polyolefins for under the hood applications

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FOCUS: AIR INTAKE MANIFOLDS TECH DAY: Allizé Plasturgie, ITECH, Lyon, France, March 5, 2019 POLYOLEFIN MATERIALS FOR UNDER THE HOOD APPLICATIONS

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Page 1: Polyolefins for under the hood applications

FOCUS: AIR INTAKE MANIFOLDS

TECH DAY: Allizé Plasturgie, ITECH, Lyon, France, March 5, 2019

POLYOLEFIN MATERIALS FOR UNDER THE HOOD APPLICATIONS

Page 2: Polyolefins for under the hood applications

2

Classification: General Business Use

• Florence Almeida-Bluntzer

• Geert-Jan Doggen

• Dave Brands

• Linda Havermans

PLEASED TO BE WITH YOU

• Sébastien Huguet

Page 3: Polyolefins for under the hood applications

3

Classification: General Business Use

INTRODUCTION TO AECTRA

HROMATKA GROUPAECTRA PLASTIQUES2019

Lyon

PE/PP SABIC

2018Une équiped‘experts

3.000 t en stock – 4 entrepôts

10 salariés

120 références en

stock

AECTRA PLASTIQUES

FRANCE

Page 4: Polyolefins for under the hood applications

4

Classification: General Business Use

INTRODUCTION TO AECTRA

WE INNUMBERS

10Countries

64Account

managers

Reliability Transparency

CompetenceTrust

>5.800Active

customers

15Warehouses

3Laboratories

Financialsolidity

21Technicians

Passion forplastics

WORDSSteadygrowth

OUR SCALE ISEUROPE

Page 5: Polyolefins for under the hood applications

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Classification: General Business Use

INTRODUCTION TO SABIC

*Forbes 2018 **Billion

1976Company

established

34,000Employees

around the world

50Countries of operations

3rd

Largest globalchemical company*

120th

Largest publiccompany in the world*

4Core

businesses

64World-class

plants worldwide

11,534Global patent

filings

≈ 150New products

each year

US$ B**

Totalassets

86US$ B**

Netincome

4.9US$ B**

Annualrevenue

39.9

Page 6: Polyolefins for under the hood applications

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Classification: General Business Use

SOLUTIONS ACROSS THE ENTIRE VEHICLE

Heavy Truck

Crash & Chassis

Exteriors

Interiors

Under-the-Hood &

Fuel Systems

Automotive Glazing

Lighting

Page 7: Polyolefins for under the hood applications

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Classification: General Business Use

•Starter, stop-start battery trays & covers•HEV & EV pack components•Battery on board charging

•Air Intake manifold•Air filter box•Air inlet duct

SOLUTIONS FOR UNDER THE HOOD

Battery

2 Cooling & HVAC

Air Induction

E&E

Fuel & EVAP

•Cooling reservoir•Air guide•HVAC unit

•Power distribution boxes•Connectors & sensors•Engine ignition coils

•Carbon canister•Fuel tank•SCR tank

5

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Page 8: Polyolefins for under the hood applications

AIR INTAKE MANIFOLDS

POLYOLEFIN MATERIALS FOR UTH APPLICATIONS

Page 9: Polyolefins for under the hood applications

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Classification: General Business Use

AIR INTAKE MANIFOLDS

STRATEGIES & CHALLENGES

Manufacturing and quality improvements• Reduced production cost• Improved quality• Improved consumer experience

3

Engineering challenges• Validate polyolefin for naturally aspirated global engine• Balance and retention of properties up to 140°C• Unique fiber technology for optimized design

2

Regulatory and corporate strategies• Reduce CO2 emissions with weight reduction• Cost optimization• Global powertrain programs, global supply

1

Page 10: Polyolefins for under the hood applications

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Classification: General Business Use

TYPICAL REQUIREMENTS FOR NON TURBO SMALL ENGINES

AIR INTAKE MANIFOLDS

TEXT

Max. short-term temperature: 150°C

Operating temperature: -40°C up to +140°C

Operating pressure:-70kPa to +38kPa

Operating life:10 years or 242 000 km

SurroundingconditionsSalt, dust…

Resistance to automotive fluids:fuel, oil, coolant, transmission, brake…

Pressure resistance: Pressure pulse test, leak test…

Resistance to vibrations: -40°C up to +140°C

Impact resistance:Thermal shock…

Page 11: Polyolefins for under the hood applications

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Classification: General Business Use

PA6.6 REFERENCE SOLUTIONS FOR AIM

Page 12: Polyolefins for under the hood applications

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Classification: General Business Use

