield

ASTM D638

MPa (psi)

40-57 (5800-8300)

45-50 (6500-7300)

45-50 (6500-7300)

Elongation at yield

3-5

3-5

Elongation at break

250-300

325

250 - 300

Tensile Modulus

MPa (psi)

1400-2100 (203000304000)

1500-1800 (218000261000)

1400-2100 (203000304000)

Flexural strength

ASTM D790

Flexural modulus

MPa (psi)

45-55 (6500-8000)

45-50 (6500-7300)

45-55 (6500-8000)

MPa (psi)

1600-1800 (232000261000)

1600-1800 (232000261000)

1600-1800 (232000261000)

IZOD impact, notched .

@ 23C (73F)

ASTM D256

J/m

no break

no break

no break

IZOD impact, notched .

@ -40C (-40F)

ASTM D256

J/m

50-110

207

65

Hardness, Shore D

ASTM D2240

70-75

70-75

70-75

Hardness, Rockwell R

ASTM D785

90

80

90

Abrasion resistance

TABER

mg/1000 rev

Friction coefficient: static

dynamic

ASTM D1894

0.1-0.2

0.2

0.1-0.2

0.1-0.2

0.2

0.1-0.2
220-230 (428-446)

THERMAL (DSC)

ASTM D3418

Melting point

C (F)

240-245 (464-473)

220-227 (428-440)

Heat of fusion

J/g

42

28

28

Cristallizing point

C (F)

222 (432)

205 (400)

205 (400)

J/g

40

28

28

Cristallization heat
Deflection temperature

ASTM D648

load 0.46 MPa (66 psi)

C (F)

90 (195)

80 (175)

90 (195)

load 1.82 MPa (264 psi)

C (F)

70 (160)

65 (150)

70 (160)

Glass Transition (Tg)

DMTA

C (F)

85 (185)

80 (175)

85 (185)

Brittleness temperature

ASTM D746A

C (F)

<-76 (<-105)

<-76 (<-105)

<-76 (<-105)

2.5

2.5

2.5

Thermal stability

TGA begin - at 1%
weight loss in air

C (F)

405 (760)

405 (760)

405 (760)

Linear thermal expansion coefficient

ASTM D696

10-6 /K (10-6 /F)

90 (50)

100 (56)

90 (50)

Thermal conductivity .
@ 40C (104F)

ASTM C177

W/m.K

0.15

0.15

0.15

Specific heat

23C

J/g.K

0.95

0.95

0.95

ASTM D257

ohm.cm

> 1016

> 1016

> 1016

ohm.in

> 1016

> 1016

> 1016

kV/mm

15

14

15

V/mil

385

350

385

DIN 53483

2.6

2.6

2.6

UL-94 Flammability test

UL-94

Class

V-0

V-0

V-0

Limiting Oxygen Index

ASTM D 2863

52

52

52

Molding shrinkage

ELECTRICAL
Volume resistivity .
@ 23C, 50% RH
Dielectric strength .
@ 23C, 3.2 mm thick
Dielectric constant, 23C .
@ 106 Hz

ASTM D149

FIRE RESISTANCE

Note: All data for compression moulded samples unless otherwise specified.

Physical Properties
Thermal properties
Halar ECTFE copolymers offer a wide useful surface
temperature range from -80C to +150C in non loadbearing applications.

The maximum service temperature can be affected

by the presence of system stresses and chemical
environment. Stress cracking for standard grades may

appear in the 125-150C range, especially for highMI grades. Halar 902 was recently developed as an
improved stress-crack resistant grade.
Halar ECTFE shows excellent resistance to
degradation by heat, high-energy radiation and
weathering. It has low smoke properties and is nonflame propagating.

Table 3: Thermal properties

Property

Test Method

Unit

Melting point

ASTM D3417

C (F)

240-245 (464-473)

Heat of fusion

J/g

42

Cristallizing point

C (F)

222 (432)

Cristallization heat

J/g

40

ASTM DSC

Standard Copolymers

J/g.K

0.95

@ 100C

J/g.K

1.26

@ 200C

J/g.K

1.55

@ 300C

J/g.K

1.64

Specific heat (@ 23C)

Glass Transition (Tg)

DMTA

C (F)

85 (185)

Thermal stability

TGA begin - at 1% weight

loss in air

C (F)

405 (760)

Deflection temperature

ASTM D648

load 0.46 MPa (66 psi)

C (F)

90 (195)

load 1.82 MPa (264 psi)

C (F)

70 (160)

Maximum service Temp.

C (F)

150 (302)

Brittleness temperature

ASTM D746A

C (F)

<-76 (<-105)

Thermal conductivity @ 40C (104F)

ASTM C177

W/m.K

0.151

@ 95C (203F)

0.153

@ 150C (302F)

0.157

Flammability

UL 94

Rating

V-0

Limiting Oxygen Index

ASTM D2863

52

Coefficient of linear thermal

expansion
The following table and figure 1 shows the linear
thermal expansion coefficient for Halar ECTFE.

Table 4: Coefficient of linear thermal expansion

Temperature range

in/in-F

cm/cm-C

-30 to +50C (-22 to 122F)

4.4 x 10-5

8 x 10-5

50 to 85C (122 to 185F)

5.6 x 10-5

10 x 10-5

85 to 125C (185 to 257F)

7.5 x 10-5

13.5 x 10-5

125 to 180C (257 to 356F)

9.2 x 10-5

16.5 x 10-5

Fig. 1: Linear thermal expansion of Halar resin



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Stress cracking temperature

Parts made from Halar ECTFE resin have a limited
resistance to crack formation under stress at elevated
temperatures. This phenomenon can be observed
by utilizing Fed. Spec. L-P-390C Class H, a test
procedure originally designed for polyethylene. In
this test, 1/4 in wide strips of .05 in. thick sheet
are wrapped around a in. diameter mandrel and
exposed to various temperatures in forced-draft
ovens. The calculated strain (elongation) of the strip
wrapped on the 1/4 in. diameter mandrel is about 16
percent. The temperature at which Halar resin will
stress crack appears to be predominantly a function
of molecular weight and molecular-weight distribution.
Based on these results from the above test, the
following grades of Halar resin have the indicated
stress-cracking temperatures.

Halar 902 was recently developed as an improved

stress-crack resistant grade. It is particularly
recommended for the extrusion and/or compression
molding of thick shapes, for sheet thermoforming,
load-bearing applications at high temperatures,
higher thermal rating of cables, and rotomolding.

Hardness
Hardness is the materials resistance to indentation
(penetration by a hard object). It is normally measured
with a Shore durometer, which measures the depth
of indentation achieved with a standard indenter
for a given time under a given load, according to the
ASTM D2240 testing method. Different Shore scales
are defined depending on the materials hardness: for
hard polymers like Halar ECTFE the Shore D scale is
normally used.

Table 5: Stress cracking temperature

Halar Grade

Melt Index

Stress cracking
Temperature

300

2 g/10 min

150C (302F)

500

18 g/10 min

140C (284F)

Shore D hardness values for the most common

fluoropolymers are reported in the following diagram.

