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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Classification: General Business Use

• Florence Almeida-Bluntzer

• Geert-Jan Doggen

• Dave Brands

• Linda Havermans

PLEASED TO BE WITH YOU

• Sébastien Huguet

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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

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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

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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

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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

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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

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AIR INTAKE MANIFOLDS

POLYOLEFIN MATERIALS FOR UTH 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

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

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

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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…

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Classification: General Business Use

PA6.6 REFERENCE SOLUTIONS FOR AIM

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Classification: General Business Use

AIR INTAKE MANIFOLDS

SOLUTION: SABIC® PP COMPOUND G3135X

Relative Cost

Ap

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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

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Classification: General Business Use

Relative Cost

Ap

pli

ca

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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

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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

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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

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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%

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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

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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

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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

TAKEAWAYS

POLYOLEFIN MATERIALS FOR UTH 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

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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

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ca

tio

ns

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rati

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ture

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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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THANK YOU