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Contacts worldwide Additives for

Thermoset Composites
Asia
BASF East Asia Regional Headquarters Ltd.
Formulation Additives by BASF
45/F, Jardine House
No. 1 Connaught Place
Central
Hong Kong
[email protected]

Europe
BASF SE
Formulation Additives
67056 Ludwigshafen
Germany
[email protected]

North America
BASF Corporation
11501 Steele Creek Road
Charlotte, NC 28273
USA
[email protected]

South America
BASF S.A.
Rochaverá - Crystal Tower
Av. das Naçoes Unidas, 14.171
Morumbi - São Paulo-SP
Brazil
[email protected]

ED2 0319e

BASF SE
Formulation Additives
Dispersions & Pigments Division
67056 Ludwigshafen
Germany
www.basf.com/formulation-additives

The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not
relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specific purpose. Any
descriptions, drawings, photographs, data, proportions, weights, etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. The agreed
contractual quality of the product results exclusively from the statements made in the product specification. It is the responsibility of the recipient of our product to ensure that any proprietary rights
and existing laws and legislation are observed. When handling these products, advice and information given in the safety data sheet must be complied with. Further, protective and workplace hygiene
measures adequate for handling chemicals must be observed.

® = registered trademark of the BASF Group Europe, March 2019

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We create chemistry
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16 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 1

Leveling is defined as the ability of a coating to flow out after application in order to reduce any surface irregularities such as brush
PREAMBLE
and roller marks, orange peel, peaks or craters.

Good to know
Orange peel is a surface
BASF
is the world’s leading chemical company and a premier provider of innovative solutions
bumpiness or waviness that is for the paints and coatings industry. BASF offers virtually every ingredient needed to
often caused by poor leveling make high-quality coatings and has the know-how to solve formulation challenges and
and resembles skin of an support the development of new coating concepts. Our portfolio encompasses
orange. dispersions, pigments, resins and a broad range of additives such as light stabilizers
and formulation additives.

When it comes to formulation additives, BASF offers a strong portfolio of industry-

Figure 12:
leading products that help to enable sustainable and performance-driven solutions.
Good and bad leveling (“orange peel”)
Our offer is comprised of the broadest technology base of dispersing agents, wetting
agents, surface modifiers, defoamers, rheology modifiers and film forming agents.

We prioritize our understanding, listening and collaboration skills to serve our

BASF serves the composites industry with three major classes of wetting agents and surface modifiers which includes products based customers' needs. With global manufacturing capabilities, a strong research and
on polysiloxanes, polyacrylates and fluorinated polyacrylates. The properties of wetting agents and surface modifiers by chemistry are development platform, full-service regional technical laboratories, pre-screening
illustrated in Figure 13. capabilities and a team of experienced and knowledgeable experts, BASF can help
make your coatings better and your business more successful.

This brochure has been developed to give composites and gelcoat producers, molding
companies and assemblers first-hand guidance on the use of formulation additives
from BASF and on making the most out of their performance characteristics.

Looking for innovative solutions where little helpers make all the difference for your
high-quality composites?

BASF – We create chemistry

5: Excellent effect 0: No effect

Figure 13:
Properties of wetting agents and surface modifiers by chemistry
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2 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 3

Composites:
An Introduction
Table of Contents Composites materials are clearly established in nearly all
significant economic sectors. Innovative developments for new
applications, or as substitutes for metallic alloys, are key
Additives are used in low quantities by weight but help improve
the cost performance ratio of the final composite part.

elements in demanding markets like aerospace, automotive, As composite materials can be tailored to meet specific needs,
energy, sports and military. several properties like strength, stiffness, weight, aesthetics,
Composites: An Introduction 3 resistance to corrosion and chemical stability can be
Traditional composites typically consist of combinations of considerably improved through proper choice of additives.
Manufacturing Processes for Thermoset Composites 4
different components:

BASF Formulation Additives for Composites 8 Finding accurate raw materials is one of the most important
Matrix is generally a thermosetting resin as unsaturated steps for developing the ideal composite part. Commonly used
・ Air Release Agents 10 polyesters or epoxies that binds the reinforcement together, raw materials for composite formulations are shown in
keeps it firmly in place and protects it from environmental Figure 1.
・ Dispersing Agents 12 influences.