Fig. 2: Shore D



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Surface properties
Halar ECTFE resins have a critical surface tension of
wetting comparable to that of the polymers of ethylene
and chlorotrifluoroethylene, the two constituents that
make up the Halar copolymer. Halar ECTFE is not
wetted by water but oils and hydrocarbons readily
spread on its surface. The wettability of Halar can
be markedly improved by etching with sodium-based
etchants normally employed for PTFE.

Angle of contact and surface tension

Table 6: Critical surface tension wetting
Substrate

US unit

Halar ECTFE

32 dynes/cm

SI Unit
0.032N/m

PCTFE

31 dynes/cm

0.031N/m

Polyethylene

31 dynes/cm

0.031N/m

PVDF

25 dynes/cm

0.025N/m

FEP

16 dynes/cm

0.016N/m

Table 7: Contact angle

10

Surface

Water

Hexadecane

Halar ECTFE

99C

<5

PCTFE

109C

36C

PVDF

105C

41C

HDPE

98C

<5

Surface smoothness

particle trapping. The formation of biorganic films and

bacterial colonies is significantly reduced.

Halar ECTFE is distinguished from all other

fluoropolymers by its exceptional surface smoothness
which precludes the shedding of particles and avoids

PVDF

A comparison of pipe internal surfaces by Atomic

Force Microscopy (20x20 m) is shown in the
following pictures.

PFA

Halar ECTFE

Halar pipes exhibit a low incidence of microbial bio-fouling, making it ideal for use in UPW (ultra pure water)
applications.

Fig. 3: Average direct cell count/cm

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Fig. 4: Highest direct cell count/cm

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Optical properties Appearance

Halar ECTFE has excellent optical properties with low haze, as well as excellent light transmission throughout a
wide range of wavelengths. The index of refraction of Halar 500 at 21C for 589 nm light is 1.4476.

Fig. 5: Light transmission vs. wavelength

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Fig. 6: Light transmission vs. wavelength

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Halar 650 is a clear grade that was designed for use in semiconductor work-bench environments (windows,
sight glass). Its chemical composition was modified to reduce crystallinity, enhancing transparency.

Table 8: Physical properties of Halar 650

Physical Properties

Method

Units

Typical values

Melting point

ASTM D 3418

C
(F)

190-200
(374-392)

Glass Transition Temperature

DMS

C
(F)

75
(167)

Max. Use Temperature

dimensional stability of extruded

sheets

C
(F)

60
(140)

Density

ASTM D 792

1.72

Melt flow index

ASTM D 1238

5 - 10

Tensile strength at yield

ASTM D 1708

MPa (psi)

30 (4300)

Tensile strength at break

ASTM D 1708

MPa (psi)

41 (5850)

Elongation at yield

ASTM D 1708

Elongation at break

ASTM D 1708

300

Fig. 7: Light transmission of Halar 650

(ALARMILANDMIL


4RANSMITTANCE


















7AVELENGTHNM





13

Mechanical properties
Halar ECTFE is a strong, hard, tough, abrasion
resistant, highly impact-resistant material that
retains its useful properties over a broad range
of temperatures. Its low-temperature properties,
especially those related to impact, are particularly

outstanding. Halar ECTFE also has good tensile,

flexural and wear resistant properties. Mechanical
property information is provided in the table and
figures below.

Table 9: Mechanical properties

Property

Test Method

Unit

Standard Copolymers

Terpolymer
(Halar 600)

Halar 902

Tensile stress at yield

ASTM D638

30-32 (4300-4600)

MPa (psi)

30-32 (4300-4600)

30-32 (4300-4600)

Tensile stress at break

MPa (psi)

40-57 (5800-8300)

45-50 (6500-7300)

45-50 (6500-7300)

Elongation at yield

3-5

3-5

Elongation at break

250-300

325

250 - 300

MPa (psi)

1400-2100 (203000304000)

1500-1800 (218000261000)

1400-2100 (203000304000)

MPa (psi)

45-55 (6500-8000)

45-50 (6500-7300)

45-55 (6500-8000)

MPa (psi)

1600-1800 (232000261000)

1600-1800 (232000261000)

1600-1800 (232000261000)

Tensile Modulus
Flexural strength

ASTM D790

Flexural modulus
IZOD impact, notched .
@ 23C (73F)

ASTM D256

J/m

no break

no break

no break

IZOD impact, notched .

@ -40C (-40F)

ASTM D256

J/m

50-110

207

65

Hardness, Shore D

ASTM D2240

70-75

70-75

70-75

Hardness, Rockwell R

ASTM D785

90

80

90

Abrasion resistance

TABER

mg/1000 rev

Friction coefficient: static

ASTM D1894

0.1-0.2

0.2

0.1-0.2

dynamic

0.1-0.2

0.2

0.1-0.2

Short term stresses

Tensile Properties
Tensile properties are determined by clamping a
test specimen into the jaws of a testing machine and
separating the jaws at a specified rate in accordance
with ASTM D638. The force required to separate the
jaws divided by the minimum cross-sectional area is
defined as the tensile stress. The test specimen will

elongate as a result of the stress, and the amount of

elongation divided by the original length is the strain.
If the applied stress is plotted against the resulting
strain, a curve similar to that shown for instance in
Figure 8 is obtained for ductile polymers like ECTFE.

Fig. 8: Tensile curve for Halar ECTFE

"REAK

3TRESS-0A

9IELD

3LOPETENSILEMODULUS

3TRAIN

14

Fig. 9: Tensile modulus vs. temperature

4ENSILEMODULUS;-0A=




















4EMPERATURE;#=

Fig. 10: Tensile stress vs. temperature



3TRESSATYIELD

4ENSILESTRESS;-0A=4



3TRESSATBREAK


















4EMPERATURE;#=

15

Flexural Properties
Flexural properties were determined in accordance
with ASTM D790 using the three-point loading
method. In this method the test specimen is
supported on two points, while the load is applied to
the center. The specimen is deflected until rupture
occurs or the fiber strain reaches five percent.

Flexural testing provides information about a

materials behavior in bending. In this test, the bar is
simultaneously subjected to tension and compression.
Note: all data for compression moulded samples
unless otherwise specified.

Fig. 11: Flexural modulus vs. temperature (ASTM D-790)



&LEXURALMODULUS PSI





















4EMPERATUREIN#

16









Long term static stress

Creep and Stress Relaxation
When a bar made of a polymeric material is
continuously exposed to a constant stress, its
dimensions will change in response to the stress.
This phenomenon is commonly called creep. In
the simplest case, the tensile mode, the test bar will

elongate as a function of time under stress. The term

strain is used for the amount of length increase or
elongation divided by the initial length.
Creep can also be observed and measured in a
bending or flexural mode, or in a compressive mode.
The creep information presented in this manual was
developed using the tensile mode.

