High-heat nylon in air intake/air cooler combination


Dutch materials firm DSM has collaborated with Tier One automotive supplier Mahle GmbH to develop the world’s first high-volume use of high-heat plastic in an air intake manifold (AIM) that integrates a water-cooled charge air cooler (CAC) for use in BMW’s B48 engine. It applies DSM’s high temperature resistant polyamide 46 Stanyl Diablo OCD 2100. BMW uses the B48 engine in several different car models.

Car manufacturers want to deliver higher-performing engines while still meeting the new emission limits. One means of achieving this in turbo systems is to integrate the CAC into the AIM, using liquid to more effectively cool the air instead of air-to-air cooling. CAC integration also reduces the air duct length, thereby improving engine responsiveness and reducing turbo lag.

“Such a design can drive the AIM’s continuous operating temperature up to 220°C, which in turn boosts the mechanical demands on the materials used in those components. This new geometry also requires materials with robust weldability and weldline aging resistance in order to maintain the part’s integrity. The Stanyl Diablo fulfilled all customer requirements.” Says Valecka, Project Manager at Mahle.

DSM offers a complete portfolio of high-performance materials for air intake manifolds whether they have an air-to-air CAC or an integrated, liquid-cooled CAC. This includes Akulon polyamide 6, Akulon Diablo polyamide 66, Stanyl and Stanyl Diablo polyamide 46. DSM engineered its Diablo technology specifically for continuous-use temperatures up to 230°C. The new Stanyl Diablo HDT2700 is also said to offer a heat deflection temperature (HDT) under load even beyond existing Stanyl Diablo grades.

The mechanical properties of both the HDT2700 and OCD2100 grades provides weld strength and ensures part integrity under pressure pulsation loads. These materials are said to outperform competitive materials in regards to thermal oxidative stability, maintaining high stiffness at elevated temperatures and pressure loads. Furthermore, Stanyl provides up to 40% weight reduction versus aluminium.

DSM’s new Akulon Diablo HDT2500 withstands a 220°C continuous-use temperature and has a heat deflection temperature (HDT) of 240°C. Akulon Diablo fills the gap between Akulon PA6, Akulon PA66/6 and Stanyl Diablo by combining long-term heat-aging performance and mechanical properties.


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