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Phenolic molding materials are increasingly being designed in to replace metal components in engines and transmissions. The effective use of phenolics requires the integration of part design, processing and material selection, not simply the substitution of a new material into an old design. In this paper we outline relevant design data and methods for Metal Alternative Design (MAD) with phenolic molding materials.

Parts made from phenolic molding materials must be postcured to promote the thorough crosslinking required for end usage at temperatures above about 175°C. Since the time and energy used in postcuring can represent about ten percent of part cost, efficient postcuring offers significant potential savings. Based on a kinetic description of the phenolic crosslinking reaction, we have developed a computer model to predict the development of the glass transition during postcure. This model provides a convenient CAD tool for minimizing postcuring costs.