Polyolefins for under the hood applications
Transcript of Polyolefins for under the hood applications
FOCUS: AIR INTAKE MANIFOLDS
TECH DAY: Allizé Plasturgie, ITECH, Lyon, France, March 5, 2019
POLYOLEFIN MATERIALS FOR UNDER THE HOOD APPLICATIONS
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Classification: General Business Use
• Florence Almeida-Bluntzer
• Geert-Jan Doggen
• Dave Brands
• Linda Havermans
PLEASED TO BE WITH YOU
• Sébastien Huguet
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Classification: General Business Use
INTRODUCTION TO AECTRA
HROMATKA GROUPAECTRA PLASTIQUES2019
Lyon
PE/PP SABIC
2018Une équiped‘experts
3.000 t en stock – 4 entrepôts
10 salariés
120 références en
stock
AECTRA PLASTIQUES
FRANCE
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Classification: General Business Use
INTRODUCTION TO AECTRA
WE INNUMBERS
10Countries
64Account
managers
Reliability Transparency
CompetenceTrust
>5.800Active
customers
15Warehouses
3Laboratories
Financialsolidity
21Technicians
Passion forplastics
WORDSSteadygrowth
OUR SCALE ISEUROPE
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Classification: General Business Use
INTRODUCTION TO SABIC
*Forbes 2018 **Billion
1976Company
established
34,000Employees
around the world
50Countries of operations
3rd
Largest globalchemical company*
120th
Largest publiccompany in the world*
4Core
businesses
64World-class
plants worldwide
11,534Global patent
filings
≈ 150New products
each year
US$ B**
Totalassets
86US$ B**
Netincome
4.9US$ B**
Annualrevenue
39.9
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Classification: General Business Use
SOLUTIONS ACROSS THE ENTIRE VEHICLE
Heavy Truck
Crash & Chassis
Exteriors
Interiors
Under-the-Hood &
Fuel Systems
Automotive Glazing
Lighting
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Classification: General Business Use
•Starter, stop-start battery trays & covers•HEV & EV pack components•Battery on board charging
•Air Intake manifold•Air filter box•Air inlet duct
SOLUTIONS FOR UNDER THE HOOD
Battery
2 Cooling & HVAC
Air Induction
E&E
Fuel & EVAP
•Cooling reservoir•Air guide•HVAC unit
•Power distribution boxes•Connectors & sensors•Engine ignition coils
•Carbon canister•Fuel tank•SCR tank
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AIR INTAKE MANIFOLDS
POLYOLEFIN MATERIALS FOR UTH APPLICATIONS
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Classification: General Business Use
AIR INTAKE MANIFOLDS
STRATEGIES & CHALLENGES
Manufacturing and quality improvements• Reduced production cost• Improved quality• Improved consumer experience
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Engineering challenges• Validate polyolefin for naturally aspirated global engine• Balance and retention of properties up to 140°C• Unique fiber technology for optimized design
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Regulatory and corporate strategies• Reduce CO2 emissions with weight reduction• Cost optimization• Global powertrain programs, global supply
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Classification: General Business Use
TYPICAL REQUIREMENTS FOR NON TURBO SMALL ENGINES
AIR INTAKE MANIFOLDS
TEXT
Max. short-term temperature: 150°C
Operating temperature: -40°C up to +140°C
Operating pressure:-70kPa to +38kPa
Operating life:10 years or 242 000 km
SurroundingconditionsSalt, dust…
Resistance to automotive fluids:fuel, oil, coolant, transmission, brake…
Pressure resistance: Pressure pulse test, leak test…
Resistance to vibrations: -40°C up to +140°C
Impact resistance:Thermal shock…
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Classification: General Business Use
PA6.6 REFERENCE SOLUTIONS FOR AIM
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Classification: General Business Use
AIR INTAKE MANIFOLDS
SOLUTION: SABIC® PP COMPOUND G3135X
Relative Cost
Ap
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PPc
PA6
PA66
PEEK
HTPA
PPS
100ºC
200ºC
300ºC
150ºC
250ºC
50ºC
G3135X
PBT
SABIC PP compound G3135X
