A great challenge for plastics

2008-04-11 Manufacturing News

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Ultramid A3W2 G10 plastics from BASF, first serial application in the end caps of charge air intercoolers by the Behr company, in use for the Ford line of compact vans.

BASF’s highly heat-stabilized and highly filled Ultramid* A3W2 G10 plasitcs has found its first serial application in the end caps of charge air intercoolers manufactured by the Behr company. In this context, G10 stands for 50% glass fibers.

This plastics material was tailor-made to meet Behr’s requirements since there was no PA 66-based material on the market that could withstand the continuous temperatures of 190°C [374°F] and the excess-pressure fluctuations between 0.1 and 1.5 bar encountered in the intercooler system. These ongoing ups and downs at such high temperatures pose a great challenge for plastics. The Behr charge air intercooler is already in use in the current Ford line of compact vans, namely, the Transit Connect/Tourneo Connect with a 1.8-liter TDCi common-rail turbo diesel engine.

Charge air intercooler end caps made of Ultramid A3W2 G10. View High resolution image. photo: BASF

Breathing hot air into the car’s lungs
BASF’s highly heat-stabilized and highly filled Ultramid A3W2 G10, in use in the current Ford Transit Connect/Tourneo Connect.

Recently, Bosch announced use of Ultramid for an alternator cover that is an electrical component installed in the engine compartment. Because these flame retardant plastics are rated in fire safety class V0, Bosch is now using BASF’s Ultramid A3UG5 LS. A polyamide 66, Ultramid A3UG5 LS, can also be laser-written very easily. With this cover, the novel material has found its first application in automotive construction.

* Trademark of BASF.

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