Industrial Products Manufacturing Company

           

 

 

 

Home

About Us

Contact Us

 

 

 

 

 

 

 

 

 

Back to Ezecast Menu Page

 

 

 

 

 

 

 

 

   

 

™

   

 

 

HEAT CURED POLYURETHANE CAST ELASTOMER SYSTEMS

 

Specifications

 

 

DESCRIPTION:

 

Ezecast casting systems are two component systems which can, be used to produce high quality Polyurethane elastomers with shore hardness ranging from 30A to 98A These systems can be processed manually or by two component casting machines. Large and complex parts can be cast without any difficulties using Ezecast systems.

 

 

SALIENT FEATURES:

 

  • HIGH ABRASION RESISTANCE:  Ezecast products are able to withstand a great deal of mechanical wear and tear. This ensures a longer life of the products.

  • EXCELLENT OIL RESISTANCE:  Ezecast products are practically unaffected by oils and lubricants.

  • HIGH ELASTICITY:  Products made from Ezecast systems show high elasticity at all hardness levels.

  • WIDE HARDNESS RANGE:  Ezecast systems can be used to produce products of practically any hardness.

  • EXCELLENT FLEXIBILITY:  Products made using Ezecast systems are very flexible over a wide range of temperatures.

  • GOOD DAMPING PROPERTIES:  Ezecast products have relatively high, mechanical loss factors and are therefore suitable for      applications where damping of high frequency vibrations is required.

  • GOOD THERMAL RESISTANCE:  Ezecast materials can be used at temperatures ranging from -40°C to 90°C.

  • HIGH RESISTANCE TO HYDROLYSIS:  Due to their superb hydrolysis properties Ezecast products can be used in highly humid conditions without any problems.

  • EXCELLENT MACHINING PROPERTIES:  Above 80 ShoreA hardness Ezecast products can be machined easily, thus giving the user, the flexibility to produce any type of machine finished component. .

  • HIGH CHEMICAL RESISTANCE:  Ezecast has good resistance to mild acids and alkalies and is unaffected by most corrosive environments.

 

CASTING PROCEDURE:

 

Ezecast systems consists of two components which are mixed together, poured into a mould and allowed to set to form a cast elastomeric polyurethane product. Vacuuming and heating of the materials is required to ensure tough and bubble free castings. The two components are selected from the 100 series (i.e. Ezecast 101, 102,103…etc) and the 200 series (Ezecast.201, 202,203 ….etc) depending on the hardness and properties of the cast product. (Refer Table 1). If more than one component from the 200 series is to be used, then these components should be premixed in the specified ratio and used as a single component.

 

 

MOULDS:

 

Moulds made from steel, aluminium or any other thermally and dimensionally stable material may be used. While designing the moulds, shrinkage up-to 1% should be considered. Exact shrinkage should be determined experimentally. Moulds should be preheated to about 75°C-85°C and a thin, even, layer of  release agent (paraffin‑wax or silicon) should be applied. by means of a sponge or spray gun.

 

 

BONDING AGENT:

 

For metal. inserts, a bonding agent is required to ensure good adhesion between the metal and the cast polyurethane Ezecast 110 and Ezecast 210 are mixed thoroughly in the ratio of 1:4 by weight. This, mixture is applied to the metal surface (preferably sand blasted to a clean, dry, rust-free surface) by brush or spray and kept in the oven at 70°C for 5 minutes. Pour the Ezecast casting mixture immediately and cure as per usual procedure.

 

 

MANUAL PROCESSING:

 

All the products in the 100 and 200 series are liquids except Ezecast 205 which is a solid. The procedure of casting will change depending on whether a solid component is being used or a liquid component.

 

 

PROCEDURE WHEN USING LIQUID 200 SERIES COMPONENTS:

 

1) All the 200 series components should be thoroughly stirred in their containers (preferably at 60°C-70C). before use. It is very important to scrape the bottom of the container during stirring to ensure that any material which has settled down is properly mixed.

