€YSTONE oO andi oF a KEMLON PRODUCTS & DEVELOPMENT CO. wv 71592 CAPABILITIES IN COMPOSITES DOWNHOLE ¢ CHEMICAL * AEROSPACE ¢ INDUSTRIAL NUCLEAR * GEOPHYSICAL ¢ MARINE ¢ MILITARYPrototype machine area. Line of long bed lathes, up to 20' workpiece. 4 Cover sleeves ready for machining. COMPOSITE DIVISION Since 1950, the Advanced Composite Division of Keystone Engi neering/Kemlon Products has maintained a proven reputation for rel able service to industry. Two manufacturing plants and a prototype shop ‘cover over 40,000 square feet. Thus we can insure prompt delivery of advanced composite materials and machined shapes. Strict quality con- {roland inspection procedures insure that all manufactured products are made from only the finest materials and to your exact specifications. All our departments are committed to high quality workmanship and CUSTOM MACHINE WORK AND. MANUFACTURING CAPABILITIES Keystone/Kemion maintains a broad-based, mult-disciplined manu facturing operation including special equipment for high-technology products. Our total in-house capabilities guarantee excellence in work ‘manship from prototype development through production runs. PLASTIC MOLDING: Automatic and semi-automatic injection and trans- fer molding of Epoxies, Fluorocarbon resins, Polycarbonates, Polym- ides, Aromatic Polyethers, and high-performance materials. High {temperatures are used, with injection pressures up to 42,000 PSI and clamping force up 10 100 tons. RUBBER MOLDING: Conventional transfer and compression molding of Neoprene, Nittles, Fluoroelastomers, and proprietary compounds that are mixed in-house. PRECISION MACHINE WORK: Kemion does virtually all machine work inhouse utilizing numerous modern cam-operated screw machines, swiss automatic machines, programmable automatic turret and chucking lathes, and an 8-spindle production lathe. Numerically con trolled equipment includes numerous lathes and machining centers, Prototype and small lot production are done on conventional engine and turret lathes, mills, centerless and surface grinders, drill and punch presses, shears and saws. We have seven long bed lathes with capacities up to 24 inches swing and 20 feet long workpiece. All fixtures and molds are made in-house. WELDING: For critical hermetic welds that are Helium tight to 10°°ec! ssec, Kemlon uses a computer controlled Laser and an Electron Beam. These processes are used for close tolerances, dissimilar metals, and thin sections. Induction brazing and oven brazing are available, TIG and Plasma welding are used for noneriical applications, MANDRELS, COVER SLEEVES, SONDES, LOGGING SUBS, AND BONDING TECHNIQUES Keystone Engineering is a leader in the manufacture of downhole high-strength and high-temperature laminates. Our standard Kemlox ‘G"" material is ideal for Mandrels and Cover Sleeves operating from '350°F to 400°F in a downhole environment. There are standard lengths to 16 feet iong, and longer lengths are available upon special request We have proprietary bonding techniques of metal-fiberglass-rubber, void-ree resin systems, and fabric styles. Keystone/Kemlon has the total inhouse capability for the contract manufacture of induction mandrels, ‘cover sleeves, and connector accessories. Connector subs, logging heads, electronic housings, and adaptors are also machined in-house from a prototype developmental stage to production runs. All drawings are handled confidentially and treated as proprietary information, 2Engineering and Design. Table 1 : Comparison of Fabric Materials QUALITY CONTROL Keystone Engineering/Kemion Products maintains a quality control program with complete manufacturing documentation and traceability ‘The program is in accordance with and exceeds MIL 9858-A for military ‘systems requirements and is designed to achieve ultra reliable products. ‘Awitten schedule for calibrating gages, measuring, and test equipment is strictly followed in accordance with MIL 45562. ‘We routinely perform mass spectrometer and electrical leak testing, ultra sonic flaw and thickness testing, linear expansion testing, high- potential spark testing, microscopic sectioning, high-pressure (25,000 PSI) pressure testing, and other inspection/testing procedures to main- tain a very high quality assurance. Keystone/Kemion can provide single vendor responsibilty when an integrated manufacturing process is required. ENGINEERING SERVICES Keystone Engineering maintains a staff of 10 graduate engineers with an average of 10 years each of “hands-on” experience. Profession- al disciplines include Chemical, Mechanical, Electrical, and Mineral Engineering. This diversity of engineering can perform any part of your designs utlizing technology and materials suitable for downhole, geo- physical, aerospace, marine, chemical, and nuclear use. We also design ‘our own molds, jigs, fixtures, presses, and special proprietary equipment for the complete manufacturing process. MATERIALS Keystone offers a variety of industrial fabrics for strength reinforcement and many different binder systems. The fabric material can be ‘comprised of E Glass, S Glass, Graphite, Ceram- ie, oF Keviar fills. Some of our typical binder sys- tems use Epoxy, Polyester, and Phenolic resins. Ultra