Industry resins
Size relative to application space and price spread
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Classification: General Business Use
Relative Cost
Ap
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PPc
PA6
PA66
PEEK
HTPA
PPS
100ºC
200ºC
300ºC
150ºC
250ºC
50ºC
G3135X
PBT
PA6.6 rise > 1,5 €/kg over the past 20 months
AIR INTAKE MANIFOLDS
SOLUTION: SABIC® PP COMPOUND G3135X
SABIC PP compound G3135X
Industry resins
Size relative to application space and price spread
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Classification: General Business Use
SABIC® PPC G3135X VS. PA6.6-GF35
Properties andAttributes
G3135XPA66 GF30 (HR, DAM)
PA66 GF30 (HR, conditioned)
Density + - -
Flexural Modulus + + -
Tensile Strength - + +
Moisture Sensitivity + - -
Impact Resistance + + +
HDT - + +
MeltingTemperature
+ - -
Weld Strength + - -
Cost + - -
AIR INTAKE MANIFOLDS
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Classification: General Business Use
Burst test
✓ Welding areas OK
✓ 650-750kPa >> 300KPa
✓ Part break
SABIC® PPC G3135X – WELDING PERFORMANCE
AIR INTAKE MANIFOLDS
+14% tensile strength+15% force max
G3135X vs. standard PP-GF30 offers
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Classification: General Business Use
Thermal ageing tests performed according to Renault specifications
SABIC PPC G3135X HEAT AGEING PERFORMANCE
AIR INTAKE MANIFOLDS
+ 5%+ 4%
- 5% - 3%
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Classification: General Business Use
IMPORTANCE OF MATERIAL / DESIGN / PROCESS ENERGY
AIR INTAKE MANIFOLDS
Material
Design
Process
Design Optimization:
- enhance part performance according to material
→ Optimize part weight & cost versus performance
Material:- Material performances
→Material data availability for design simulations
Process:- Melt temperature- Weld strength
→ Optimize processing according to material and part design
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Classification: General Business Use
PERFORMANCE & BENEFITS WITH SABIC® PPC G3135X
Performance Key Benefits
Excellent weld strength & burst pressure performance
Improved acoustics by 5.0 dB
Balance and retention of properties up to 140ºC
Good dimensional stability & weldability
❑ Validated for:
➢ Engine size ≤ 1,6L,
➢ Naturally aspirated engines
❑ Main concerns for use on bigger engines:
➢ Part requirements (burst test)
➢ Working temperature.
Considerations
Chemical resistance (oil, gasoline, transmission fluid, coolant, etc.)
AIR INTAKE MANIFOLDS
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Classification: General Business Use
SPE award official communication
AWARD-WINNING SOLUTION
• Serial production: Volkswagen Golf EA211 1.4-1.6L engines
• Location: China
• Material Processor: Hua Tao Ltd
• Material Supplier: SABIC
• Resin: SABIC® PPc G3135X
TAKEAWAYS
POLYOLEFIN MATERIALS FOR UTH APPLICATIONS
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Classification: General Business Use
• SABIC® PPc G3135X will not reach PA6.6 level of heat resistance required for ALL UTH applications
• BUT it can meet heat resistance requirements for some applications
• AND can allow for reductions in weight and cost
• No absolute PA6.6 substitution solutions
• New mindset: more selective on the use of PA6.6
• Release PA6.6 capacity for highly demandingapplications
TAKEAWAYS
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Classification: General Business Use
OTHER PA6.6 SUBSTITUTION SOLUTIONS
PA12
PA6
PA66
PEEK
HTPA
PPS
Relative Cost
100ºC
200ºC
300ºC
150ºC
250ºC
50ºC
Ap
pli
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tio
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Co
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ULTEM
(PEI)
GTX
PPC
NORYL
Classico
VALOX™
PBT PC
Copolymer
EXTEM
(TPI)
LEXAN™
PC
G3135X
AIR INTAKE MANIFOLDS
PPc STAMAXPBT
PPc
PPPPc
PPcPBT
PPcHDPE
PCPPE
PCPPE
Battery2Cooling & HVAC
Air Induction
E&E
Fuel & EVAP5
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THANK YOU