The Euro 6 exhaust gas standard demands considerable reductions in emissions of nitrogen oxide, hydrocarbons and soot particles, compared with previous requirements. In order to meet the new limits, the automotive industry is relying on low-pressure exhaust gas recirculation as well as reductions in engine size, coupled with turbocharging to maintain the same or achieve a higher performance. These developments lead to much higher levels of loading in the charge air duct and to considerably higher temperatures and pressures.
BASF launched Ultramid Endure PA-based injection-moulding material in 2010 and claims that it is still the most heat-resistant material of its type available. It has now extended the range with the introduction of Ultramid Endure D5G3 BM, a blow-moulding grade. BASF says that the new material, which has 15% glass fibre content, demonstrates high heat ageing resistance, is easy to process and has good acoustic properties. Temperature resistance is 220°C during continuous use and the possible peak temperature is 240°C, according to the company. BASF further maintains that blow moulding’s relatively low melt temperature during processing generally results in favourable system costs and that Ultramid Endure consequently performs better than polyphenylene sulphide (PPS), for example.
Like the injection-moulding material, the new Endure grade achieves its heat stabilisation from an established technology that suppresses oxidative attack by atmospheric oxygen. The protection pervades the whole material, which means that it can be machined when necessary, in the area of connections, for example.
BASF asserts that Ultramid Endure BM possesses high melt stability and consequently remains largely cylindrical during processing and enables corrections during the production process as it responds well to changes in the processing parameters. It is claimed that it also demonstrates damping characteristics up to ten times better compared with PPS.
One of the first serial applications for Ultramid Endure D3G7 injection-moulding grade was a heat shield in a charge-air duct. The pipes between the turbocharger and intercooler, which are subjected to high temperatures, can now be manufactured by blow moulding with the new Ultramid Endure BM grade. The first close-to-production components made from Ultramid Endure BM were manufactured at the Dr Reinhold Hagen Foundation in Germany. The new material became ready for commercial use in autumn 2013.