Nylon Replaces Aluminum in Air-Intake Manifold

Plastics Engineering, June, 2001 by Hope Molinard

DSM's Stanyl engineering plastic is being integrated into the air-intake manifold of the midsized Ford Transit truck/van, which is being redesigned to reduce weight and improve fuel efficiency. Considerably lighter than the aluminum it replaces, says DSM, the Stanyl polymer also bolsters the key strengths of Ford's new diesel engine: reliability, durability, and efficiency at competitive costs.

The manifold used in the popular European service vehicle is manufactured by Siemens Automotive (Telford, U.K.), which, together with Ford, specified Stanyl TW 200 F6 grade--a 30% glass-fiber-reinforced PA (nylon) 46.

In this application, Stanyl high-heat resins combine high-dimensional stability with excellent mechanical strength at high temperatures, the manufacturer says. Unlike competitive resins such as polyphthalamide (PPA) and polyphenylene sulfide (PPS), Stanyl retains its mechanical properties--creep resistance, vibration resistance, stiffness, and heat aging resistance-at high under-the-hood temperatures, DSM notes. Moreover, says the company, it maintains a high level of impact resistance at ambient and low temperatures.

DSM also points out that, with high stiffness at operating temperatures as high as 190[degrees]C Stanyl typically allows parts to be made with thinner wall-section designs than those made from other polyamides. This feature, combined with easy injection molding, excellent flow characteristics, and short cycle times, results in a low final part cost, says DSM. For the short term, the company adds, parts made with Stanyl can withstand temperatures close to the material's melting point, of 290[degrees]C, eliminating the need for heat shields and similar components.