Post on 11-Apr-2018
Powertrain andEngineering PlasticsMaterials to Reduce Mass and Boost Performance
Franz SpitznagelDuPont Automotive Oil Pan Global Segment ManagerGermany
Patrick GranowiczDuPont Automotive Engine Covers Segment Manager Troy, MI
What we’ve learned,where we can go together…
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Engine Design and Function –a 30 Year Revolution in Engineering Plastics
We’ve come a long way!
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Engineer’s Dreams … Plastics’ Possibilities
Add function, not mass….....Lower tooling cost…………..Achieve 100% reliability…….Integrate parts for low cost ..Beat the heat ………………....Improve ease of assembly....
Improve performance…….…
Weight reduction ~ 40%<½ the tooling costPredictive EngineeringMulti-function design easeIntegrated engine cooling
Snap fits, packaging viacomplex geometriesImprove fuel economywith lower emissions,reduce NVH
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Engineering Plastics Firsts in Powertrain
1980
EmissionsCanister
Fan
GOR and ShroudsExpansionTanksAIM
1985 1990 1995 2000 2005 2010
Cyl. Head CoversAC PulleyAir ducts
New AIM
Hot-side Air Ducts
Water Pumps
Oil PanFront coverIntegrated AIM-EGR
Turbo chargers
ExhaustEGR Cooling Muffler System
ResonatorsAir –IntakeManifolds
DuPont materials examples for ICE– from the past to the future
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Sheet MetalSheet MetalAluminum die castAluminum die cast
Al sand castAl sand castMgMg
ZYTELZYTEL®® 35% GF35% GF
Wall thicknessWall thicknessDensityDensityWeight factorWeight factor(SG*Th)(SG*Th)
00
33
44
55
66
77
88
99
1010
22
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Zytel® vs. Metal - Weight Factor
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Tooling lifetime
Investment production unit
Flexibility in production
Part cost
T-Plastic ++ - +++ 1
Die Cast AL
-- + ++ 1.2
Sand Cast AL
--- -- --- Quantity dependant
Die Cast Mag
-- + ++ 1.4
Sheet Metal
+++ +++ --- 0.8*
* high quantities f.e > 1MM
Key: + higher; - lower
Cost and Productivity Comparison
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
1977 1990 1995 2010
First Rocker Cover prototype
already in 2k
Porsche Boxster-First EU Rocker
CoverFastest SOP ever30% weight saving
Adequate costsaving
New generation2k gasketfor radial
sealing??
MucellTechnology
Powertrain Engine Cylinder Covers
BMW M52 -First high mass, high complex system
30% weight saving
Attractive cost saving
Chrysler
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
1987 1990 1995 2010
Air Intake Manifolds are One of the Highest Volume Applications for Engineering Plastics
DuPont Troymachines prototypesand installslost coreprocessin Troy lab
GM introduces3800 Manifold in DuPont™ Zytel®with 2 –piecewelded design.
Porsche launches 1st European AIMIn DuPont™Zytel®
Air intake manifold in HTN PPA tointegrate more functionsand high EGR temps for thinner walls, higher temperature.VW: The charge-aircooler is incorporatedinto the intake manifold
World’s largestAIM for Ford Mustang In DuPont™ Zytel®
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
1980 2000 2008 2011
Continuous Improvement in Weight, Cost Savings with Performance Increases for Oil Pans
2009
First prototypes-
1977 in U.S.
Functional prototypes
in E.U.
First commercial part
for Daimler made by Bruss
2nd generation with functional
integration made by Elring
Klinger
o
3rd generation module with full
integration made by
Mann+Hummel
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Air ducts, from - 40°C to + 210°C Hytrel® and Zytel® blow molding -
great tools for cost and weight
Bracket Assy.
Pipe
Hose Assy.
Clamp
Hose
Duct AssemblyTotal Weight 2.8kg
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
6-8 Speed Transmissions - Real Need for Weight-Savings
Transmission oil panZytel® 70G35
Electronic transmission control system & modulesZytel® 70G35 HSLX
Seals in Vespel® partsGM 6-Speed transmissions use Hytrel® for ATF baffle and seal –to reduce fluid aeration and allow fluid-fill for life.
