CORBETTA, Italy and SOUTHFIELD,
Mich., May 9, 2017
/PRNewswire/ -- By 2020, predictions indicate that 70 percent of
light vehicles worldwide will use turbocharged engine
technology1. As a result, BASF is introducing the use of
its Ultramid Endure polyamide with high heat aging resistance up to
220° C in these engines. There are two new powertrain applications
utilizing the company's high heat resistant Endure thermoplastics;
the air intake manifold with integrated charge air cooler, and
hot-side turbo duct. Both debut on the 2017 Alfa Romeo Giulia with
the new 2.0L GME engine.
Turbochargers provide high pressure air to the engine that makes
fuel burn efficiently – delivering greater engine power while
consuming less energy. However, most standard thermoplastics cannot
maintain desired performance under the high heat and pressure
developed in a turbocharged engine, which is why BASF developed the
Ultramid Endure portfolio of engineered resins. The Endure grades
offer high heat aging resistance, good processability, excellent
weld line strength and are available for production in North America, Europe, and Asia to support global Original Equipment
Manufacturer (OEM) programs.
The Ultramid Endure portfolio can be used in many air induction
applications of the turbocharged system including the air intake
manifold, charge-air ducts, resonators, intercooler end caps and
throttle bodies. It can also achieve long-term service temperatures
of 220° C, and withstand peak temperatures of 240° C. Its notable
heat aging behavior results from an innovative stabilization
system, which greatly reduces oxygen attack on the polymer
surface.
"We predict that about 20 percent of all turbocharger
applications will require a high heat resistant plastic as engine
temperatures increase due to downsizing," said Mike Chiandussi, Powertrain Market Segment
Specialist at BASF. "BASF is able to deliver not only the
innovative materials necessary for these applications, but also the
design and welding expertise and know-how to ensure that suppliers
and automakers can incorporate them successfully into their
turbocharger system parts."
Hot-Side Turbo Duct
BASF collaborated with ABC Group Inc. to develop the hot-side
turbo duct for the Alfa Romeo Giulia. For this application, ABC
Group used BASF's Ultramid Endure D5G3 BM, a 15 percent glass fiber
reinforced blow molding grade, which has a high melt strength and
superior heat aging resistance.
ABC Group leveraged BASF's material and joining technology
expertise to optimize the infrared (IR) welding parameters for this
part. It was crucial to achieve strong welds to insure the
long-term durability of the duct.
"After conducting numerous resins trials through molding,
welding and vigorous validation testing, we were able to use an
industry-first material and meet the significant requirements for
this application," said Mary Anne
Bueschkens, CEO of ABC Group. "The part requires many weld
connections, and our engineers worked closely with BASF's material
and joining experts to understand the unique requirements, allowing
us to fine tune our infrared welding technology, and assuring
success of the welding process for this demanding high temperature
duct."
Air Intake Manifold with Integrated Charge Air Cooler
BASF worked with Magneti Marelli to develop the air intake
manifold with integrated charge air cooler for the Alfa Romeo
Giulia. The need for materials to withstand a 200°C continuous use
temperature made this air intake manifold a prime candidate for the
Ultramid Endure D3G7, a 35 percent glass fiber injection molding
grade.
The air intake manifold has a burst pressure requirement;
therefore, Magneti Marelli needed a solution that offered reliable
weld strength at elevated temperatures. Using BASF's design,
material and processing expertise, Magneti Marelli could achieve
the required burst strength and durability targets for the
assembly.
"BASF's technical support was useful to ensure the application
passed the burst requirement," said Marcello Colli, Product Manager Throttle Bodies,
at Magneti Marelli. "Their material and welding experience ensured
that we could use this heat resistant material and meet long-term
durability targets."
As heat under-the-hood increases, the Ultramid Endure portfolio
of solutions enables automakers to achieve engine downsizing and
turbocharging without sacrificing performance.
This Alfa Romeo-exclusive engine debuts in the new 2017 Alfa
Romeo Giulia and Giulia Ti premium mid-size sedan. The 2.0-liter
Alfa Romeo engine delivers 280 horsepower and 306 lb.-ft. of
torque, allowing it to launch from 0-60 mph in 5.1 seconds, and
achieve a top speed of 149 mph.
For more information, visit www.automotive.basf.com
1 Source: Honeywell, a global developer of automotive
turbochargers
For press photos, click on the link below:
https://www.basf.com/en/company/news-and-media/news-releases/2017/05/p-17-211.html
About BASF
BASF Corporation, headquartered in Florham Park, New Jersey, is the North
American affiliate of BASF SE, Ludwigshafen, Germany. BASF has more than 17,500 employees
in North America, and had sales of
$16.2 billion in 2016. For more
information about BASF's North American operations, visit
www.basf.us.
At BASF, we create chemistry for a sustainable future. We
combine economic success with environmental protection and social
responsibility. The approximately 114,000 employees in the BASF
Group work on contributing to the success of our customers in
nearly all sectors and almost every country in the world. Our
portfolio is organized into five segments: Chemicals, Performance
Products, Functional Materials & Solutions, Agricultural
Solutions and Oil & Gas. BASF generated sales of about
€58 billion in 2016. BASF shares are traded on the stock
exchanges in Frankfurt (BAS),
London (BFA) and Zurich (BAS). Further information at
www.basf.com.
About ABC Group Inc.
Founded in 1974, ABC Group Incorporation is one of the world's
leading, full-service automotive suppliers of thermoplastic
components and systems to Original Equipment Manufacturers (OEM's).
Our global headquarters is in Toronto,
Canada, with 36 domestic and international locations across
Canada, United States, Mexico, Brazil, Germany, Spain, Poland, Japan
and China. For further information
about ABC Group Inc., please visit www.abcgroupinc.com.
About Magneti Marelli
Magneti Marelli designs and produces advanced systems and
components for the automotive industry. With 86 production units,
12 R&D centres in 19 countries, approximately 43,000 employees
and a turnover of 7.9 billion Euro in
2016, the group supplies all the major car makers in Europe, North and South America and the Far East. The business
areas include Electronic Systems, Illumination, Powertrain,
Suspension and Shock Absorbing Systems, Exhaust Systems,
Aftermarket Parts & Services, Plastic Components and Modules,
Motorsport. Magneti Marelli is part of FCA.
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SOURCE BASF