Cast Elastomers: High-Performance Polyurethanes for Demanding Applications
Cast elastomers are a unique class of thermosetting polyurethane (PU) elastomers that are processed by liquid casting rather than conventional thermoplastic molding techniques. They are formed by reacting a liquid prepolymer (a low-molecular-weight polymer) with a liquid curative (chain extender and/or crosslinker). This mixture is then poured into a mold at atmospheric pressure and cured, typically with heat, to form a solid, highly durable, and resilient elastomeric part. This casting process allows for the production of large, complex, and heavy-duty components that would be challenging or impossible to create with other methods.
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The key characteristic of cast elastomers is their exceptional combination of properties, often surpassing those of conventional rubbers and plastics. These include:
High Load Bearing Capacity: Ability to withstand significant compressive and tensile forces without permanent deformation.
Superior Abrasion and Tear Resistance: Excellent durability in demanding wear applications.
Excellent Impact Strength: Resilience against sudden forces.
High Resilience: Ability to return to original shape after deformation.
Good Chemical Resistance: To oils, greases, solvents, and various industrial chemicals.
Wide Hardness Range: Can be formulated from very soft (eraser-like) to very hard (almost plastic-like) durometers.
Noise Reduction Properties: Due to their damping capabilities.
Cast elastomers find extensive applications in industries requiring robust, long-lasting components capable of withstanding severe operational conditions. In the mining and heavy industry, they are used for wear linings, conveyor belts, rollers, and impact pads due to their extreme abrasion and tear resistance. The automotive industry employs them for suspension components, bushings, seals, and shock absorbers, benefiting from their durability and damping properties.
Other significant applications include material handling (wheels, rollers, bumpers), oil and gas (seals, scrapers, pipeline pigging components due to chemical resistance and toughness), agriculture (harvesting equipment parts), and sporting goods (skate wheels, surfboard fins). The ability to formulate custom cast elastomers with tailored properties, coupled with their long service life and high performance in harsh environments, continues to drive their adoption as a preferred material for critical, heavy-duty applications.