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
New Opportunities for Weight Saving with High Performance Plastics
Front cover, Zytel®;Zytel® HTN PPA Turbocharger housing
Super-tough Zytel®+ Zytel® HTN PPA
EGR Cooler unitsZytel® HTN - PPA
Toyota PriusZytel®HTN51G35HSLR Plastic muffler in Zytel® HTN PPA
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
New Powertrain Trends
CO2 / Emissions Influence Change• Small engines - down to 2 cylinder
• Effective ICE fuel consumption
• Bio-fuel
• HEV, EV, Hybrid diesel plus “clean” fuel
• Turbos/Bi-turbos for small diesel and fuel engines
• Modular approach for efficiency & savings (VW approach)
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
DuPont Technical Support
Material DevelopmentProcess Development and Processing SupportApplication Development SI ProcessDesign Assistance
InnovativeSystem
Solutions
Processing
Design Material Formulation
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
DuPont Engineering Polymers CAE Resources
Unigraphics
Solid-Works
PATRAN
ANSA
HYPER MESH
CATIA
Moldflow
ABAQUSANSYSMARKLS-DYNAMoldflow
Local Workstations
High Performance LINIX Cluster
Modeling
Analysis
Hardware
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
DuPont Engineering Polymers CAE Solutions
Injection Molding Analysis• Filling• Cooling• Shrinkage• Fiber Orientation• Warpage
Structural AnalysisStatic StressDynamic StressImpact
NVH AnalysisAcoustic FrequencyResponseNoise RadiationNoise Penetration
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
World’s 1st Pass-Car Oil Pan in NylonWinner – 2008 SPE Most Innovative Use of Plastics Award
Daimler 4 cylinder diesel engine oil pan DuPont™ Zytel® 70G35 HSLR A4
Integration in future oil pan models could include: oil pick-up pipe, oil level switch, oil filter and other oil return components or oil pumps.
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Accelerations
0.02.04.06.08.0
10.012.014.016.018.0
812
1117
1422
1728
2033
2338
2644
2949
3255
3560
3865
4171
4476
[rpm]
Acc
eler
atio
n [m
/s2]
Order 2.5Order 3Order 4Order 6.5
Mold Filling
Dynamic Structural Analysis
Impact AnalysisCAE Tools for Daimler Oil Pan
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Materials: Where We Can Go With You …• CaCL resistance• Dimensional stability• Electrical friendly resins • Flammability to V0• Greater heat resistance• Hydrolysis resistance• Renewably Sourced
• e.g. Zytel® RS 6,10 resin (47% renewable content) for radiator end tanks
• Super productivity materials• OTHER NEEDS?
Denso radiatorend tanks of Renewably Sourced Nylon 6,10
More than 1/3 of our product offering is new over the past 5 years
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Materials Choice is Driven by Engineering NeedsPe
rfor
man
ce
Cost
Tefzel®PTFE
Zytel®Hytrel®
Crastin®
Zytel® HTNPPA
Zenite®LCP
Vespel®PI
Vespel®PIVamac®/Viton®
Elastomer
Minlon®Crastin® PBTRynite® PET
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
High Temperature Heat Aging - Polyamides
Zytel®70G35HSLRA4
Zytel®HTN PPA
New DuPont PA material family
coming in 2010
High Performanceresins family
<160°C
<180°C
<190°C
<200°C
<220°C
>220°C
DuPont resins for Powertrain
Zytel®70G35HSLX
Zytel®EFE 270056
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Choosing the Right Material for the Right Reasons
2
4
6
8
10Processing window
Surface appearance
AOA heat aging 170°C, 1000h
AOA heat aging 150° C,3000h
Hot oil resitance
Glycol resitance
Chemical Resistance
Warpage
Dimensional stability
Thoughness
HSLB HSLR HSLX HTN
Zytel® 70G35 grades, Zytel® HTN 51G35
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Superflow, Superstiff and Mucell®Materials
Super flow material for thin wall technology Zytel® 70 G35 HSLRA4
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Superflow, Superstiff and Mucell®Materials
Super Stiff material for Structural Applications Zytel® HTN 51LG50
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
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Mucell® for weight savings and productivity gains
Superflow, Superstiff and Mucell®Materials
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Lohner Porsche: the first hybrid vehicle
Ferdinand Porsche built the first standard hybrid power unit in 1900.
His Lohner-Porsche featured a combustion engine as well as an
electric hub motor and could store energy in a battery.
The World's First Hybrid Vehicle
Tesla: the first full electrical sports car
Stay Tuned forthe Upcoming SegmentVehicle Electrification
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Materials to Help Electrify Vehicles
Hitoshi ShioyaDuPont Automotive Global Electrical &
Electronic Applications Segment Leader
Paul KaneDuPont Automotive Global Electrical & Electronic Senior Development Programs Manager
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com
Copyright © 2009 DuPont. The DuPont Oval Logo, The miracles of science™, DuPont™, Zytel®, Hytrel®Vespel®, Mucell®, Tefzel®, Minlon®, Rynite®, Zenite®, Crastin®, Vamac®, and Viton® are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Because we cannot anticipate or control the many different conditions under which this information and/or products may be used, neither DuPont nor the authors guarantee the applicability or the accuracy of this information or the suitability of its products in any given situation. Users of DuPont products should make their own tests to determine the suitability of each product for their particular purposes. The data listed herein falls within the normal range of product properties but they should not be used to establish specification limits or used alone as the basis of design. Disclosure of this information is not a license to operate or recommendation to infringe a patent of DuPont or others.
CAUTION: This product is not permitted to be sold for use in medical applications involving implantation in the human body or where contact with internal body fluids or tissues will equal or exceed 24 hours. For applications involving contact of less than 24 hours, see “DuPont Medical Caution Statement,” H-50102 or contact your DuPont sales representative.
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Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com