AIR INTAKE MANIFOLDS

SOLUTION: SABIC® PP COMPOUND G3135X

Relative Cost

Ap

pli

ca

tio

ns

at

Co

nti

nu

ou

s O

pe

rati

ng

Te

mp

era

ture

s

PPc

PA6

PA66

PEEK

HTPA

PPS

100ºC

200ºC

300ºC

150ºC

250ºC

50ºC

G3135X

PBT

SABIC PP compound G3135X

Industry resins

Size relative to application space and price spread

Page 13: Polyolefins for under the hood applications

13

Classification: General Business Use

Relative Cost

Ap

pli

ca

tio

ns

at

Co

nti

nu

ou

s O

pe

rati

ng

Te

mp

era

ture

s

PPc

PA6

PA66

PEEK

HTPA

PPS

100ºC

200ºC

300ºC

150ºC

250ºC

50ºC

G3135X

PBT

PA6.6 rise > 1,5 €/kg over the past 20 months

AIR INTAKE MANIFOLDS

SOLUTION: SABIC® PP COMPOUND G3135X

SABIC PP compound G3135X

Industry resins

Size relative to application space and price spread

Page 14: Polyolefins for under the hood applications

14

Classification: General Business Use

SABIC® PPC G3135X VS. PA6.6-GF35

Properties andAttributes

G3135XPA66 GF30 (HR, DAM)

PA66 GF30 (HR, conditioned)

Density + - -

Flexural Modulus + + -

Tensile Strength - + +

Moisture Sensitivity + - -

Impact Resistance + + +

HDT - + +

MeltingTemperature

+ - -

Weld Strength + - -

Cost + - -

AIR INTAKE MANIFOLDS

Page 15: Polyolefins for under the hood applications

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Classification: General Business Use

Burst test

✓ Welding areas OK

✓ 650-750kPa >> 300KPa

✓ Part break

SABIC® PPC G3135X – WELDING PERFORMANCE

AIR INTAKE MANIFOLDS

+14% tensile strength+15% force max

G3135X vs. standard PP-GF30 offers

Page 16: Polyolefins for under the hood applications

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Classification: General Business Use

Thermal ageing tests performed according to Renault specifications

SABIC PPC G3135X HEAT AGEING PERFORMANCE

AIR INTAKE MANIFOLDS

+ 5%+ 4%

- 5% - 3%

Page 17: Polyolefins for under the hood applications

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Classification: General Business Use

IMPORTANCE OF MATERIAL / DESIGN / PROCESS ENERGY

AIR INTAKE MANIFOLDS

Material

Design

Process

Design Optimization:

- enhance part performance according to material

→ Optimize part weight & cost versus performance

Material:- Material performances

→Material data availability for design simulations

Process:- Melt temperature- Weld strength

→ Optimize processing according to material and part design

Page 18: Polyolefins for under the hood applications

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Classification: General Business Use

PERFORMANCE & BENEFITS WITH SABIC® PPC G3135X

Performance Key Benefits

Excellent weld strength & burst pressure performance

Improved acoustics by 5.0 dB

Balance and retention of properties up to 140ºC

Good dimensional stability & weldability

❑ Validated for:

➢ Engine size ≤ 1,6L,

➢ Naturally aspirated engines

❑ Main concerns for use on bigger engines:

➢ Part requirements (burst test)

➢ Working temperature.

Considerations

Chemical resistance (oil, gasoline, transmission fluid, coolant, etc.)

AIR INTAKE MANIFOLDS

Page 19: Polyolefins for under the hood applications

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Classification: General Business Use

SPE award official communication

AWARD-WINNING SOLUTION

• Serial production: Volkswagen Golf EA211 1.4-1.6L engines

• Location: China

• Material Processor: Hua Tao Ltd

• Material Supplier: SABIC

• Resin: SABIC® PPc G3135X

Page 20: Polyolefins for under the hood applications

TAKEAWAYS

POLYOLEFIN MATERIALS FOR UTH APPLICATIONS

Page 21: Polyolefins for under the hood applications

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Classification: General Business Use

• SABIC® PPc G3135X will not reach PA6.6 level of heat resistance required for ALL UTH applications

• BUT it can meet heat resistance requirements for some applications

• AND can allow for reductions in weight and cost

• No absolute PA6.6 substitution solutions

• New mindset: more selective on the use of PA6.6

• Release PA6.6 capacity for highly demandingapplications

TAKEAWAYS

Page 22: Polyolefins for under the hood applications

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Classification: General Business Use

OTHER PA6.6 SUBSTITUTION SOLUTIONS

PA12

PA6

PA66

PEEK

HTPA

PPS

Relative Cost

100ºC

200ºC

300ºC

150ºC

250ºC

50ºC

Ap

pli

ca

tio

ns

at

Co

nti

nu

ou

s O

pe

rati

ng

Te

mp

era

ture

s

ULTEM

(PEI)

GTX

PPC

NORYL

Classico

VALOX™

PBT PC

Copolymer

EXTEM

(TPI)

LEXAN™

PC

G3135X

AIR INTAKE MANIFOLDS

PPc STAMAXPBT

PPc

PPPPc

PPcPBT

PPcHDPE

PCPPE

PCPPE

Battery2Cooling & HVAC

Air Induction

E&E

Fuel & EVAP5

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Page 23: Polyolefins for under the hood applications

THANK YOU