・ Wetting Agents and Surface Modifiers 14 Reinforcements are usually in the form of fibers or particles ・ATH ・Air release agents
・Calcium carbonates ・Dispersing agents
that enhance the mechanical and physical properties of the
・TiO2 ・Wetting agents &
parts.
・Kaolin surface modifiers
・Colored pigments ・Mold release agents
Fillers and pigments are used to enhance coloristic and other ・Shrinkage control agents
physical properties. Fillers are typically the least expensive
components of major ingredients. They improve functional
properties such as water and temperature resistance and can Fillers/
Additives
help control shrinkage. Pigments

Formulation Additives are applied to optimize composite

properties like shrinkage, rheology, flow and wetting behavior
and adhesion.
Reinforce-
Resins
ment

・Unsaturated polyesters ・Glass fibers

・Epoxy resins ・Carbon fibers
・Vinyl esters ・Aramid fibers
・Polyurethanes ・Natural fibers

Figure 1:
Example formulation components for thermoset composites.
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4 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 5

Manufacturing
Manufacturing Processes for Thermoset Composites

Processes for
The matrix nature, reinforcement type and the designated end application of the designed
composite part are crucial selection elements for the fabrication process. The basic
manufacturing methods used to fabricate composites include: lay-up, spray-up, filament
winding, pultrusion and resin transfer molding. The major fabrication routes for thermoset

Thermoset Composites
composites are shown in Figure 2.

Short-Fiber
・Injection Molding BMC / TMC
・Compression Molding
Fabrication routes ・Liquid Molding (RTM)
・Spray-up SMC
for thermoset
composites
Continuous-
Fiber
・Lay-up
・Filament Winding
・Liquid Molding (RTM)
・Pultrusion
Figure 2:
Fabrication routes for thermoset composites

SMC/BMC/TMC (Sheet/Bulk/Thick Molding Compounds):

SMC, BMC and TMC are premixes made up of thermoset resins, mineral fillers and additives.
The compounds are further formed into complex shapes through high volume injection or
compression molding processes at high temperatures of around 150°C. The resulting
composite parts compete with steel parts in their mechanical properties, ensure pronounced
chemical and, corrosion resistance and allow very high design freedom.

SMC BMC TMC

Fiber content: 10-60% Fiber content: 10-30% Fiber content: 10-20%
Fiber length: 25-50 mm Fiber length: 6-12 mm Fiber length: 12-50 mm

Characteristics: Characteristics: Characteristics:

Superior mechanical Better flow and Combined properties
properties due to the temperature resistance of BMC (good flow)
longer fibers than SMC due to the and SMC (best
shorter fibers and mechanical properties)
higher filler content

Figure 3:
Composition and characteristics of SMC/BMC/TMC compounds
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6 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 7

Manufacturing Processes for Thermoset Composites

Hand Lay-up RTM (Resin

Hand lay-up consists of manual positioning of fiber reinforced
mats or prepreg plies onto a prepared mold. Thermosetting
Transfer Molding)
resins are then applied by brushing, spraying or resin infusion.
RTM is a vacuum-assisted closed mold process. Fiber
Entrapped air can be removed with the aid of rolling, and the
reinforcements are positioned in a matched male and female
laminate can be left to dry at room temperature. Curing can be
mold, which is then closed and clamped. The matrix is injected
accelerated in ovens or by vacuum. Hand lay-up is a simple
under pressure until the mold is filled. The parts cured in the
and relatively low cost processing method for large
mold are normally heated by controller. RTM is a fast and
components such as wind turbine parts and boats.
clean process to produce composites with large surface areas,
complex shapes and smooth finishes like boat hulls and wind
turbine blades.