Tensile creep of Halar ECTFE at various temperatures and under different stresses:

Fig. 12: Tensile creep of Halar ECTFE @ 23C


-0A

-0A

-0A

3TRAIN


















4IMEHOURS

Fig. 13: Tensile creep of Halar ECTFE @ 75C


-0A



-0A

-0A



3TRAIN




















4IMEHOURS

17

Fig. 14: Tensile creep of Halar ECTFE @ 125C


-0A



-0A



3TRAIN




















-0A

-0A







4IMEHOURS

Fig. 15: Tensile creep of Halar ECTFE @ 150C

3TRAIN












10

4IMEHOURS

18



On the other hand if a specimen is deformed and kept

for a long time at constant strain, the stress that must
be applied to keep deformation constant decreases

with time. This effect is known as stress relaxation

and basically depends on the same physical
phenomena as creep.

Stress relaxation after 1000 hours in Halar ECTFE specimens deformed by 2% as function
of temperature:

Fig. 16: Stress relaxation of Halar ECTFE after 1000 hours

3TRESSRELAXATIONHOURSTOTALSTRAIN



3TRESSPSI




























4EMPERATUREIN#

19

Electrical properties
General characteristics

Volume resistivity

Halar ECTFE standard and modified copolymers

exhibit high bulk and surface resistivities, high
dielectric strength, low dielectric constant, and
moderate dissipation factor. The dissipation factor
varies slightly with the frequency for frequencies
above 1 kHz. Overall, the A.C. losses of Halar ECTFE
are much lower than the A.C. losses of PVDF. The
dielectric constant of Halar is stable across broad
temperature and frequency ranges. Halar ECTFE
can be used as jacketing of plenum rated cables in
more demanding applications. Its excellent electrical
properties simplify the design of high-performance
cables. The very low moisture absorption properties
of Halar ECTFE and the temperature insensitivity
ensure that cables utilizing Halar jackets maintain
their electrical performance under a wide variety of
environmental conditions. PVC jacketed cables have
been shown to deteriorate significantly in electrical
performance due to moisture absorption during
aging. Halar ECTFE low temperature properties allow
installation in any season without risk of cracking or
splitting.

Volume resistivity is defined as the electrical

resistance offered by a material to the flow of current,
times the cross sectional area of current flow per unit
length of current path. The test is run by subjecting
the material to 500 volts for 1 minute and measuring
the current. The higher the volume resistivity, the more
effective a material will be in electrically isolating
components.

Property

ASTM

Halar ECTFE

Volume resistivity (xcm)

D 257

>1015

Surface resistivity ()

D 257

>1014

Dielectric strength at 1mm

thickness (kV/mm)

D 149

30-35

Relative dielectric constant

D 150

at 1 kHz

2.5

at 1 MHz

2.6

Dissipation Factor
at 1 kHz

0.0016

at 1 MHz

0.015

Many applications for thermoplastic resins depend

upon their ability to function as electrical insulators.
Several tests have been developed to provide the
designer with physical parameters that help to predict
how well a particular resin can perform that function.

20

6OLUMERESISTIVITY;/HMXCM=

Table 10: General electrical properties

Fig. 17: Volume resistivity

%
%
%
%
%
%
%
%
%
%








4EMPERATURE#



Dielectric constant

Dissipation factor

Dielectric constant is defined as the ratio of the

capacitance of a condenser using the test material
as the dielectric to the capacitance of the same
condenser having only vacuum as the dielectric.
Insulating materials are used in two very distinct
ways: (1) to support and insulate components from
each other and ground, and (2) to function as a
capacitor dielectric. In the first case, it is desirable to
have a low dielectric constant. In the second case,
a high dielectric constant allows the capacitor to be
physically smaller.

Dissipation factor (also referred to as loss tangent or

tg delta) is a measure of the amount of heat (energy)
dissipated by a material under alternating voltage.
Low dissipation factors are desirable in most cable
applications, especially with communications LAN
copper wires.

Fig. 19: Dissipation factor

Fig. 18: Dielectric constant

$ISSIPATIONFACTOR

%

$IELECTRICCONSTANT




% 

% 

% 










4EMPERATURE#















4EMPERATURE#

Halar grades for Wire & Cable

applications
Halar ECTFE offers excellent abrasion resistance
and mechanical properties over a broad range of
temperatures and chemical resistance to a wide
variety of acids, bases, and organic solvents. It is
rated for continuous use from cryogenic temperatures
up to 150C and higher. It offers good electrical
properties and fire and smoke performance. It
is an ideal choice for various telecommunication
applications, signal cables, coaxial, and jacketing
requiring excellent weatherability and/or chemical
resistance.
The improved copolymer structure of Halar 902
imparts much improved thermal stress cracking
resistance and an increased thermal rating
temperature. This is a low melt index grade for heavy

wall applications. For jacketing applications requiring

a medium melt flow index, Halar 930LC and Halar
350LC are ideal candidates. Halar 500LC is a high
melt index grade for thin wall applications at high line
speeds. For even thinner walls, Halar 1450LC is a
very high melt index grade for specialty applications.
Halar 558 is a completely pre-compounded
chemically foamed grade which provides similar
performance to FEP with a dielectric constant up to 25
% lower depending on the wall thickness. Where cost
reduction and/or lighter weight cable may be desired,
Halar ECTFE foam is a sound choice. Cables made
from Halar 558 have met the fire performance
requirements in NFPA 90a and tested according to
NFPA 262.

21

Environmental resistance
General chemical resistance
properties

Concentration of the attacking chemical which

may be a complex completely different than the
individual components,

Halar ECTFE demonstrates excellent overall chemical

resistance. In general only few species are known
to chemically attack Halar and a limited number of
chemicals can significantly swell the polymer leading
to a worsening of the performance of the material.

Exotherm or heat of reaction or mixing pressure,

due primarily to the effect of pressure on
concentration of a reactive gas,

Halar fluoropolymer is especially resistant to:

strong and weak inorganic acids and bases,
weak organic acids and bases,
salts,
aliphatic hydrocarbons,
alcohols,
strong oxidants,
halogens.
However, Halar ECTFE can be swelled, in particular
at high temperatures, by some:
esters,
aromatic hydrocarbons,
ethers,
ketones,
amides,
partially halogenated solvents.
Halar ECTFE can be attacked by amines, molten
alkali metals, gaseous fluorine, and certain
halogenated compounds such as CIF3.
Chemical attack and swelling are very complex
phenomena. The known factors affecting chemical
suitability of Halar ECTFE or any other plastic for a
chemical application, not listed in order of priority, are
as follows:
Specific chemical or mixture composition,
Temperature and temperature variation,

22

Time of exposure,
Stress levels,
Velocity,
Suspended solids,
Thickness,
EMF potential of the supporting metal compared to
the ground potential.
The recommended procedure to determine suitability
of Halar ECTFE is as follows:
Determine as accurately as possible the chemicals
in the stream in question,
Determine the maximum temperature and the
normal operating temperature,
Review the maximum recommended temperature
from the list provided.
The maximum recommended temperatures listed
below typically refer to the exposure of non-stressed
parts; if relevant stresses are present, a more severe
effect on the material should be taken into account.
Moreover, the effect of synergism or reaction or
complex formation with mixtures cannot be predicted
by the table. In any case, appropriate chemical
resistance tests using a representative sample of the
stream should be performed.

