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Material breakthrough

An exclusive insight into the first high temperature polyamide for blow-molded ducts that can handle continuous-use temperatures over 220°C

 

As the inventor of Diablo technology, DSM adds Stanyl Diablo OCD 2305 BM as the latest addition to its portfolio of stable high-temperature products. This material is the first high-temperature polyamide 46 (PA46) on the market designed for standard high temperature blow molding machines. Stanyl Diablo offers a significant cost benefit compared to metal and PPS due to its lower weight and scrap rate. Machines currently using PPS can easily be converted to Stanyl Diablo without any additional investment.

The material was developed to answer the needs of the automotive market, where new EU legislation has set stringent emission reduction targets for 2015. This has led to a trend in smaller vehicles with downsized engines. Creating these smaller engines requires new part designs. For air ducts, neither metal nor injection molding offer the design flexibility needed to fit complex under-the-hood geometries. It’s time for the next generation of hot charge air ducts created using blow molding techniques, the most cost-effective way to produce these parts.

Next generation performance
Stanyl PA46 retains stable mechanical properties at high temperatures, making it an ideal material for air duct applications. With temperature resistance up to 230°C, it suffers negligible loss in mechanical performance after 3000 hours heat aging.

The material’s elongation at break remains stable above 2%, even after 3,000 hours of heat aging (measured on tensile bars).

Parts made from Stanyl OCD 2305 BM meet the OEM’s demanding parameters, including pressure cycle testing at 230°C and chemical resistance from blow-by and exhaust gas recirculation (EGR).

Stanyl PA46 BM offers clear advantages compared with PPS, resulting in a significant cost benefit: including weight reduction up to 10%, which is due to lower density (1330 g/cm3 for PA46 vs. 1440 g/cm3 for PPS), and better wall thickness distribution enabled by the material’s superior melt strength. It offers exceptional handling and impact resistance, because PPS is a brittle material that easily breaks during handling and assembly. Since broken parts are only checked and identified after assembly, reducing breakage is a direct way to save on processing and assembly costs. Stanyl reduces the risk of broken parts to provide a marked reduction in scrap rate.

Further advantages include no cross-linking after machine shut down. Stanyl PA46 BM offers easier start-up, and no additional investment in machines and tools. After longer machine stop, Stanyl PA46 BM only shows a visco-drop, while PPS cross-links. Further more, noise absorption is better than both PPS and metal.

ETM is the first company to deliver serial ducts made out of Stanyl Diablo OCD2305 BM, when the company looked for an alternative blow molding material to produce hot charge air ducts for Volkswagen.

“ETM set out to meet the needs of its customers for both today and tomorrow,” adds Klaus Klockow, general technology manager at ETM. “The new DSM material is clearly designed to address the challenges faced by the automotive industry. We are happy to bring to market the first blow molded ducts made in Stanyl Diablo OCD 2305 BM and approved by Volkswagen.”

DSM, the inventor of Diablo technology, has more than 25 years of experience supplying material for air induction systems. Combining our application development expertise with the extensive knowledge base of our fundamental research team, we help to determine which material properties are needed for air induction applications.

 

 

 

 

7 February 2013

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