Re-writing the rulebook

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DuPont is enabling OEMS to produce more lightweight, more sustainable vehicles by replacing metal car components with plastic.

EPPM sat down with Hans-Hermann Kirner, DuPont's Key Account Manager for performance plastics in the automotive industry, at Fakuma 2014 in Friedrichshafen. The meeting followed the company's news that two leading automotive fluid specialists chose DuPont Zytel nylon resins for rigid and flexible coolant pipes. EPPM wanted to explore the shift from metal to plastic in automotive production.

Material, process, design

Kirner explained that using PA66 for rigid coolant pipes is a simple switch from traditional materials thanks to its rigidity, resistance to pressure and temperatures of up to 150 degrees centigrade. In addition, PA612 - a Long Chain Polyamide that is suitable for its flexibility - has helped enable an extruded coolant pipe with in-built ridges for flexibility of movement into areas where there is space in some directions. Although the concept is simple, it is representative of the shift the automotive industry is making to stay competitive.

"This part was created not only using the extrusion process," said Kirner, "but it's also about material choice and design. Replacing metal is interesting in terms of weight, yes, but the full benefits are a combination of material selection, process knowledge and the design of the part."

The flexible coolant pipe application was nominated by the Society of Plastics Engineers for the 'Most Innovative Use of Plastics Award' in the 'Chassis and Hardware' category, with winners to be announced on November 12th 2014. But it is competitions like these that help raise the profile of new innovations, turning the heads - and preconceptions - of OEMs.

"In 2008, we submitted a a Daimler oil pan that was made in DuPont Zytel nylon, which reduced overall weight by a significant 1.1 kg contributing to fuel savings and lower CO2 emissions. We submitted and won. Whenever there is something different, we believe in making people aware so others can appreciate the technology," Kirner stated.

"20-30 years ago nobody thought it could be done. But like we always say, the easy stuff has already been done, so there's more challenging things to do, and replacing metal parts which had never been replaced by plastic before takes 10-15 years. We ask, what are the materials and how can we modify them to make them more temperature- or impact-resistant, what are the requirements, what are the obstacles?"

Taking on the challenge

The science behind replacing metal components with plastic alternatives is not just a case of developing the right material, attitude is equally as important and Kirner described this side of evolving how we produce vehicles as a real challenge for the supply chain.

"Sometimes we have people saying they are confident with what they have, 'I don’t want anything new', so you have to work holistically with the OEM and Tier 1 to take on the challenge and believe in the application and make it work.

"OEMs who are used to metal ... [may] not know much about plastics. So why should they come up with a plastics solution when all their investment has gone into metal? OEMs have to be open to new technology from a new supplier. If the OEM won't take the risk, there's no project."

Because of this, change in automotive can be gradual even though the benefits of cost and weight reduction are plain to see, while there are other benefits the OEM can discover once they take the plunge. Raising the oil pan case study again, Kirner explained that the new component reduces noise thanks to its flexible, absorbing qualities.

Noise reduction is an interesting new challenge the industry is facing, according to Kirner, as electric cars become increasingly prominent. "You start it by pushing a button - you don't know if the engine is on or not - then you drive. The noise level in the car is so low that noise from other sources are suddenly noticeable, so we have to think of ways to reduce the noise levels of those components with without compromising other properties."

Evolution

The evolution of the car - with driverless cars and electric cars anticipated to roll into the mainstream - fascinates Kirner, as the opportunities for future projects and challenges stretches out before him.

"With driverless cars, they communicate with each other, so do you need a seat belt or air bag? How does this change the industry for those suppliers? We might not need a steering wheel, maybe just an iPad. Also, do I need my own car? You could look on your smartphone and reserve a car, arrange it to come to your house, drop you off and come back and take you home. Kind of like a taxi. So do the interiors change? The materials might need to be more resistant to stretch and wear, while it has to be a nice environment."

The synergies between automotive and plastic material development have so many benefits. Kirner explained that DuPont has matter experts and a long history of collaboration in automotive, as well as in other fields such as electricals, which will play an increasingly important role in automotive production.

"Electrical will become a part of the automotive industry," Kirner said. "Plastics help OEMs to reduce carbon dioxide and therefore benefit the industry - it's a great field to work in especially if you look to a combination of real experts. Sometimes we don't want to reinvent the wheel, we want to look at what already exists and how we can use existing products in automotive providing more value to the customer."

For Kirner, the realistic future of electric drive is as part of a hybrid vehicle. He sees a future of zero-emission city centres, where short journeys and speed restrictions are better suited for electric drive, while combustion engines will come into play for longer journeys outside of the towns where speed is important and plastic will gradually play a larger and larger role in the inner workings of these vehicles as performance materials that can withstand the tough environment under the bonnet are adopted by OEMs.

The expert used packaging as a good example of how automotive needs to evolve. He said: "Packaging has moved away from glass towards plastics. Some businesses made the change, some didn't and it's interesting to see that today many of those who kept the glass have disappeared. It's the same for automotive. We need to have flexibility. Those who do that - who take the risk - will survive. You need the mindset to say 'we will try this - sometimes we fail, sometimes we win, but we need to change' rather than saying 'OK, but I've always done it like this'. Sooner or later you'll disappear."

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