New Material Solutions for Engine Cooling and Other Demanding Underthe-Hood Environments Presented to the SPE Design & Development with Automotive Plastics Conference* Steven Mok, Chris Murphy, Gary Kozielski, David Glasscock Clive Robertson Modified to Include Product Trademarks, Grades for Clarifications
2 Topics What is a Polyphthalamide or PPA Properties Comparison Between PPA & PA66 Applications Overview in: Engine Cooling Transmission Engine Oil Fuel Air Induction
PPA (PolyPhthalamide) Family is a High Performance Engineering Polymer 3 High performance engineering polymers PEI PES PAR PSU PI PEEK LCP PPA PPS PCT PolyPhthalAmide Engineering polymers PC MPPO PA TPE PET PBT ACETAL Standard polymers ABS PS SMA PVC PMMA SAN PP HDPE LDPE AMORPHOUS SEMI-CRYSTALLINE
4 PPA is Special Category of Polyamide (ASTM) ASTM D5336 : It is a Polyamide Use of Aromatic Acids : Terephthalic Acid or/and Isophthalic Acid Combination of the Two Ingredients Comprises at least 55 Molar Percent Polyamide 66 (PA66) Adipic Acid Aliphatic Aromatic Terephthalic Acid Isophthalic Acid
PPA is a Family of Resins: Product & Processing Performance Differs with the Polymer Chemistry 5 Polymer Chemistry PA66 (Zytel ) PA6T/DT ** (Zytel HTN51) PA6T/6I/66 (Competitive PPA) Reference Here Tg (C) by DMA Tm (C) ISO 11357 DTUL@ 1.8MPa (C) ISO 75 %H20, 24Hrs ISO 62 PA66 65 263 252 1.2% PPA 1 140 300 264 0.5% PPA 2 125 312 278 0.5% PA6T/66 (Zytel HTN52) PPA 3 90 310 285 0.5% ** D : 2-Methyl Pentamethylene Diamine
PPA Resins Characteristics and Benefits to Your Automotive Applications 6 Characteristics Benefits 1. Mechanical Properties Less Affected by Moisture 2. Mechanical Properties Retention due to Higher Glass Transition Temperatures, Long Term Heat Aging 3. Hydrolysis and Long Life Coolant Resistance 4. Resistance to Automotive Chemicals and Environment 5. Creep Resistance at Higher Temperatures Savings in weight, cost due to thinner walls Metal Replacement at Higher Temperatures, Savings in weight, cost due to thinner walls Higher service temperature, longer life Higher Temperature Engine Coolant Components, Longer Service Life Higher Temperature Under the hood Components, Longer Service Life Dimensional Stability for Higher Load Metal Replacement Applications
PPA Has Long, Proven History of Delivering Cost-Effective Solutions under the Harsh & in Demanding Automotive Environment to our Customers Throughout the World 7 Engine Water Jacket Spacer Thermostat Housing Pump Impeller Headlight Components Heater Valve Motor Housing Transmission Solenoid Engine Cover Brake Booster Components Suspension Module Resonators Fuel Cutoff Valve Charge Air Cooler Tire Pressure Transmitter
PPA Maintains Mechanical Properties under Humid Environment: but Moisture Effects PPAs Differently 8 250 Dry As Molded 50% RH Zytel HTN 51 Series: Least Impacted by Moisture Source: Suppliers Datasheets: PA66 (ISO527); PPA s (ASTM D638), Tested @ 23oC Tensile Strength (MPa) 200 150 100 50 0 PA66 (35%glass) PPA 1-6T/DT (35%glass) PPA 2-6T/6I/66 (33%glass) PPA 3-6T/66 (35%glass) Zytel HTN 51 Competitive Zytel HTN 52 PPA
9 PPA Retains Rigidity Well at Higher Temperatures Flex Modulus (MPa) 10000 8000 6000 4000 PA66 (33%glass) PPA 1- PA6T/DT (35%glass) PPA 3- PA6T/66 (35%glass) Zytel HTN 51 Series: Best Retention of Rigidity at High Temperature 2000 30 60 90 120 150 180 210 240 Temperature (C) LEGEND PPA 1 - Zytel HTN 51 PPA 3 - Zytel HTN 52
PPAs Provide Better Resistance to Hot Long Life Coolant than PA66; Performance Varies Depending on PPA Chemistry 10 Zytel HTN 51 Series: Least Impacted by Exposure to Long Life Coolant Zerex LLC G05, Full Immersion @ 130C, Properties Tested @ 23C LEGEND PPA 1 - Zytel HTN 51 PPA 2 - Competitive PPA (PA6T/6I/66)
