🧩 PC+PPSU – Polycarbonate + Polyphenylsulfone
(Very high-performance technical material, intended for applications requiring extreme resistance to temperatures, impact, and chemical substances. Used in the automotive, aerospace, and medical industries for structural parts and heat-resistant components.)
🔹 What is PC+PPSU
PC+PPSU is an advanced blend of polycarbonate (PC) and polyphenylsulfone (PPSU), both being high-performance polymers.
PPSU offers exceptional thermal and chemical stability, while PC contributes rigidity and impact resistance. The result is an ideal material for technical parts exposed to temperatures above 150 °C without deformation or oxidation. Unlike PC+PBT or PC+PET, PC+PPSU maintains its mechanical properties even after repeated contact with hot liquids, oils, or steam.
🔧 Composition
- Polycarbonate (PC): 50–70 %
- Polyphenylsulfone (PPSU): 30–50 %
- Thermal Stabilizers: 1–3 %
- Density: 1.28–1.33 g/cm³
- Softening Point: ≈ 220–230 °C
- Melting Point: ≈ 280–300 °C
- Chemical Resistance: Excellent (alcohols, oils, fuels, detergents).
- Continuous Heat Resistance: Up to 180–190 °C.
🚗 Where PC+PPSU is used in the automotive industry
| Component | Example parts | Observations |
| Engine / Technical | Pump covers, thermal housings, fittings | Excellent oil and heat resistance |
| Braking Systems | Brackets, manifolds, covers | Dimensional stability at high T |
| Electrical Systems | Power connectors, ECU housings | Exceptional thermal and electrical insulation |
| Premium Interior | High-strength glossy or tech parts | Does not deform, stable appearance |
🔧 Welding Temperature and Methods
| Method | Optimal Temperature | Observations |
| Hot Air | 300 – 340 °C | Requires precise control; dense material |
| Heat Plate (Mirror) | 290 – 320 °C | For thick, strong joints |
| Manual Extrusion | 290 – 320 °C | For long cracks, structural reinforcements |
🔩 What to Weld PC+PPSU With (Material Compatibility)
As a top-tier technical material, PC+PPSU has limited compatibility, only with other high-temperature blends.
✅ Compatible with:
- PC+PPSU ↔ PC / PPSU / PSU / PC+PBT / PC+GF – good bond.
- PC+PPSU ↔ PC-FR / PC-HI – partially compatible.
❌ Incompatible with:
- PP, PE, PA, PVC, PS, ABS, ASA, TPO – completely different melting points.
💡 ReplastMD Recommendation:
Use PC+PPSU rods or technical PC+GF rods at 310–330 °C. Uniformly preheat the part; PPSU has high thermal inertia. Cool slowly, protected from drafts, to avoid micro-cracks.
🏭 Manufacturers and Trade Names
- Solvay: Radel® PPSU / Radel® PC Blend
- SABIC: Lexan® XHT / HPX
- Covestro: Makrolon® PPSU Blend
🧠 How to Identify PC+PPSU
- Engraved marking: >PC+PPSU<, >PPSU/PC<, >Radel<, >Lexan XHT<.
- Glossy or semi-matte surface, dense, slightly dark color (yellowish-brown).
- Softens at ≈ 300 °C without bubbling.
- Resists contact with solvents and hot oil.
- ReplastMD practical test: if the part is heavy, hard, slightly brown, and does not deform under hot air below 250 °C – confirmed PC+PPSU extreme temperature material.
🛠️ PC+PPSU Welding at ReplastMD:
At our ReplastMD service center (Chisinau, Ciocana sector), we perform professional PC+PPSU welding for engine bay technical covers, thermal housings, and high-power connectors.