Chemical resistance chart

The table below presents an overview of the chemical
resistance of Halar ECTFE to the most common
chemicals.

Please note that the present document provides the

reader a substantial overview. Nevertheless, in case
of any doubt one should contact Solvay for further
information.

Table 11: Overview of the chemical resistance of Halar ECTFE

Chemical

Formula

Concentration

Max. Temp. [C]

Acids
Hydrochloric

HCl

37 %

150

Hydrofluoric

HF

50 %

150

Nitric

HNO3

65 %

66

Phosphoric

H3PO4

85 %

150

Sulphuric

H2SO4

98 %

125

oleum

23
150

Bases
Ammonium hydroxide

NH4(OH)

30 %

Potassium hydroxide

KOH

30 %

121

Sodium hydroxide

NaOH

50 %

121

Sodium hypochlorite

NaClO

5% - stabilized at pH 12

150

n-Hexane

CH3(CH2)4CH3

100 %

150

Toluene

C6H5CH3

100 %

66

Methanol

CH3OH

100 %

65

Ethanol

CH3CH2OH

100 %

140

100 %

> 100

Hydrocarbons

Alcohols and ethers

Organic acids, esters and ketones

Acetic acid

CH3COOH

Acetone

50 %

> 121

CH3COCH3

100 %

66

Acetophenone

C6H5COCH3

100 %

50

Ethyl Acetate

CH3COOCH2CH3

100 %

50

Dimethyl formamide

CH3CON(CH3)2

100 %

50

Dimethyl sulphoxide

CH3SOCH3

100 %

> 100

100 %

25

Classic polymer solvents

N-Methylpyrrolidone
Halogenated solvents
Chlorobenzene

C6H5Cl

100 %

66

Chloroform

CHCl3

100 %

not resistant

Amines and nitriles

Acetonitrile

CH3CN

100 %

> 100

Aniline

C6H5NH2

100 %

100

Dimethyl amine

(CH3)2NH

100 %

25

H2O2

30 %

> 88

Crude oil

100 %

150

Dexron II (gear oil)

100 %

150

Gasoline

100 %

150

Diesel Fuels

100 %

150

Mineral oil

100 %

150

Peroxides
Hydrogen peroxide

Fluids used in the automotive industry

23

Permeability

Figure 20 shows the permeability coefficients of

hydrogen, nitrogen, oxygen and ammonia in Halar
ECTFE as a function of temperature. For simple
gases which do not form specific interactions with
the polymer chains permeability increases with
decreasing molecular dimensions. Permeability of the
polar molecule NH3, on the other hand, is higher than
expected simply basing on its size.

In general Halar ECTFE offers an excellent

permeation resistance to many chemicals.

Barrier properties strongly depend on the nature

(polarity, size) of the chemicals present in the
environment and an overview on the permeation
properties of the material can be given according to
the features of the penetrating species.

Figure 21 and 22 show the permeability coefficients

of chlorine and hydrogen sulfide in Halar ECTFE
compared with those of other fluorinated and
hydrogenated materials.

Gases
Halar ECTFE has excellent permeation resistance to
simple gases.

Fig. 20: Gas permeability in Halar ECTFE*



.( 
(

0;CMqMMMqATMqD=



/


.
























4#

* Data from L.K.Massey, Permeability Properties of Plastics and Elastomers, PDL (2003)

Fig. 21: Chlorine permeability of Halar ECTFE compared with other polymers


($0%

0;CMqMMMqATMqD=



0&!



%4&%
%#4&%













4#

24









Fig. 22: Hydrogen sulfide permeability of Halar ECTFE compared with other polymers



0;CMqMMMqATMqD=

($0%


%#4&%


%4&%
06$&























4;#=

Water vapor permeability in Halar ECTFE is about

750 cm3mm/matmd at 23C and 7600 cm3mm/
matmd at 90C. It is worthwhile noting that in the
same temperature range, the permeability coefficient
in PVDF rises from values similar to Halar at room
temperature to 37000 cm3mm/matmd, about five
times higher than Halar, at 90C.
Figure 23: Water vapor permeability comparison of
different polymers at 23C

Fig .23: Water vapor at 23C

,$ 0%



0;CMqMMMqATMqD=

Water
Water is a small, polar molecule that can interact
with polymer chains forming hydrogen bonds.
Permeation resistance of Halar ECTFE to water vapor
is better than other fluoropolymers, as PVDF, and its
permeability coefficients are close to perfluorinated
polymers.

($ 0%



06#



06$&



%#4&%



0&!

0#4&%



7ATER6APORAT#

0!

Figure 24: Water vapor permeability comparison of

different polymers at 90C [from C.M.Hansen, Progr.
Org. Coat., 42, 167-178 (2001)]

25

Fig. 24: Water Vapor at 90C

06$&



0;CMqMMMqATMqD=

%#4&%
0&!




Aqueous electrolytes
n+ mThe permeation of electrolytes A x B y in Halar ECTFE
as in hydrophobic fluoropolymers involves the
passage of the neutral specie A xB y and not of the ions
An+ and Bm-. (see Figure 25)
In general the permeability coefficients of electrolytes
are low even from conce ntrated solutions and they
are related to the volatility of the electrolyte: only
volatile species have a non negligible permeation
rate, while the permeation of non volatile electrolytes
can not be detected even after years.
However, when considering the permeation of
aqueous solution, also the permeation of water
discussed above should be considered.

7ATER6APORAT#

Fig. 25: Permeabilities of HCl and HNO3 molecules in fluoropolymers from aqueous solutions

06$&

%

0;GqMMMqD=

%#4&%
0&!
% 

% 

% 

(#LFROMASOLUTION

Organic chemicals
As the permeation process can be described as the
sorption of the penetrating species on the material
surface followed by its diffusion through the polymer
chains, it should be clear the linkage between

(./FROMASOLUTION

permeability and swelling: chemicals that are known

as swelling agents for Halar ECTFE (see the section
above) are also expected to have a significant
permeation rate in the polymer.

Fig. 26: Liquid permeabilities of a few common chemicals in Halar ECTFE, compared with PVDF and PFA

0;GqMMMqD=



DISSOLVED



06$&
%#4&%
0&!







(EXANE#

26

-ETHYLENECHLORIDE
#

$IMETHYLACETAMIDE
#

-ETHANOL#

Weathering resistance

Halar ECTFE are barely affected after 5000 hours

exposure to the UVB-313 source of light in the QUV
Weatherometer or after 9 years of the Florida outdoor
weathering. The figures 27 and 28 below illustrate the
exceptional weathering resistance of Halar films.

