In the automotive industry there is an increased demand for powertrains to deliver better fuel economy, higher efficiency and reduce emissions. The trend to improve engine efficiency with better fuel economy and an increase in engine power owes a lot to turbocharge technology. Increase in engine performance and efficiency results in high heat and more aggressive gasses often under high pressure.

Air Management Systems, such as air ducts, turbo charger hoses, and seals are expected to withstand these high temperatures up to 250°C peak. Metals such as aluminums and certain types of rubbers can withstand these hot temperatures, but the design associated with these materials often incorporate higher weight, complex processing parameters, and multiple part numbers. They are either eco-neutral or non-eco-friendly materials. So, the challenge lies in the metal and rubber materials that may offer performance but not design flexibility nor simplicity during the assembly process.

The Arnitel duct replaced a thermoset rubber hose and rigid plastic hybrid assembly, significantly reducing the weight, cost and design complexity of the vehicle’s turbocharger system. The nomination recognized the combined efforts of DSM, General Motors, Cikautxo Group and HENN GmbH & Co KG. To read more about the award and material solutions application visit: Arnitel hot charge air duct recognized during 2019 Altair Enlighten Awards.

The ideal air duct

set new standards in high temperature flexible air duct applications.

The Arnitel HT advanced engineered TPCs expand the temperature capability of traditional TPC by offering up to 190°C peak and 175°C operating temperature capability—well beyond the capability of TPC materials that are traditionally positioned for air duct applications.

This material offers long-term heat aging performance and robust chemical resistance; therefore, high temperature ducts can be made from a single material solution. By using one material there is less potential for leakage because of less parts and connection areas.

A single material solution also makes it easier and faster to process, equating to a system cost advantage and weight reduction up to 50%. Arnitel HT also offers flexibility and mechanics even at low temperature.

Another ideal material solution

Stanyl Diablo OCD 2305 BM is another blow moldable solution that can handle continuous use temperatures up to 230°C. It offers a weight reduction up to 10% vs PPS and up to 30% vs aluminum, along with improved toughness, peak temperature capability and superior strength-at-temperature as compared to traditionally available PA66-based blow moldable materials.

After heat aging, it has robust elongation retention. Plus, it has a proven chemical resistance to EGR and blow by condensate. Stanyl PA46 retains mechanical properties at high temperatures, making it ideal for duct applications. It suffers modest loss in mechanical performance after 3,000 hours heat aging.

Both these material solutions offer weight reduction, proven performance and cost effectiveness. Also, grades with higher strength can be used to reduce wall thickness and therefore also save further weight in some applications.

To learn more about Arnitel HT and Stanyl Diablo OCD 2305 BM, or to request test samples, contact us or visit plasticsfinder.com for additional information, including technical data sheets.