Spray Lay-up Pultrusion

Pultrusion is a high-volume production process for composite
Spray lay-up is a conventional open mold process. Gelcoat is
profiles. Reinforcement materials (long fibers, mats or fabrics)
applied as a first layer onto a previously waxed mold and then
are pulled and guided through a bath of matrix for
cured. Chopped reinforcements and thermoset resins are then
impregnation, passed through a heated die for curing and cut
sprayed onto the mold and left to cure at room temperature in
at the end of the line into various tubes and flat sheets with
ovens or autoclaves. Spray lay-up allows more shape
excellent mechanical and chemical properties.
complexity and a quicker production time than hand lay-up.
This process is suitable for large components with less
complex geometries such as boats and bath tubs.

Filament Winding
Filament winding refers to the winding of thermoset resin
impregnated fiber rovings under tension around a rotating
mandrel. These fabricated circular composite products with a
hollow core are then cured at room temperature or in ovens
and used in applications where weight, chemical resistance,
pressure and temperature are an important concern. Pipelines,
tanks and vessels are example applications of filament winding
produced composite parts.
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8 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 9

BASF Formulation
BASF Formulation Additives for Composites

Additives for Composites

Formulation additives are essential formulation components of composite materials.
They are used to optimize the matrix properties and adapt the reinforcements for
particular applications. Additives stabilize pigments and fillers to prevent their
sedimentation in composite formulations. They also improve the flow, slip and rheology
behavior and contribute to proper fiber wetting. Formulation additives are significant
raw materials which enhance the quality of the laminate’s finish and extend the product
durability of the composite parts.

Typical Epoxy Glass Fiber A Typical Gelcoat Composition

- SMC Composition
1-3 parts 3 parts 2 parts

10 parts

24%
60% 15%
100 parts

1-3%

Epoxy System Inorganic Filler UP Resin Accelerator

Additives Glass Fiber Pigments and Fillers Peroxide
Formulation Additives

Figure 4:
Formulation additives content in typical composite formulations

BASF offers a number of solutions for the composites industry and a wide range of formulation
additives including air release agents, low to medium molecular weight dispersing agents,
Nomenclature high molecular weight dispersing agents and wetting agents, and surface modifiers.

Efka® PB:
Polymer based defoamers
Low/medium
Efka® SI:
Silicone based defoamers
Air release agents molecular weight
dispersing agents
Dispex® Ultra FA / Efka® FA:
Low molecular weight dispersing agents
Dispex®
Efka® PU: Efka® PB Efka® SI Efka® FA
Ultra FA
Polyurethane based dispersing agents

Efka® PX:
High molecular
Controlled or advanced polymers
Wetting agents &
weight dispersing
Efka® PA: surface modifiers
Polyacrylic based dispersing agents
agents
Efka® SL:
Efka® Efka® Efka®
Slip and mar agents
Efka® SL Efka® FL
PU PX PA
Efka® FL:
Flow and leveling agents
Figure 5:
BASF Formulation Additives for Composites
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10 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 11

Air Release
Air Release Agents

Agents
Matrices used in compound formulations and gelcoats often include soluble impurities
as surface active substances that stabilize entrapped air during the processing and
application of the parts.

Entrapped and stabilized air remains as micro- or macro-foam in the system after
curing and can be a considerable source of porosity, weak points, insufficient fiber
wetting and poor mechanical properties in composite materials.

Removing incorporated air from the mostly highly viscous systems make the use of air
release agents imperative.

Air release agents take effect by destroying foam or preventing its formation, enabling
coalescence of air bubbles, increasing their diameter and making them rise easily to
the surface and collapsing.

Good to know
Different denominations like
“defoamer”, “antifoaming agent” or
“air release agent” are used
interchangeably to describe
products designed to control or
prevent foaming. The distinction
between the different terms is
blurred since most foam controlling
products can serve all three roles.

