To meet the needs of the Automotive industry, DSM Engineering Plastics has introduced Stanyl Diablo OCD2100. This new grade is the first member of a next generation family of Stanyl grades that offer a revolutionary improvement in long term thermal stability. This technology, developed and patented by DSM, extends the functional life of components well beyond the limits of other high temperature polyamides. By limiting thermal oxidative breakdown, Stanyl Diablo withstands more than 3,000 hours temperature exposure up to 230°C with less than 15% loss in mechanical properties.
Requirements for Under The Bonnet (UTB) applications are changing constantly. Environmental requirements, EURO V and VI legislation and the call for reduced fuel consumption have resulted in significant changes, e.g. the use of smaller engines with higher turbo pressures and EGR (Exhaust Gas Recirculation). As a consequence, automobile UTB components such as air ducts, air intake manifolds and charge air cooler end-caps are exposed to continuously rising operating temperatures. With increasingly critical temperature and tougher life time requirements, long term service life of components made from current thermoplastics can be at risk.
According to Ton Vet, Turbo Systems Application Development Manager at DSM, continuous temperature levels up to 230°C are now increasingly common for UTB applications: - Stanyl Diablo OCD2100 outperforms current high heat resins on high temperature stability, but also on weldability, weld strength and the weld`s long term heat stability. Longer and better lifetime reliability of parts is also possible because of the material`s low creep and its fatigue behavior. Part design and function can be reached more easily and, more importantly, UTB part reliability can be guaranteed for the lifetime required.
Dan Bishop, Global Marketing Manager Stanyl, adds: - With Stanyl Diablo OCD2100, metal replacement options have been expanded tremendously. In addition to the cost reduction that can be achieved by replacing metals, the use of Stanyl Diablo OCD2100 also offers possible cost down options for applications running in specialty materials such as PPS. Stanyl allows the cost effective design of UTB applications, thanks to its excellent retention of stiffness at elevated temperatures, superior toughness levels, resistance to greases and oils and - above all - ease of processing, especially when compared to other High Performance Materials such as PPS, PPA and PEI.
After an intense study of both chemical and physical degradation mechanisms, DSM Engineering Plastics` R&D Department was able to identify the exact material properties that needed to be controlled in order to develop this next generation of high temperature resistant Stanyl Diablo grades.
Willy Sour, Product Development Specialist Stanyl, stresses that this fundamental knowledge of the exact degradation mechanism is the key to Stanyl Diablo`s success. - Stanyl Diablo does not only rely on traditional anti-oxidants, as is the case for competitive products. By actual control of the oxidation mechanism, loss of mechanical performance is effectively reduced, as shown in the attached pictures of cross sections of long term heat treated test bars. That is why Stanyl Diablo is able to offer best-in-class long term heat stability.