high product quality is achieved through ‘a combination of proprietary resin injection meth- PROPERTY | LOWEST <= HIGHEST ‘ods and wet-wrapping techniques. See Tables 1, 2, and 3 for fundamental information on the ditfer- Heat ‘ent fabric fills. Posistance| S°#9hite Kevlar Glass SGlass Ceramic Keystone Engineering has several other proprietary resin systems with heat resistances Density | Ceramic €Glass $Glass Graphite Kevlar from 400°F to 500°F for downhole and industrial Use. We willbe glad to discuss how our other high- Toughness | Graphite Ceramic EGlass SGlass Kevlar posal Act Stites }EGlass Ceramic SGlass Kevlar Graphite Cost EGlass SGlass Kevlar Graphite Ceramic QUOTATIONS Impact Keystone Engineering is responsive to indus- feckianca omy: Ceremio, EGles Scheme Kedar try with fast, accurate quotes and deliveries. Our LINEAR THERMAL EXPANSION, PERCENT Figure 1 : Linear Expansion of Patterns K-143 & K-181 10 TEMPERATURE, "© wo 200 250 Sales and Engineering staff are glad to discuss how we can solve your design and composite material problems, from prototype development through production runs. Allinquiries are handled in confidence. DISCLAIMER ‘ata contained heron is based on tests conducted on repcesortatve samples ether trom our own testing tor ‘Snoonemed ata supped by reno oe manstactrers ana {as winin tho normal rango of product properties. However, ‘his data should not be Used wo ecabeh specication lis nor {Used alone asa basis fr design. Sell assumes no cation ‘ef abiy for any aves Tushod by I or fr the ful. ‘branes wih respect to these products, Al such aavee is pro- “dod grats and Bayer assumes sole eeponsiiy fr feu ‘Sbtaned in rlance thereon. ls suggested tat the purchaser 300 380 andl ens dolore if hase metals ae uted Te he SRplcate: Al spectestone re sujet ange wthKEMLOX * Keystone Engineering fabricates a standard epoxy laminate which approaches the maximum obtainable properties for a fiberglass reinforced material. Our Kemiox "G" material has {good strength at high temperatures, excellent thermal and electrical proper: ties, good machinabily, and outstand- ing chemical resistance. These properties are based on an E Glass fll and are listed in Tables 2 and 3. Key- stone Engineering also incorporates other fabric fills such as Graphite, Kevlar, Ceramic, and $ Glass. ur standard resin systems can incorporate all of these different fills to achieve different properties. Table 1 compares the heat resistance, density, toughness, stiffness, cost, and impact resistance of these fabric fils. Our standard Kemlox "G” cannot be mold- 4, but is available in several different standard patterns. The two most- requested patterns are listed below. PATTERN K-143 Pattern K-143 has about 80% ofits reinforcement orientated in the axial direction ofthe rod or tube. Thus the K- 143 pattern produces an epoxy lami nate with a very high tensile strength. The flexural and tensile strength are (greater than the K-181 pattern. The K- 4143 pattern is ideal for tensileoaded rods and cylinders. PATTERN K-181 Pattern K-181 has approximately {80% of its reinforcement in both the axial and radial direction. thas a better burst and compressive strength than the K-149 pattern. The K-181 pattem is ideal for downhole tubes and thinwall sections. KEYSTONE ENGINEERING CO. ‘Composite Division P.O. Box 14666 6310 Sidney Street Houston, Texas 77021 (713) 747-5020 TWX 910-881-1592 Table 2 : Kemlox "G” Specifications PROPERTY 1149 187 Specific Gravity 1.82 1.82 Resin Content, 9 301035, 301035, Heat Resistance, °F 400 400 Flexural Strength, PSI 80,000 t0 95,000 | 64,000 to 72,000 Flexural Modulus, PSI x10"* 3.01035 3.01035 Compressive Strength, PSI 54,000 Tensile Modulus, PSI x10® 3104 304 Tensile Strength, PSI 58,000 25,000 Dielectric Constant, KCS 4.41055 4.11055 Dielectric Strength, Volts/Mi short time, .12” thickness 500 00 Volume Resistivity, Ohm-cm, @ 50% relative humiity 1x 10" 1x10 Impact Strength, Izod 121015 121015 Hardness, Rockwell M 1150117 11510 117 Flame Resistance Seif Extinguishing | Sot Extinguishing Color Red or Black Fed or Black Water Absorption, % weight gain atter 24 hours 0.05 10 0.07 0.08 10 0.07 Linear Coetficient of Expansion, X10" iniin °F 40 56 Table 3: Kemlox “G" Chemical Resistance % WEIGHT CHANGE, CHEMICAL IMMERSION TIME, DAYS 50 180 365 ‘Acetic Acid, 1096 $0.29 40682 | +073 Acetone +033 +1.00 = ‘Ammonium Hydroxide, 289% +0.70 +220 | +240 ‘Ammonium Nitrate, 50% +021 +060 | +0.73 Ethyl Acetate +045 +045 | +0.72 Ethylene Glycol 0.03 -023 | +009 Hydrochloric Acid, 1096 0.00 -009 | 032 Hydrochloric Acid, 379 0.21 -5.70 - Hydrogen Peroxide* = S - Isopropyl Alcohol 0.02 -005 | +001 Jet Fuel +0.08 +014 | +032 Methy! Ethyl Ketone 40.24 4034 | +035 Nitric Acid, 30% 0.21 4.80 = Nitric Acid, 50% ** - - - 4108 Octane Gasoline +0.07 +013 | +031 Phosphoric Acid, 10% +027 +054 | +065 Phosphoric Acid, 98% +0.10 +074 | +090 Sodium Chloride, 20% +028 +040 | +067 Sodium Hydroxide, 19% +017 +038 | +050 ‘Sodium Hydroxide, 509% 0.23 =1.30 a Sodium Sulfate, 30% +024 +064 | +074 Sulfuric Acid, 396 -0.09 = +0.09 Sulfuric Acid, 70% +0.20 +038 | +042 Sulfuric Acid, @590"** = = = Water, Distilled +0.21 +067 | +063 “Dataminated ““Toplayerdelarinaiog Delaminated ater Taye