Halar ECTFE undergoes very little change in

properties or appearance upon outdoor exposure to
sunlight. Both accelerated and outdoor weathering
studies demonstrate the remarkable stability of the
polymer to UV light and weather. The properties of

Fig. 27: Florida exposure 45 South

4ENSILEPROPERTIESOFMIL(ALAR &ILM







2ETENTIONOFTENSILESTRENGTH 2ETENTIONOFELONGATION






!GINGTIMEYEARS

Fig. 28: QUV weatherometer






2ETENTIONOFTENSILESTRENGTH



2ETENTIONOFELONGATION
$%



$%



MIL(ALAR%#4&%&ILM
HOURSOF156WEATHEROMETER
















!GINGTIMEHOURS

Resistance to high energy radiation

Halar ECTFE has demonstrated excellent resistance
to many sources of radiation up to 200 Mrad.

27

Fire resistance
Halar ECTFE offers a superior combination of
properties in comparison to other partially fluorinated
plastics, according to the following independent tests:

High-Current Arc Ignition (HAI): this test measures

the relative resistance of insulating materials to
ignition from arcing electrical sources,

UL-94,

High-Voltage Arc Tracking Rate (HVTR): this test

determines the susceptibility of an insulating
material to track or form a visible carbonized
conducting path over the surface when subjected
to high-voltage, low current arcing,

LOI limiting oxygen index,

Auto ignition temperature,
Factory Mutual (FM).
When placed in a flame, unlike most thermoplastics,
Halar ECTFE does not melt or drip. Char is formed,
which serves as an oxygen and heat transfer barrier.
On removal of flame, it immediately extinguishes.
It will not ignite or propagate flame in atmospheres
which contain up to 52% of oxygen. Halar ECTFE has
excellent low smoke properties.

Table 12: Fire resistance

UL 94

V-0 rating at 0.18 mm

Limiting Oxygen Index (ASTM D 2863)

> 52%

Auto-Ignition Temperature (ASTM D1929)

655C

Factory Mutual (FM 4910)

compliant

There are two types of pre-selection test programs

conducted on plastic materials to measure
flammability characteristics.
The first determines the materials tendency either to
extinguish or to spread the flame once the specimen
has been ignited; this program is described in UL
94. Specimens moulded from the plastic material
are oriented in either a horizontal or vertical position,
depending on the specifications of the relevant test
method, and are subjected to a defined flame ignition
source for a specified period of time. The vertical
rating V-0 indicates that the material was tested
in a vertical position and self-extinguished within
the shortest burn time after the ignition source was
removed, and doesnt drip flaming particles, showing
highest safety (see Table 12).
The second test program measures the ignition
resistance of the plastic to electrical ignition sources.
The materials resistance to ignition and surface
tracking characteristics is described in UL 746A.
The basic tests used to evaluate a materials ability to
resist ignition are (see Table 13):
Hot-Wire Ignition (HWI): this test determines the
resistance of plastic materials to ignition from an
electrically heated wire,

High-Voltage, Low-Current Dry Arc Resistance

(D495): this test measures the time that an
insulating material resists the formation of a
conductive path due to localized thermal and
chemical decomposition and erosion,
Comparative Tracking Index (CTI): this test
determines the voltage that causes a permanent
electrically conductive carbon path after 50 drops
of electrolyte have fallen on the material.

Table 13: Ignition resistance according to UL

standard 746A
Thickness
mm

Flame
Class

HWI

HAI

HVTR

D495

CTI

0.18

V-0

1.5

V-0

3.0

V-0

Halar grades tested according to the UL Standard 746A: 100, 200,

300, 400, 500, 5001, 5002.

UL Thermal Index (RTI)

Halar ECTFE has been investigated with respect
to retention of certain critical properties, according
to UL Standard 746B. The end-of-life of a material
is assumed to be the time when the value of the
critical property has decreased to 50 percent of its
original value. The maximum service temperature for
a material, where a class of critical property will not
unacceptably compromised through chemical thermal
degradation is defined as Relative Temperature Index
(RTI).
More than one RTI may be appropriate for a given
material depending on the property requirements for a
given application (see Table 14):
RTI Elec: Electrical RTI, associated with critical
electrical insulating properties,
RTI Mech Imp: Mechanical Impact RTI, associated
with critical impact resistance, resilience and
flexibility properties,
RTI Mech Str: mechanical Strength RTI, associated
with critical mechanical strength where impact
resistance, resilience and flexibility are not
essential.

28

Table 14: UL Thermal Index (RTI)

Thickness mm

RTI Elec

RTI Mech
Imp

RTI Mech Str

0.18

150

150

150

1.5

160

150

160

3.0

160

150

160

Halar grades tested according to the UL Standard 746B: 100, 200,

300, 400, 500, 5001, 5002.

Since ordinary air contains roughly 21 percent

oxygen, a material whose oxygen index is appreciably
higher than 21 is considered flame resistant because
it will only burn in an oxygen-enriched atmosphere.

Table 15: Limiting Oxygen Index

LOI

Halar ECTFE

ETFE

> 52%

32%

Limiting Oxygen Index LOI

The oxygen index is defined by ASTM D 2863 as
the minimum concentration of oxygen, expressed as
volume percent, in a mixture of oxygen and nitrogen
that will support flaming combustion of a material
initially at room temperature under the conditions of
this method.

29

Safety, Hygiene, Health Effects

Fluoropolymer resins like Halar ECTFE are known
for their high chemical stability and low reactivity.
Where toxicological studies have been conducted on
fluoropolymers, no findings of significance for human
health hazard assessment have been reported. None
of the fluoropolymers is known to be a skin irritant or
sensitizer in humans.

European Commission Directive 2002/72/EC and

its amendments, relating to plastics materials and
articles intended to come into contact with foodstuffs.
Halar ECTFE grades comply with the specifications
of the United States Food and Drug Administration
(FDA) 21CFR 178.1380.

Following massive exposure to fluoropolymer resin

dust by inhalation, increases in urinary fluoride were
produced; however, no toxic effects were observed.
Some Halar resins are formulated with additives
such as fillers, pigments, stabilizers, etc, to provide
favourable processing, or other characteristics. These
additives may present other hazards in the use of the
resins.

Several grades of Halar are recognized under each

of these standards. Information on current listings for
specific grades is available from your Solvay Solexis
representative.

The Safety Data Sheet, available for each of the

commercial grades, should be consulted for specific
health information and to follow all the necessary
safety instructions.

National Sanitation Foundation

NSF International is a no-profit, non-governmental
organization that develops standards for public health
and safety. It also provides lists of materials that
conform to their standards.

For further details, please consult the brochure Guide

for the Safe Handling of Fluoropolymers Resins

Toxicity of decomposition products

The main Halar grades must be processed at
temperatures between 260C and 280C. Under
these conditions, there is no risk of decomposition
of the ECTFE polymer (except in the presence of
contaminants)
In general, it is important to ensure good ventilation
in the workplaces. In order to avoid decomposition,
it is imperative that the material not be heated to
a temperature above 350C. The main fluorinated
product emitted during combustion is hydrofluoric
acid (HF) which is dangerous if inhaled or if it comes
into contact with the skin or the mucous membranes.
As an indication with respect to HF, the ACGIHTLVCeiling value (the concentration that should not to
be exceed during any part of the working exposure)
is 2 ppm (1.7 mg/cm), the indicative occupational
exposure limit values established by Directive
2000/39/EC is 3 ppm (2.5 mg/m) for short-term (15minutes) exposure period and the IDLH (Immediately
Dangerous to Life or Health Concentrations ) value set
by NIOSH is 30 ppm.
In the event of fire, it is preferable to extinguish it with
sand or extinguishing powder; use of water may lead
to the formation of acid solutions.

