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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.

Growing interest in the use of engineering grade phenolics for a variety of automotive engine components has been accompanied by concerns regarding the toughness of these materials. In a recent study, the toughness properties of several commerical phenolics and thermoplastics were compared. The data demonstrate that short fiber-reinforced phenolics are capable of substantially better performance than is generally appreciated. ft newly developed phenolic compound, which offers a 35% improvement in toughness over previously available phenolics, is also introduced.