Depending on the application and customer needs, BASF offers a complete range of
air release agents for thermoset resins-based composite formulations.
The products are based on a broad technology portfolio of polysiloxanes, polyacrylates
and/or other organic polymers.

Conventional
Blank Efka® PB 2744 Efka® SI 2009
air release agent

Figure 6: Figure 7:
Air release performance of Efka® PB Air release performance of Efka® SI
2744 in a solvent-free 2-pack 2009 in a clear unsaturated polyester
polyurethane system
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12 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 13

Dispersing Agents
Dispersing Agents

The use of dispersing agents results in reduced viscosity, increased filler and pigment loading, improved color strength and a stable
dispersion of the compound.

The dispersing process takes place in three steps: Wetting of the particle surface by the surrounding liquid; break-down of the particle
agglomerates using high shear mixers; and stabilization of the finely milled pigments.

Wetting

wn
k-do
B rea

Stabilizing

Figure 8:
Wetting, agglomerate break-down and pigment stabilization process

Insufficient stability might provoke flocculation that leads to an increase in particle size, loss of gloss and color strength and to a
settling tendency. A side effect is a higher viscosity that precludes reasonable fiber wetting.

For unsaturated polyester-based composites, control of shrinkage control is an important factor. The shrinkage of the pure resin and
styrene increases the internal stress of the molded parts and causes surface waviness, geometry changes and crack formation in the
composites part.

For this reason, resin incompatible low-shrink additives are very often used in, for example, SMC/BMC compounds and have to be
stabilized. Commonly used shrink control technologies used in UP resins are shown in Figure 9.

LDPE (Low density polyethylene)

・Less crack formation in composite parts

LS (Low shrink formulations)

PS, HIPS (high-impact polysterene), PMMA
・Dimension stability
・Lower internal stress

LP (Low profile formulations)

PVAc and UP in Styrene
・High shrink control Blank Efka®
・Class A surfaces coating without surface treatment PU 4061

Figure 9: Figure 10:

Common shrink control additives Stabilization performance of Efka®
PU 4061 in an LS containing UP resin

BASF high molecular weight dispersing agents comprise a high number of anchoring groups along the polymer backbone. The
resin-like character allows for excellent compatibility with both the UP resin and the shrink control agents enhancing homogeneity and
stabilization of the compounds. Figure 10 shows the stabilization effect of Efka® PU 4061 in an LS Formulation.
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14 Additives for Thermoset Composites

Formulation Additives by BASF
Additives for Thermoset Composites
Formulation Additives by BASF 15

Wetting Agents &

Wetting Agents & Surface Modifiers

Surface Modifiers
Substrate wetting and the profile of the cured surface of composite materials depend heavily on the nature of the substrate, surface
tension of the compounds and coating applied on the top of the parts.

Wetting agents and surface modifiers are often used in composite systems to balance surface tension differences as well as to
prevent surface defects such as bad substrate wetting, fish eyes, leveling or slip-related effects.

Substrate wetting

Main influencing factors little to no wetting (Θ > 90°C)

ompound’s surface tension partial wetting (Θ < 90°)
Substrate's surface tension wetting (Θ ~ 0°)

Related defects
Craters, edge crawling, de-wetting,
fish eyes

Three wetting conditions and their relation to contact angles

Leveling

Main influencing factors

Compound's rheology
ompound’s surface tension

Related defects
Orange peel, waviness, pinholes,
decreased gloss

time
Leveling in a time dependent process

Slip
Main influencing factors
Additives chemistry and it’s
positioning within the compound

Related defects
Blocking, decreased mar resistance,
intercoat adhesion

Orientation of organomodified silicones at a surface

Figure 11:
Theoretical aspects of substrate wetting, leveling and slip
Additives for Thermoset Composites