Approvals
Food Contact
The fluorinated monomers used in the Halar
copolymers (ethylene, chlorotrifluoroethylene)
and terpolymers (ethylene, chlorotrifluoroethylene,
perfluoropropylvinylether) meet the requirements of

30

International Water Contact Standards

Listings expire periodically and depending on market
demand they may or may not be recertified. Contact
your Solvay Solexis representative for the latest listing.

NSF Standard 61 Drinking Water System

Components Health Effects
The table below lists the Halar ECTFE polymers
certified to meet NSF Standard 61 at 85C (185F)

Table 16: Halar ECTFE in compliance with NSF

Standard 61
Grade
Halar 300LC - Halar 350LC - Halar 500LC
Halar 901 - Halar 902

Medical Applications
Biological tests ca rried out on Halar ECTFE
according to USP chapter 88 Biological reactivity
tests, in vivo have demonstrated its compliance with
the requirements of USP Plastic Class VI.
Although USP Class VI testing is widely used and
accepted in the medical products industry, it does
not fully meet any category of ISO 10993-1 testing
guidelines for medical device approval.
Each specific type of medical product must be
submitted to appropriate regulatory authorities for
approval. Manufacturers of such articles or devices
should carefully research medical literature, test and
determine whether the fluoropolymer is suitable for
the intended use. They must obtain all necessary
regulatory agency approvals for the medical product
including any raw material components.
Solvay Solexis does not allow or support the use
of any of its products in any permanent implant
applications. If you have any questions regarding
the companys implant policy, please contact your
Solvay Solexis representative

Processing
Introduction
Halar ECTFE is a melt-processable fluoropolymer
that can be processed like conventional
thermoplastic materials. Basic processing
recommendations are described below.

Materials of c onstruction
All parts coming into contact with hot Halar resin
should be made of corrosion resistant materials
such as Xaloy 306, B.C.I. No.2, Duranickel, or
Hastelloy C. The hoppers, slides and throats should
be sufficiently corrosion resistant so that rust is not
introduced to the resin. It is especially important to
prevent contact of the melt with copper alloys and
unprotected tool steel which can reduce the melt
stability of the resin. However, corrosion testing on
metal plaques of carbon steel show that the current
Halar ECTFE technology reduces the corrosivity of
the polymer.

Extruder type
Table 17: Typical extruder design
Machine size

No limitation

Length/Diameter ratio

20:1 30:1

Barrel heating

Standard heating methods,

three or more zones

Flange heating

Required

Screw type

Single flight
Compression ratio 2.5:1 3:1
Metering length: 25%
Smooth transition (at least 3-4
flights)

Breaker plate

Recommended

Screen pack

60, 80, 100, 60 mesh (optional)

Drive

Adjustable from 5 to 100 rpm

Melt thermocouple

Recommended

Pressure gauge

Recommended

General considerations
Temperatures should be set to produce a melt
temperature in the range of 260 to 280C (500 to
540F). At startup, the melt is kept at the low end of
the temperature range. When all equipment is running
satisfactorily, the melt temperature is adjusted to
produce the best extrudate. At the end of all runs, the
Halar resin should be purged from the machine and
the temperature lowered below 200C (400F).

Handling
No special treatment is required. Drying is
unnecessary since the resin will not absorb water.

The low water absorption inhibits the dissipation

of frictional static charges. Consequently, the resin
container should be covered at all times to prevent the
deposition of contaminants on the pellets or powder.
When bringing the resin from a colder room, the
closed drum liner should not be opened until the resin
has reached the temperature of the processing room.
This avoids condensing atmospheric moisture on the
pellets or the powder.

Regrind
Regrind can be used with no loss in properties. It can
be blended with virgin Halar at a level not to exceed
15%. Regrind which has excessively darkened should
be discarded.

Safety
Refer to the Halar ECTFE Material Safety Data
Sheet for detailed recommended procedures for
safe handling and use. As with all polymer materials
exposed to high temperatures, good safety practice
requires the use of adequate ventilation when
processing Halar ECTFE. Ventilation should be
provided to prevent exposure to fumes and gases that
may be generated. Excessive heating may produce
fumes and gases that are irritating or toxic.
Thermal stability
Although Halar resin is a stable material, degradation
can occur if the maximum recommended processing
temperature is exceeded. Degradation is a function
of time, temperature and nature of the metal surface
in contact with the molten resin. Development of a
grey-tan color in the extrudant serves as a warning
sign that degradation is occurring. Black specks in
the extrudant indicate severe localized degradation
at hot spots or spots in the system. If black specks
appear in the extrudant, it is recommended that the
equipment be shut down and thoroughly cleaned.
Temperature limitations
Thermogravimetric analysis (TGA) of Halar resin
indicates that the polymer decomposes thermally
at 350C (662F). Thermal decomposition can also
be expected at lower temperatures if the exposure
time is long enough (e.g., excessive residence time
that may be encountered in extruders and injection
molding machines). In practice, discoloration, black
specks, etc. may be encountered when the melt
temperature exceeds 300C (575F) for an extended
period of time. If interruptions in processing occur, the
resin should be purged immediately from the barrel.
Polypropylene or high density polyethylene may be
employed for this purpose. If purging is not possible,
the temperature should be lowered to 200C (400F)
while repairs are being made.

31

Recommendations for extrusion

Corrosion-resistant materials are recommended for
all surfaces in contact with hot resin. Halar resin
can thermally degrade to HCl which is corrosive to
metal surfaces. Studies have indicated that the resin
begins to degrade after 45 minutes at 270C (520F);
thus, residence times in extruders should be held to
a minimum and care should be taken not to overheat
Halar ECTFE resin during processing.
Corrosion-resistant materials of construction are
recommended not only to insure reasonable
equipment life but also to protect Halar resin from
degradation. Molten Halar resin will decompose on
extended contact with iron, copper or brass. The
products of decomposition are a black degraded
resin with HCl gas.
The recommended practice when extrusion is
interrupted is to purge the equipment.

Table 18: Typical extruder operating conditions

Halar 500 - 300

Halar 901

Equipment .
temperatures

C (F)

C (F)

Rear barrel
Mid barrel
Front barrel
Clamp
Die

235-260 (460-500)
260-270 (500-520)
260-277 (500-530)
265-277 (510-530)
270-280 (520-540)

250-265 (480-510)
260-270 (500-520)
270-280 (520-545)
270-280 (520-545)
277-290 (530-550)

Melt temperature .
at the die exit

270-295 (520-560)

290 (560)

Melt pressure .
at the die

70-200 bar .
(1000-3000 psi)

70-200 bar .
(1000-3000 psi)

Good extrusion practice recommends that the

temperature profile be developed upward from
the minimum temperatures recommended. This
will ensure optimum results with no danger of
degradation.

