BASF develops charge-air section plastics in commercial vehicle

BASF develops charge-air section plastics in commercial vehicle

4:49 AM, 11th June 2012
BASF develops charge-air section plastics in commercial vehicle
Plastic air and oil module for trucks made of Ultramid.

LUDWIGSHAFEN, GERMANY: A plastic compound from BASF has, for the first time, found use in the charge-air section of a commercial vehicle. The charge-air duct on the DD13/DD15 truck engines is one of the first large production applications for the new polyamide grade Ultramid A3W2G6. The component, produced by ElringKlinger, offers high mechanical and thermal capabilities. The multifunctional oil intake module is also manufactured from a BASF polyamide. Compared to its aluminum predecessor, the lightweight charge-air duct made from the BASF polyamide is 1.8 kg, or 50 per cent, lighter.

The charge-air duct must survive 3,000 hours of pressure fluctuations between 0.4 and 3.5 bar. These are special requirements in the commercial vehicle sector. The oil intake module on the DD13/DD15 also presents demanding challenges for the material. It is made from Ultramid A3WG7 and, in addition to the oil intake connection and oil supply line, incorporates an integrated check valve. In the component test, the aged material has to withstand over 10 million oil pressure pulsation cycles between 5 and 13 bar at 120°C. Substitution of Ultramid for metal and the high degree of functional integration resulted in cost and weight reductions of 0.8 kg, or 50 per cent per part.

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