 

2) Take the 200 series component (or combination of components) in a. container. The quantity should be slightly more than that required as per the mixing ratio (Table 1). Add 2gm of Ezecast 204 (for obtaining better physical properties) for every kilogram of the 200 series components taken and stir thoroughly. Heat both the 100 and 200 series components separately up-to 70°C and vacuum the materials at an absolute pressure less than 10 mm Hg for about 10 to 15 minutes. Keep the materials back in an oven and maintain the temperature at 55°C-65°C).

 

3) Stir the 100 series steadily while adding the exact quantity of the 200 series component to it (mix temperature-55°C to 65°C). Mix thoroughly, scrapping the sides and bottom of the container. Time taken for this should be less than 2 minutes.

 

4) Degas/vacuum the mixture immediately for about 2 minutes to remove air bubbles which are trapped during mixing.

 

5) Pour the degassed material into the preheated mould( 70°C-80°C ). To minimize air bubbles entrapment, pouring is done along one of the walls of the mould.

 

6) Place the mould in an oven at 100°C-110°C for 2 to 3 hours and demouId. The exact time required to demould depends upon the mould geometry and may vary from casting to casting.

 

7) The demoulded part is immediately put back into the oven (without allowing it to cool down much) and cured for 16-24 hours to achieve full physical proper ties.

 

 

PROCEDURE WHEN USING SOLID EZECAST 205:

 

1) Take a known weight of the 100 series component in a container and heat it to 70°C., Vacuum this material at an absolute pressure less than 10 mm Hg for 10 to 15 minutes and keep it in an oven to maintain its temperature at 60°C ‑ 65°C.

 

2) Take the solid Ezecast 205 (slightly more than the quantity required as per the mixing ratio) in another container and heat it to 100°C to melt it. Care should be taken to use up the Ezecast 205 immediately and in no case should its temperature be allowed to exceed 110°C.

 

3) Stir the 100 series component (at 60°C-65°C) steadily while slowly adding Ezecast 205 (at 100°C). Mix thoroughly. If the 100 series component is not stirred while adding Ezecast 205 then some of the Ezecast 205 may

precipitate as crystals.

 

4) Degas the mixture immediately for about 2 minutes to remove air bubbles which are trapped during mixing.

 

5) Pour the degassed material into the preheated mould (80°C-90°C). Pouring is done along one of the walls of the mould to minimize air entrapment.

 

6) Place the mould in an oven at 110°C-120°C for 1.5 to 2 hours and demould. The exact time required to demould depends on the mould geometry and may vary from casting to casting to 3 hours and demould. The exact time

 

7) The demoulded part is immediately put back into the oven (without allowing it to cool down much) and cured for 18-20 hours to achieve full physical properties.

 

 

MACHINE PROCESSING:

 

Ezecast can be processed by a two component, low pressure elastomer casting machine. In this case, the degassed materials can be heated upto higher temperatures around 80°C. The mixing ratio is adjusted on the machine and the mixed bubble free material is directly poured into the preheated moulds.

 

 

MIXING RATIOS:

 

TABLE 1:

 

Heavy Duty PTMEG Based System: Applications requiring high abrasion resistance, tensile strength, resilience, hydrolysis resistance and shock absorbing properties

 

Sr No.

Shore Hardness

Ezecast

 

 Comp. A

Ezecast Comp. B

Temp. A

Temp.B

Mixing Ratio A:B

Pot Life

1.

94° A

106

205

65° C

100° C

100:16.3

7 Min

2.

90° A

105

205

65° C

100° C

100:12.5

8 Min

3.

85° A

105 +107

205

65° C

100° C

(50+50):10.6

10 Min

4.

80° A

107

205

65°C

100°C

100:8.6

10 Min

5.

75° A

105

205+207

65° C

100 C

100:(9.3+11.3)

12 Min

6.

70° A

105

205+207

65°C

100 C

100:(6.5 +20)

12 Min

7.

65° A

105

207

65°C

100 C

100:45

12 Min

 

Heavy Duty Polyether Based System: Applications requiring high hydrolysis resistance, good abrasion resistance, flexibility and low heat build up.

 

Sr. No.

Shore Hardness

Ezecast Comp.A

Ezecast Comp.B

Temp A

Temp B

Mixing Ratio A:B

Pot Life

1.

96° A

101

205

60°C

100° C

100:20.5

5 Min

2.

