High-resistance plastic withstands temperatures up to 230°C

Using DSM’s high temperature resistance polyamide 46, Stanyl Diablo OCD 2100, Germany-based Mahle is producing the first high-volume application of high-heat plastic AIM/CAC combination for use in BMW’s B48 engine. BMW uses the B48 engine in several different car models.

Performance, sustainability driving combined AIM/CAC design
Legislation aimed at lowering vehicles’ CO2 emissions is driving innovation. Car manufacturers want to deliver higher-performing engines while still meeting the new emission limits. One means of achieving this in turbo systems is to integrate the CAC into the AIM, using liquid to more effectively cool the air instead of air-to-air cooling. CAC integration also reduces the air duct length, thereby improving engine responsiveness and reducing turbo lag.

“Such a design can drive the AIM’s continuous operating temperature up to 220°C, which in turn boosts the mechanical demands on the materials used in those components. This geometry also requires materials with robust weldability and weldline aging resistance in order to maintain the part’s integrity. The Stanyl Diablo fulfilled all customer requirements.” says Mr. Valecka, Project Manager integrated manifold BMW B48 at Mahle.

DSM delivers a wide range of material options
DSM offers a complete portfolio of high-performance materials for air intake manifolds whether they have an air-to-air CAC or an integrated, liquid-cooled CAC. This includes Akulon polyamide 6, Akulon Diablo polyamide 66, Stanyl and Stanyl Diablo polyamide 46. DSM engineered its Diablo technology specifically for continuous-use temperatures up to 230°C. The new Stanyl Diablo HDT2700 further offers a best-in-class Heat Deflection Temperature (HDT) under load even beyond existing Stanyl Diablo grades.

The excellent mechanical properties of both the HDT2700 and OCD2100 grades provides superb weld strength and ensures part integrity under pressure pulsation loads. These materials outperform competitive materials in regards to thermal oxidative stability, maintaining high stiffness at elevated temperatures and pressure loads.

As under the hood performance requirements become more extreme, Stanyl Diablo materials deliver robust performance, function integration, and design flexibility while eliminating the need to return to metals Stanyl provides up to 40% weight reduction versus aluminium, and its excellent processing characteristics reduce material and production costs.