 Considering that the one primary concern in the auto sector across the world is about how to reduce the weight of vehicles, DSM Engineering Plastics, based in the Netherlands with manufacturing and sales facilities in several countries, may well find itself at the centre of attention during K2010, the trade fair for plastics and rubber to be held from October 27 to November 3 at Dusseldorf in Germany. That is because following the successful introduction in 2007 of Stanyl Diablo OCD2100, a high performance grade of Stanyl for under-the-bonnet (UTB) applications, DSM will now showcase two new Diablo high heat resins at K 2010 – Stanyl Diablo OCD2300 and Akulon Diablo.
Both these products are a direct response to some of the main trends in the automotive industry, including weight reduction. The new materials also facilitate system cost optimisations and productivity gains, long-term sustainability and reduced environmental impact. Stanyl Diablo OCD2300 is a high heat PA46 material, developed specifically to meet the need for long-term temperature resistance at elevated temperatures. It joins the family of Stanyl PA46 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 at ageing temperatures of 230°C before its tensile strength is less than half of its initial value.
 “The 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 as for example 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 lifetime requirements, the long-term service life of components made from current thermoplastics can be at risk. Stanyl Diablo OCD2300 is currently the only high performance PA that can withstand these temperatures whilst offering better mechanical properties than other high performance polymers for these types of applications,” explains Christian Kilgus, Business Development Manager, DSM Engineering Plastics.
The product was recently tested, validated and released by a German OEM for use in application up to 230°C CUT, where key applications include resonators, hot charge air ducts and charge air-cooler end-caps. “It was found to outperform current high heat resins on high temperature stability as also on weldability, weld strength and the weld’s long-term heat stability. Part design and function can be reached more easily and, more importantly, UTB part reliability can be guaranteed for the lifetime required. During injection molding, tool temperatures of 80°C and melt temperatures of around 300°C are normally used. Short cycle times can be achieved to reduce system costs,” Kilgus adds.
 The company will also introduce Akulon Diablo, a high heat PA6 material. This high performance grade of Akulon was developed specifically for use in air/fuel systems, which may be subject to temperatures of up to 210°C continuous use, even 230°C over shorter periods. Akulon Diablo is currently being sampled and will be commercially available later this year.
According to Ralph Ramaekers, Global Manager, Powertrain Engine/Transmission & Turbo for DSM Engineering Plastics, “The addition of both Stanyl Diablo OCD2300 and Akulon Diablo significantly increases metal replacement options for UTB applications. Our Diablo portfolio now allows us to meet all the needs of the supply chain for air ducts. Also, we have extensive application knowledge to support customers with CAE, design and design optimisation so they can meet OEM requirements.”
Also, at K 2010, DSM Engineering Plastics will announce the commercialisation of Akulon RC, a portfolio of post-industrial recycled grades of PA6 for use in automotive under-the-bonnet applications. The new material is planned to be available from the end of 2010 – with first commercial applications following in early 2011. Akulon RC will be available in a number of grades, including RC grades of Akulon® Ultraflow®. The development of Akulon RC is fully in line with the automotive industry’s drive for ecologically sound and sustainable solutions. The new material is being evaluated by, amongst others, leading Tier I supplier Mark IV Systemes Moteurs. “At Mark IV we are currently evaluating DSM’s new Akulon RC grades for our applications. DSM is clearly leading in their environmental approach to customers,” says the company’s raw materials buyer Valerie Tiddia.
 DSM has an established reputation for delivering eco-efficient automotive solutions, offering CO2/emission/fuel consumption reduction via metal-to-plastic conversion in applications such as air inlet manifolds and air ducts. The company is one of the world’s leading suppliers of quality engineering thermoplastics through sustainable solutions. The company recorded sales in 2009 of Euro 648 million and employs some 1,600 people worldwide. As a strong partner to the automotive industry, DSM Engineering Plastics has introduced a range of both new materials and specific grades of existing materials, designed to deliver the required performance, while meeting the overall industry trends for lighter, more effective and greener solutions. Engineering plastics play an important role in this segment as they offer significant opportunities for system cost reduction, improved reliability and weight reduction for fuel economy.
On the India front, as reported earlier, DSM Engineering Plastics has tied up with the Pune-based Automotive Research Association of India (ARAI) to develop solutions that will help reduce the weight of the automobiles. One of the projects on the anvil is to develop an air bag technology as per the international standards for the passenger cars in India. “We are going to be working on various applications for the Indian auto industry and one of them will definitely be on reducing the weight of the passenger cars. Environmental issues are also high on the agenda and the combination of ARAI’s technical expertise in R&D, testing, certification, homologation and framing of vehicle regulations with DSM’s domain expertise in devising plastic solutions for vehicles will go a long way in revolutionising the auto manufacturing process,” says Shrikant Marathe, Director, ARAI.
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