Champion of metal replacement technology DSM is going to continue pushing the envelope for engineering plastics innovation in automotive at K 2016.
The global science company will be bringing the newest additions to its ForTii high performance polyphthalamides portfolio and a new high temperature-resistant Arnitel TPE for hot air ducts to Düsseldorf this October and announced the news at EMG's pre-K press event in Antwerp last week (June 8th 2016).
Three years ago, we were not present in the size and scope that we are today.
K Show presents a timely opportunity for DSM to check back on what it has brought to market since the last outing three years ago. Indeed, DSM is proud to be investing in its research and development output with some 300 employees working in R&D around the world developing, among others, the company’s flagship high-temperature materials including ForTii and Arnitel.
"[The K rhythm] makes it clear what has happened in the last three years," said Joost d'Hooghe, Commercial Director DSM Engineering Plastics. "Three years ago, we were not present in the size and scope that we are today."
Both engineering plastics destined for K 2016 debuts offer cost and weight savings for automotive manufacturers.
DSM Engineering Plastics: DSMPR488
DSM ForTii MX
ForTii MX grades from DSM provide a more cost-effective alternative than ever to die-casting metals.
The ForTii MX polyamide for die-cast metal replacement applications is targeted at a segment that has been largely overlooked by metal replacement materials developers. The market for die cast replacement is currently growing at around 10 per cent annually and DSM believes the increasing availability of high performance materials such as ForTii MX will ensure that high growth continues and could very well increase.
ForTii MX grades naturally offer better properties than existing PPA materials as far as strength and toughness are concerned, with grades available with glass fibre reinforcement from 30 to 50 per cent, making it a good choice for structurally-loaded parts such as housings, covers and brackets in the automotive powertrain, air and fuel systems, suspension and chassis.
Injection mouldings in ForTii MX will be able to compete advantageously with parts die-cast in aluminum, magnesium and zinc
Programme Manager for die cast replacement Ralf Ponicki said: "In terms of heat deflection temperature (HDT/A 305°C) and toughness, they are considerably better than most other PPAs currently on the market. Injection mouldings in ForTii MX will be able to compete advantageously with parts die-cast in aluminum, magnesium and zinc.
"ForTii MX exhibits a comprehensive property profile that some competitive solutions can only partially cover with using additional blend technology. Many pure PPA based compounds remain their good mechanical strength and dimensional stability up to around 100°C but in environments with temperatures above 130°C the mechanical strength drops severely. This effect sometimes is compensated by using blend technology, but sacrificing dimensional stability as well as mechanical strength up to 100°C. ForTii MX (PPA) combines the best of two worlds - best mechanical performance (especially impact strength) in combination with high dimensional stability at ambient elevated (100°C) and high temperatures with limited influence of moisture."
Stability is also being promoted as a dominant characteristic in the new Arnitel thermoplastic copolyester elastomer (TPC) for flexible hot charge air ducts for turbocharged engines. The material offers manufacturers the novel option of producing ducts in a single material, in a single step - doing away with plastics-rubber and metal-rubber combinations and resulting in cost savings of up to 50 per cent and weight savings of up to 40 per cent.
Hot charge ducts transfer hot compressed air from the turbocharger of an advanced petrol or diesel engine into the intercooler, meaning they need to withstand high temperatures for prolonged periods of time. Furthermore, they need to handle engine movements relative to the cooler attached to the chassis, requiring them to have more flexible end sections which tend to be made of heavy thermoset rubbers which are expensive to tool and difficult to recycle.
Photo: DSM Engineering Plastics: DSMPR486
DSM Artitel TPE
New high temperature resistant Arnitel TPE from DSM replaces plastics-rubber and metal-rubber combinations in hot air ducts.
Arnitel HT claims to tackle these disadvantages with its ability to function in temperatures of up to 180 degrees C, fluctuating up to 190 degrees C, elasticity and mechanical strength, and chemical resistance properties.
By using a single solution based on a material with excellent mechanical performance and a relatively low density in an optimised design, it is possible to obtain weight savings of as much as 40 per cent.
Global Segment Manager Air/Fuel at DSM Kurt Maschke explained: "Ducts produced in Arnitel HT can withstand the internal operating pressures which are demanded by car producers, not only for models in production today but also for upcoming generations ... by using a single solution based on a material with excellent mechanical performance and a relatively low density in an optimised design, it is possible to obtain weight savings of as much as 40 per cent."
One of the first producers of air ducts to take advantage of the nw material is Spanish manufacturer CIKAUTXO, which worked alongside DSM in developing the first Arnitel HP part.
"We believe that Arnitel HT will enable us to make important cost reductions and increase consistency and reliability in our production of high performance ducts," stated Dr Gurmendi at CIKAUTXO. "Our new ability to make better optimised parts in a single step provides us with a tangible advantage in the market."