Recommendations for injection

moulding
Conventional reciprocating single screw extruders
are employed.
Corrosion-resistant materials are recommended for
all surfaces in contact with hot Halar ECTFE resin.
This requirement pertains to inside cylinder walls
and the screw. Some surface-hardened tool steels
have been used successfully in limited duration
runs. The standard practice of never allowing the hot
resin to remain stagnant in the injection moulding
equipment should be carefully followed. If moulding
is interrupted, the resin should be purged out of
the equipment immediately with polypropylene or
high-density polyethylene. If purging is not possible,
temperatures should be lowered to 200C (400F)
while changes are being made.

32

Shot size
In injection moulding of Halar resin, the
recommended shot size (including sprue and runners)
is between 40 and 70 % of machine capacity. If
undersized shot weights are used, the resin tends
to degrade because of long residence times in the
cylinder. Oversized shots result in uneven heating
and/or cold materials.
Injection moulding conditions
Part design, mould design, cycle time and plasticating
capacity of the press cause moulding condition to
vary from part to part. A certain amount of trial and
error is therefore necessary to determine optimum
moulding conditions. It is recommended to start at the
lower temperature and pressure levels and gradually
increase alternately until optimum is achieved.
Temperature of the injection cylinder
Temperatures higher than 287C (550F) should be
avoided. As a general rule, temperatures should not
be set higher than necessary to obtain rapid fill at
reasonable injection pressures.
Injection pressure
Pressure exerted on the material can range from 50
bar (700 psi) to 1380 bar (20000 psi); thinner sections
require higher pressures.
Mould temperature
Mouldings with good surfaces and optimum physical
properties ordinarily require mould temperatures
between 90 and 150C (200-300F). if only a water
heater is available, it should be run as hot as possible.
With this type of heater, the surface of the parts will
be somewhat less glossy and small cavities may be
difficult to fill. Oil or electrical heating is preferred.
Mould cycles
The time cycle required for a particular mould
depends to a very large extent upon the design of the
mould and the thickness of the part.
Usually total cycle time is 20-40 seconds for a part
less than 3 mm (1/8 inch) thick. The ram forward time
is approximately 10 seconds. A thicker part requires
longer time with 60-150 seconds being typical for a
part of over 6 mm ( inch) thickness. In this case, the
ram forward time would be increased to 25 seconds.
Mould release
Halar seldom requires a mould release agent. If
it is found necessary to use a release agent, one
that has been found to work well is FreKote 44-NC
manufactured by Dexter Corporation (Seabrook, New
Hampshire).
The typical injection moulding conditions are shown in
Table 19.

Table 19: Typical injection moulding conditions

Temperatures
Rear cylinder
Mid cylinder
Forward cylinder
Nozzle
Mould

230-245C (450-470F)
245-260C (470-500F)
260-275C (500-525F)
255-265C (490-510F)
100-110C (220-230F)

Pressure exerted on material

55-140 bar (800-2000 psi)

Timing
Total cycle (seconds)
Ram forward time (seconds)
Screw speed (rpm)

20-150
10-25
30-100

Recommendations for compression

moulding
The following procedure can be followed as a
guideline for a typical compression moulding cycle.
Use a positive pressure mould; it consists of a top
plate, a bottom plate and a frame.
Heat the mould to 260C (500F).
Feed the room temperature pellets into the mould.
Apply a pressure of 15 bar (200 psi) for 5-10 seconds.
Reduce pressure to 5 bar (40 psi) and maintain
pressure; the press will close gradually as the material
melts; always keep the melt and plates in contact;
complete melting will take approximately 1-10 hours
for a 15 mm (5/8 inch) thick plaque.
Increase the pressure in steps throughout the melting
cycle until 15 bar (200 psi) is reached.
After 1-10 hours, turn on the cold water.
Maintain 15 bar (200 psi) until the plaque is at room
temperature (about 20 minutes for a 15 mm, 5/8 inch
thickness)

NOTE: All the information given in these pages can

only be considered as examples for processing

of Halar ECTFE. It cannot be considered as
specifications or as a guarantee for successful
extrusion or moulding of Halar ECTFE.

33

Secondary Processing
Welding
Halar ECTFE is a thermoplastic material that can
be welded using the standard techniques known
for common plastics, for example PE or PVC. In
particular, hot gas welding is routinely used to thermoweld Halar ECTFE liners. Tensile tests performed on
the welded seams have proven that fusions are 100%
as reliable as the original material.

The following general recommendations will apply

when hot gas welding Halar ECTFE liners.
Equipment
Use welding guns with heating power of 800 W or
higher.
Proper temperature measurement is crucial to ensure
consistent welds. It is good practice to measure the
temperature of the gas stream inside the nozzle, at 57 mm (1/4) from the outlet.
Good quality Halar ECTFE welds can be obtained
when nitrogen or clean and dry air is used. Welding
in nitrogen is recommended when the welding facility
lacks a clean and dry source of air.
Different welding tips are available. High speed
welding tips are used for the primary weld, while
tacking tips can be used to hold in place the various
sections of the liner.
Health, Safety and Environment
As with all polymers exposed to high temperatures,
good safety practice requires the use of adequate
ventilation when processing Halar ECTFE. Excessive
heating may produce fumes and gases that are
irritating or toxic. Ventilation or proper breathing
equipment should be provided to prevent exposure to
fumes and gases that may be generated.
Refer to the Halar ECTFE Material Safety Data
Sheets for detailed recommended procedures for
safe handling and use. Contact your regional Solvay
Solexis office for a copy.
Recommendations for Welding
Use round welding rods made of the same Halar
grade of the profiles to be welded.
Warning: Welding together profiles made from
different grades is not recommended. If it is
unavoidable contact your regional Solvay Solexis
Technical Service representative.
Scrape carefully the surfaces to be welded. When
using fabric backed sheets, remove the fabric along
the welding line (2 or 3 mm on each sheet) to prevent
fibers inclusions. Align and hold the two sheets to be
welded at a distance not larger than 0.5-1 mm (20-40
mils).

34

V-shape the groove between the two sheets using the

appropriate scraper. Avoid the use of makeshift tools
as it could result in an irregular weld bead. Thoroughly
clean the welding area and the welding rod.
Warning: The use a cleaning solvent may cause fire
hazard due to the heat generated by the gun.
Clean the nozzle of the welding gun with a brass
brush, adjust the air flow at 50-60 standard liters/
minute (1.8 2.1 cfm) and set the temperature of the
welding gun as indicated in the table below.

Table 20: Welding gun temperature

Halar ECTFE grade

Welding Gun Temperature

901, 300, 350, 500

380 - 425C (380-400C for thin liners)

902

425 - 495C

Note: The temperatures recommended in this

document must be intended as measured inside
the nozzle. If the welding gun is equipped with
a thermometer, check the readings using a
thermocouple before commencing the welding
operations.
Weld holding the gun at a 45-60 angle and adjust
the welding pressure and speed ensuring that the
welding rod and the sheets melt simultaneously.
Welding speeds in the 0.1-0.5 cm/s (or 1/16-1/4 per
second) range are usually suitable.
If the speed is too low, the welding rod will overheat
and start flowing; on the other hand, if the speed is
too high, the welding rod will not melt properly and the
groove between the two sheets will not be duly filled
by the molten material.
Similarly, if the welding pressure is too low, the groove
between the two sheets will not be completely filled,
while an excessive force may cause dimples along
the welding bead which will eventually act as stress
concentrators.