BASF’s Formulation Additives

Focus Portfolio for Composites

Shrink Additives Stabilisation

Efka® PU 4061 / Efka® PU 4010
BMC / TMC Viscosity Reduction
Efka® FA 4610 / Efka® FA 4611 /
Efka® FA 4620

Air Release
Efka® PB 2020 / Efka® PB 2720 /
Efka® PB 2744
Anti-Sedimentation
Efka® FA 4647 / Efka® FA 4665
Anti-Separation
Efka® PU 4061 / Efka® PU 4010
Pultrusion
Fiber Wetting and Deaeration
Efka® PB 2020 / Efka® PU 4061
Viscosity Reduction
Efka® FA 4610 / Efka® FA 4611 /
Efka® FA 4620

Anti-Separation
Efka® PU 4061

SMC
Fiber Wetting and Deaeration
Efka® PB 2020 / Efka® PU 4063
Wetting and Dispersing
Efka® FA 4610 / Efka® FA 4611 /
Efka® FA 4620

Air Release
Efka® PB 2020 / Efka® PB 2720

Gelcoats
Flooding / Floating
Efka® PA 4401 / Efka® PX 4300
Flow / Leveling
Efka® FL 3785 / Efka® SL 3033
European Version

BASF SE
Formulation Additives
Dispersions & Pigments Division
67056 Ludwigshafen
Germany
www.basf.com/formulation-additives
Additives for Thermoset Composites

Air Release Agents

Applications Unsaturated Polyester Epoxies / Polyurethanes

Product Name Features Gelcoats Pultrusion SMC/BMC Casting Laminating Putties Gelcoats Pultrusion Casting Laminating Flooring/Lining

Polymer based Air Release Agents

Efka® PB 2001 Brings fast de-aeration even in

viscous compounds

Efka® PB 2010 Most suitable air release agent for

transparent systems up to medium
thicknesses

Efka® PB 2020 Brings fast de-aeration while

increasing wetting (e.g. towards
fibres), even in viscous compounds

Efka® PB 2720 Most efficient air release agent

combined with broad applicability.
Suitable for pigmented compounds

Efka® PB 2744 Ultra low VOC de-aerator with

excellent and fast performance
againt micro and macro foam

Silicone based Air Release Agents

Efka® SI 2040 Designed for ambient cured

systems and low shear forces

Efka® SI 2722 Efka® SI 2722 can be used in

pigmented or non-pigmented
resin systems

Efka® SI 2723 Low odour version of Efka® SI 2722

Excellent Good

Substrate Wetting Agents and Surface Modifiers

Applications Unsaturated Polyester Epoxies / Polyurethanes

Product Name Features Gelcoats Laminating Gelcoats Pultrusion Casting Laminating Flooring/Lining

Fluorinated Polyacrylates

Efka® FL 3277 Provides additional substrate wetting

as well as anti-cratering over straight
polyacrylate additives

Straight Polyacrylates

Efka® FL 3740 EH Flow agent with higher de-aeration

properties compared to Efka® FL 3741

Efka® FL 3741 Highly compatible flow agent with

additional air release effect

Efka® FL 3778 Brings leveling without slip, supports

the action of air release agent Efka®
PB 2720

Efka® FL 3785 Brings leveling, no slip and

contributes to deaeration

Modified Polysiloxanes

Efka® SL 3031 Slip & leveling agent with good

substrate wetting and anti-cratering
properties

Efka® SL 3033 Slip & leveling agent with good

substrate wetting and anti-cratering
properties

Efka® SL 3035 Leveling agent with moderate slip

Efka® SL 3200 Solvent-free slip and leveling agent

European Version

with a strong reduction of surface

tension

Efka® SL 3236 Slip & leveling agent with additional

air release effect

Excellent Good
Additives for Thermoset Composites

Low molecular weight dispersing agents

Applications Unsaturated Polyester Epoxies / Polyurethanes

Product Name Features Filler Loading Gelcoats SMC/BMC Pultrusion Casting Laminating Putties Gelcoats Pultrusion Casting Laminating Flooring/Lining