DuPont Zytel HTN 51 (PPA 1) Selected for the First Water Jacket Spacer for Open Deck Engines 11 Lexus GS-300 Toyota Zero Crown Function - Directs long-life coolant flow to transfer heat away from key areas of the combustion chamber, minimizing variations in cylinder wall temperatures. Benefits - Toyota engineers credit the improved cooling with increasing fuel economy by three-tenths of a mile per gallon, or 1 percent, while extending engine life. Zytel HTN - Coolant Resistance; Rigidity & Strength; Dimensional Stability Winner of 2005 Society of Plastics Engineers Most Innovative Plastics - Powertrain Award
PPA Delivers Performance/Benefits to Engine Cooling Applications 12 Water Outlet Resistance to Hot Long Life Coolant Dimensionally Stable Due to Creep Resistance Low Creep to Maintain Sealing Cost & Weight Reduction vs Aluminum, PPS No Secondary Operations Like Deflashing With PPS Feasible Complex Shapes for Optimum Flow Smooth Surface Facilitates Flow Water Pump Impellers Thermostat Housing
PPA Enables Parts Integration & Metal Replacement in Transmission Components 13 Aged in ATF Dexron 3 @ 150 C, 3000hr Tested 14 at 23 C PPA 1- PA6T/DT (35%glass Zytel HTN 13 51 series) Tensile Modulus (GPa) 12 PA66 (35%glass) 11 PPA 2- PA6T/6I/66 33% Glass (Competitive PPA)) 60 80 100 ISO 527 Tensile Stress (MPa) Improved Resistance to ATF over PA66 PPAs offer High Modulus & Strength But Performance Varies Low Creep Low Coefficient Thermal Expansion Transmission coil
14 PPA Delivers Performance to Engine Oil Components Elongation (%) Aged in Mobil 5W30 Synthetic Oil @ 150 C, 3000hr Tested at 23 C 1.8 1.6 1.4 1.2 PA66 (33%glass) PPA 1- PA6T/DT 35%Glass (Zytel HTN 51) PPA 2- PA6T/6I/66 33% Glass (Competitive PPA) 15 20 25 30 ASTM D638 Tensile Stress (kpsi) Strong & Rigid Parts at High Temperatures Tight Tolerance Low Creep to resist Leakage Longer Service Life : Improved Resistance to Hot Engine Oil over PA66 Property Retention Varies Based on PPA Chemistry Motorcycle Engine Cover
15 PPA = Cost Effective Fuel Component Solutions Material: PPA1- PA6T/DT Zytel HTN 51 (Toughened Unreinforced) Chemical Resistance to Hot Motor Fuels Tensile Strength (MPa) 60 40 20 Low Swell Low Permeability to Fuel Reduce cost, weight vs metal, PPS Superior Resistance to Acid Wash compared to POM 0 ISO 527 DAM, 23C 1000 Hrs, 36% Sulfuric Acid, 23C Diesel Fuel Component Fuel Cutoff Valve
PPA - Low Creep Under Load at High Temperatures 16 Accelerated Flexural Creep by DMA; Load of 28 MPa @ 150 C Zytel HTN 51 Series Offers Best Creep Protection LEGEND PPA 1 - Zytel HTN 51 PPA 2 Competitive PPA (PA6T/6I/66) PPA 3 - Zytel HTN 52
17 PPA May be Used at Higher Temperatures Over Time Zytel HTN 51 Series Offers Best Heat Aging Protection Tested at 23 C LEGEND PPA 1 - Zytel HTN 51 PPA 2 - Competitive PPA (PA6T/6I/66)
18 PPA Cost-Effectively Replaces Metal High Temperature Modulus & Strength for Use Closer to Engine Improved Air Heat Aging Performance for Higher Temperature Use Low Coefficient Thermal Expansion for Dimensional Stability Low Creep at High Temperatures to Maintain Seal Charge Air Cooler Resonator Heat Shield
19 PPA Delivers Cost Effective Solutions in Your Demanding Automotive Applications For Engine Cooling, Transmission, Engine Oil, Air Induction, Fuel: High Temperature Capability Excellent Short & Long Term Mechanical Performance Stability of Performance Under Humid Environment Low Coefficient of Thermal Expansion for Metal Replacement Excellent Chemical Resistance to Automotive Fluids PPA is a Family of Resins: Properties vary because of Different Polymer Chemistry
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