Stycast 82 SIRSW1RR

Stycast 82 SI RS W1 RR is a two-component, silicone-based syntactic foam specifically designed for aerospace applications that require lightweight construction and high compressive strength. Supplied as a black material and mixed at a 10:1 ratio by weight, it is formulated with micro balloons to achieve an exceptionally low density without sacrificing structural integrity. This non-corrosive system is ideal for bonding lightweight moulded parts and creating effective thermal barriers in environments where weight reduction is a critical priority.

In its uncured state, the material has a very low mixed viscosity of approximately 240 mPa-s and a generous pot life of around 4 hours at 25℃. It is essential to use moderate shear during the mixing process, as high shear conditions can crush the delicate micro balloon structure and alter the material’s final properties. For a void-free finish, the mixture should be de-aired under a vacuum of 3-4 kPa before application to ensure that no entrapped air affects the thermal or mechanical performance.

The curing process is typically performed at elevated temperatures, requiring 2.25 hours at 150℃ followed by a 1-hour post-cure at 200℃ to fully stabilise the foam. Once cured, the material functions as a high-performance thermal insulator with a conductivity of 0.163 W/m-K and a Shore A hardness of 60. It is engineered to withstand extreme heat, maintaining its integrity at temperatures up to 315℃ with minimal weight loss. To ensure a successful cure, all surfaces must be kept free of contaminants such as sulphur, nitrogen, or heavy metal salts, which can inhibit the chemical reaction.