Dispex Ultra® Increases colour acceptance

FA 4420 of inorganic pigments 100-150 pHr

Dispex Ultra® Increases colour acceptance

FA 4425 and reduces floatation 100-150 pHr

Dispex Ultra® For fillers. Possible fluidizing

FA 4431 by post addition 100-150 pHr

Efka® FA 4610 Standard choice for fillers

and inorganic pigments
(e.g. 200 phr of CaCO3). >170 pHr
Antisettling properties
are inherent

Efka® FA 4611 Broad compatibility in a wide

range of resin systems. Very
efficient in wetting and dis-
persing of titanium dioxide >170 pHr
and other inorganic pigments.
High pigment and filler loading
possible. Strong reduction
of mill base viscosity

Efka® FA 4620 For inorganic pigments and

fillers in cobalt catalyst free
compounds. Able to wet
275 phr of ATH. Same >170 pHr
anchoring group as Efka®
FA 4612. Antisettling
properties are inherent

Efka® FA 4644 For fillers such as ATH or

CaCO3. Antisettling 100-150 pHr
properties are inherent

Efka® FA 4647 For fillers in fiber-reinforced

thermosetting systems.
Antisettling properties are 100-150 pHr
inherent

Efka® FA 4665 For fillers and inorganic

pigments. Prevents settling
and improves color ca. 150 pHr
separation. Antisettling
properties are inherent

Efka® FA 4666 For fillers and inorganic

pigments. Prevents settling
and improves color separation.
Efka® FA 4666 can be used ca. 150 pHr
in pastes. Antisettling
properties are inherent

Efka® FA 4672 For inorganic pigments and

extenders such as talc, above 170 pHr
ATH and quartz

Excellent Good

High molecular weight dispersing agents

Applications Unsaturated Polyester Epoxies / Polyurethanes

Product Name Features Gelcoats Pultrusion Gelcoat Pultrusion Flooring/Lining

Efka® PA 4401 Efka® PA 4401 is a polymeric dispersant for stabilizing inorganic

and organic pigments in high quality systems

Efka® PA 4402 Conventional for all standard inorganic and organic pigments
(e.g. Irgalite® range); suited for colourants (higher pigment loading)

Efka® PU 4009 Stabilizes TiO2 and standard organic pigments as found in

our Irgalite® range

Efka® PU 4010 Stabilizes TiO2, matting agents and usual organic pigments.
Improves anti sag resistance in UPE

Efka® PU 4047 Stabilizes inorganic and organic pigments such as our

Heliogen® Blue and Green and carbon black pigments

Efka® PU 4050 Stabilizes all kinds of pigments and is particularly effective with
pigments such as our DPP reds

Efka® PU 4061 Stabilizes TiO2, matting agents and usual organic pigments.
Improved anti-separation effect in UPE

Efka® PU 4063 Stabilizes all kinds of pigments and is particularly effective with
red pigments such as our DPP reds

Efka® PX 4300 Efka® PX 4300 is a controlled polymer by the use against flooding, floating
and flocculation in high quality systems and difficult organic pigments

Efka® PX 4340 Controlled polymer with higher efficiency towards pigment stabilization and
viscosity reduction. Specific of high performance organic pigments
(e.g. Paliotol®, Cromophtal®, Irgazin®)

Efka® PX 4701 Efka® PX 4701 is made by Controlled Free Radical Polymerization. It provides
a combination of strong viscosity suppression and excellent storage stability

Efka® PX 4733 Highly efficient dispersing agent which shows excellent performance in
stabilizing organic pigments in low viscosity systems. It has been specifically
European Version

developed to provide the challenging combination of strong viscosity

suppression, excellent storage stability and improved color strength

Efka® PX 4780 Efka® PX 4780 is a high molecular weight dispersing agent designed to
disperse and stabilize organic pigments and carbon-blacks, especially where
resin-matrix reactive dispersants are desired

Excellent Good