95° A

101 +104

205

60° C

100° C

(95+5):20

6 Min

3.

90° A

101 +104

205

60 C

100 C

(69+31):17.2

6 Min

4.

85° A

101 +104

205

60 C

100 C

(34+66):13.5

7 Min

5.

80° A

101 +104

205

65 C

100 C

(9+91) :10.8

8 Min

 

Medium Duty Polyether Based Systems: Non-dynamic applications requiring good hydrolysis resistance, flexibility and elongation properties.

 

Sr No.

Shore Hardness

Ezecast Comp.A

Ezecast Comp.B

Temp A

Temp B

Mixing Ratio A:B

Pot Life

1.

95° A

103

201

65° C

65° C

100:73

 5 Min

2.

90° A

102

201

65° C

65° C

100:64

6 Min

3.

85° A

101

201

65° C

65° C

100:55

 8 Min

4.

80° A

101

201+202

60° C

60° C

100:(50+10)

10 Min

 

Light Duty Polyether Based System: Application requiring high degree of flexibility, hydrolysis resistance and low hardness.

 

Sr No.

Shore Hardness

Ezecast Comp A

Ezecast Comp B

Temp A

Temp B

Mixing Ratio A:B

Pot Life

1.

70° A

101

201+202

60°C

60°C

100:(42+20)

12 Min

2.

60° A

101

201+202

60° C

60° C

100:(28.6+36.4)

12 Min

3

50° A

101

201+202

60° C

60° C

100:(26+39)

15 Min

4.

45° A

101

201+202

60° C

60° C

100:(24+41)

15 Min

5.

40° A

101

201 +202

60° C

60° C

100:(22+44)

15 Min

6.

35° A

101

201+202

60° C

60° C

100:(16+53)

15 Min

 

 

Heavy Duty Polyester Based Systems: Applications requiring excellent solvent and oil resistance, high tensile strength, abrasion and tear resistance together with low rebound resilience and hydrolysis resistance.

 

Sr No.

Shore Hardness

Ezecast Comp A

Ezecast Comp B

Temp A

Temp B

Mixing Ratio A:B

Pot Life

1.

80° A

115

205

80°C

100° C

100:9.2

10 Min

2.

70° A

115

205+208

80°C

100°C

100:(7.4+15)

10 Min

3.

65° A

115

205+208

80° C

100° C

100:(6.4+22.5)

11 Min

4

60° A

115

205+208

80° C

100° C

100: (5.5+30)

12 Min

5.

50° A

115

205+208

80° C

100° C

100: (3.7+45)

12 Min

6.

40° A

115

205 +208

80° C

100° C

100: (1.9+60)

12 Min

7.

30° A

115

208

80° C

100° C

100:75

15 Min

 

 

SAFETY PRECAUTIONS:

 

1. Handling of both Ezecast components should be done by persons wearing, safety goggles, long rubber or PVC gloves and overalls fastened at the neck and wrist.

 

2. Splashes of both these products. in the eyes must be removed immediately by careful and thorough rising with plenty of water. Medical assistance must then be obtained.

 

3. Splashes that come in contact with the skin must be removed immediately by thorough washing with soap and water.

 

4. Since both the products are processed at elevated temperatures special care is necessary during heating of the material, when removing quantities from containers, when mixing and then casting into moulds. Such work should only be carried out in well ventilated rooms with efficient exhaust ventilation at each individual work station. The flow air should be directed away from the person handling the product and should move at a rate at-least 0.5 m/sec. in the processing area.

 

5. Vapours of these products will irritate the eyes. and the mucous membranes of the nose, throat and lungs. Inhalation is therefore to be avoided under all circumstances.

 


All Ezecast formulations are subject to strict quality control, innovations and improvements. The above information is given on the basis of our best knowledge and information and is for your guidance only. Specifications, however, are subject to change and no guarantee is given or implied.

 

All Rights Reserved. 1980 - 2015

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

™ 

Industrial Products Mfg. Company 108-109 Parmar Chambers, 3/4 B. J. Road, Pune 411001 India

www.IPMCIndia.com   ●   Tel: 91-020-26129521  ●   Fax: 91-20-26124362

Since 1981