Machining
The machining of Halar ECTFE is very similar to that
of nylon. The following procedures provide guidelines
for successful machining operations with this versatile
fluoropolymer.
Internal stresses may often be created during the
machining of Halar ECTFE. These stresses may lead
to warping of a component. To avoid creating stresses
during machining, attention should be given to the
following points:
1. Use sharp tools
2. Avoid excessive clamping or cutting forces
3. Prevent overheating by use of coolants

Generally, when the above principles are followed,

stress-free parts will be obtained. In those cases
where optimal dimensional control is required,
annealing is recommended.
Annealing consists of a heat treatment in oils or other
liquids at temperatures about 50F (30C) above the
maximum exposure temperature to be encountered.
At 300F (150C) in sections of 1/2-inch, 15 minutes is
adequate. On sections 1-inch in thickness, 4 hours is
normal, and an additional 2 hours is added for each
additional inch of thickness. Due to the low thermal
conductivity of Halar ECTFE, slow heating and
cooling is required for this step.
Halar ECTFE can easily be machined on most
standard metal working machines. For best results,
particularly on long production runs, the following
should be considered:
1. Due to the previously mentioned low thermal
conductivity, the surface temperature of the work
will rise rapidly during machining. To prevent this,
coolants are recommended.
2. The relatively low melting point of the material,
468F (242C), combined with the low thermal
conductivity may cause softening of the work
surface unless the proper machining procedures
are followed.
For turning, the general type of tool used for
machining soft metals such as aluminum is also
suitable for Halar ECTFE. For optimum results, the
angles should be somewhat different. Rake angles of
30 to 40 with a side clearance angle of 5 as well as
a 5 end clearance and end cutting edge angles of 8
to 10 are used. The cutting edge of the tool should
be the same height as the turning center too low a
tool position causes running of the work on the tool
and too high a position impairs the cutting action.
In order to obtain a smooth surface finish on the
work, it is advisable to use a rounded tool for the final
cut rather than the one described above which is
intended for general purpose turning. In addition to
the use of a coolant, the lapping of the tool face will
contribute to a smoother finish.
For cut-off, a tool with 5 side reliefs, 10 to 15 end
clearance, and 5 side clearances with the top side
of the tool level to keep from biting into the work is
recommended.
In turning Halar ECTFE, there is a tendency to form a
continuous ribbon which may wind around the work.
This can be overcome by using the proper rake angle
and adjusting the cutting speed. Burring can be
avoided or minimized by using sharp, well designed
tools, proper cutting speeds, and a good coolant. In
order to prevent deformation of thin-walled parts, it

may be desirable to clamp the work in a collet rather

than at three or four points.
For milling, standard cutters (gear, wheel, face and
side, cylindrical, key-way, and finger) can be used
with Halar ECTFE as with steel, provided they
are sharp. The angles of these cutters need not
be changed although the angles used on cutters
designed for aluminum are the best since their shape
is adapted to machining soft, tough materials.
Basically, the same RPM, feed, and cutting depth
would be used in milling as in turning. A good coolant
is also essential. In order to avoid distortion of the
work and biting of the milling cutter, careful, uniform
clamping is necessary.
To avoid the formation of burrs during milling, it may
be advisable to back up the work with another plate. A
less expensive material such as nylon could be used.
Halar ECTFE can be readily sawed. When using
a power hacksaw, there are no special procedures
different from steel. There are no limits for the
thickness of the material. It is desirable to use a
coarse saw blade with about 4 to 6 teeth per inch,
and there should be some set to these.
A vertical band saw may also be used but with a little
more care. The speed of the band should not be too
high (for example, 1500 ft/min for a 3-inch thickness).
Again, a coarse tooth (4 to 6 per inch) such a skip
tooth or buttress type should be used. No coolant is
used normally in this method, and the material should
not be pressed too hard against the blade.
When using circular saws, regular, hollow ground
metal working blades are acceptable for thin sections
up to about 1/3-inch. For heavier sections, special
skip tooth or buttress type blades are required.
To drill Halar ECTFE, standard drills are generally
suitable. Sharp bits and a cooling fluid are advisable.
Regular up and down movement of the drill helps in
cooling and in clearing the hole. The feed should be
reduced as the depth of the hole increases.
Due to the elasticity of Halar ECTFE and because
of the temperature rising during drilling, it may be
necessary to use a drill diameter 0.004 to 0.020
inch greater than the size of the derived hole. When
several holes have to be drilled close to one another,
it may be necessary to plug holes already drilled
to prevent deformation. These procedures are best
established by experience.
Reaming is difficult because of the elasticity of the
material. The best results are obtained by using
a sharp, spiral fluted reamer. Some machinists fill
the hole to be reamed with a wax or tallow prior to
reaming.

35

Screw threading and tapping is quite easy with Halar

ECTFE. It is advisable to use a cutting oil to avoid
excessive heat and ensure the best finish. The use .
of the first tap can be omitted and for very small holes
only the third tap need be used.
Halar ECTFE sheet can be punched easily. .
The tools must be carefully ground and lapped if
possible. The work to be punched should be tightly
clamped.

Halar ECTFE rods and tubes can be

centerless ground on conventional equipment.
It is recommended that the work center be
approximately 0.100 inches below the center line .
of the wheels and that water-soluble oil be used .
as a coolant.
NOTE: All the information given in these pages can
only be considered as examples for processing of
Solef and Hylar PVDF. Please contact Solvay Solexis
for detailed information.

36

Solvay Solexis S.p.A.

Viale Lombardia, 20
20021 Bollate (MI), Italy
Tel. +39 02 3835 1
Fax +39 02 3835 2129
Solvay Solexis Inc.
10 Leonard Lane
Thorofare NJ 08086, USA
Tel. +1 856 853 8119
Fax +1 856 853 6405
www.solvaysolexis.com

To our actual knowledge, the information contained herein is accurate as of the date of this document. However neither Solvay Solexis S.p.A., nor any of its
affiliates makes any warranty, express or implied, or accepts any liability in connection with this information or its use. This information is for use by technically
skilled persons at their own discretion and risk and does not relate to the use of this product in combination with any other substance or any other process. This is
not a license under any patent or other proprietary right. The user alone must finally determine suitability of any information or material for any contemplated use in
compliance with applicable law, the manner of use and whether any patents are infringed. This information gives typical properties only and is not to be
used for specification purposes. Solvay Solexis S.p.A., reserves the right to make additions, deletions or modifications to the information at any time without
prior notification.
Trademarks and/or other Solvay Solexis S.p.A. products referenced herein are either trademarks or registered trademarks of Solvay Solexis S.p.A. or its
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