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DSM’s Stanyl® Diablo adopted in first high-volume, high-heat plastic AIM/CAC combination

Singapore, SG, 06 Oct 2016 16:00 CEST

Royal DSM, the global Life Sciences and Materials Sciences company, 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).
DSM’s Stanyl® Diablo adopted in first high-volume, high-heat plastic AIM/CAC combination

Using DSM’s high temperature resistance polyamide 46, Stanyl® Diablo OCD 2100, Germany-based Mahle is producing the first high-volume application of high-heat plastic AIM/CAC combination for use in BMW’s B48 engine. BMW uses the B48 engine in several different car models.

Performance, sustainability driving combined AIM/CAC design

Legislation aimed at lowering vehicles’ CO2 emissions is driving innovation. 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 Mr. Valecka, project manager integrated manifold BMW B48 at Mahle.

DSM delivers a wide range of materials options

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 further offers a best-in-class heat deflection temperature (HDT) under load even beyond existing Stanyl Diablo grades.

The excellent mechanical properties of both the HDT2700 and OCD2100 grades provides superb weld strength and ensures part integrity under pressure pulsation loads. These materials outperform competitive materials in regards to thermal oxidative stability, maintaining high stiffness at elevated temperatures and pressure loads.

As under the hood performance requirements become more extreme, Stanyl Diablo materials deliver robust performance, function integration, and design flexibility while eliminating the need to return to metals Stanyl provides up to 40% weight reduction versus aluminum, and its excellent processing characteristics reduce material and production costs.

Meet the new Akulon Diablo polyamide 66

DSM’s new Akulon Diablo HDT2500 withstands a 220°C continuous-use temperature and has aheat 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.

Inventor of the Diablo technology

DSM is a market leader in the development of high-temperature-resistant thermoplastics for automotive engines. Diablo technology, invented and patented by DSM, improves the long-term temperature resistance of materials such as Stanyl PA46 and Akulon PA66 DSM licenses the Diablo technology to other high- temperature thermoplastics suppliers.