DSM Engineering Plastics introduces new high performance grade of Stanyl® for
under the bonnet applications.
To meet the needs of the Automotive industry, DSM Engineering Plastics has
introduced Stanyl Diablo OCD2100. This new grade is the first member of a next
generation family of Stanyl grades that offer a revolutionary improvement in
long term thermal stability. This technology, developed and patented by DSM,
extends the functional life of components well beyond the limits of other high
temperature polyamides. By limiting thermal oxidative breakdown, Stanyl Diablo
withstands more than 3,000 hours temperature exposure up to 230°C with less
than 15% loss in mechanical properties.
Requirements for Under The Bonnet (UTB) applications are changing constantly.
Environmental requirements, EURO V and VI legislation and the call for reduced
fuel consumption have resulted in significant changes, e.g. the use of smaller
engines with higher turbo pressures and EGR (Exhaust Gas Recirculation). As a
consequence, automobile UTB components such as air ducts, air intake manifolds
and charge air cooler end-caps are exposed to continuously rising operating
temperatures. With increasingly critical temperature and tougher life time
requirements, long term service life of components made from current
thermoplastics can be at risk.
According to Ton Vet, Turbo Systems Application Development Manager at DSM,
continuous temperature levels up to 230°C are now increasingly common for UTB
applications: “Stanyl Diablo OCD2100 outperforms current high heat resins on
high temperature stability, but also on weldability, weld strength and the
weld’s long term heat stability. Longer and better lifetime reliability of
parts is also possible because of the material’s low creep and its fatigue
behavior. Part design and function can be reached more easily and, more
importantly, UTB part reliability can be guaranteed for the lifetime required.”
Dan Bishop, Global Marketing Manager Stanyl, adds: “With Stanyl Diablo
OCD2100, metal replacement options have been expanded tremendously. In
addition to the cost reduction that can be achieved by replacing metals, the
use of Stanyl Diablo OCD2100 also offers possible cost down options for
applications running in specialty materials such as PPS.
Stanyl allows the cost effective design of UTB applications, thanks to its
excellent retention of stiffness at elevated temperatures, superior toughness
levels, resistance to greases and oils and - above all - ease of processing,
especially when compared to other High Performance Materials such as PPS, PPA
and PEI.”
After an intense study of both chemical and physical degradation mechanisms,
DSM Engineering Plastics’ R&D Department was able to identify the exact
material properties that needed to be controlled in order to develop this next
generation of high temperature resistant Stanyl Diablo grades.
Willy Sour, Product Development Specialist Stanyl, stresses that this
fundamental knowledge of the exact degradation mechanism is the key to Stanyl
Diablo’s success. “Stanyl Diablo does not only rely on traditional
anti-oxidants, as is the case for competitive products. By actual control of
the oxidation mechanism, loss of mechanical performance is effectively
reduced, as shown in the attached pictures of cross sections of long term heat
treated test bars. That is why Stanyl Diablo is able to offer best-in-class
long term heat stability.
