Case Study: Hubcaps Made from Zytel® Combat Truck Axle Leaks
Impact-resistance, leak-resistance and lower production costs make Zytel® nylon an excellent replacement for aluminum and steel.
Application Description
Hubcap for non-driven truck axles. A first-of-its-kind replacement for aluminum and steel hubcaps, this component uses a body in Zytel® nylon resin with two molded-in inserts, a transparent nylon sight window for oil level inspection, and an aluminum flange for bolt mounting to the wheel hub. An optional side-fill opening features a screw-in plug, also in Zytel®
Materials Selected and Why
Zytel® nylon 6,6 resin was chosen for the body material because it offers:
- Outstanding resistance to repeated impact
- Oil resistance, low creep and good strength
For the side-fill plug, Zytel® provides additional impact resistance required for its exposed, protruding location.
Benefits Gained
- Improved leak resistance – Insert molding produces a highly leak-resistant fusion bond between the sight window and body, as confirmed by field and laboratory tests. By contrast, competitive aluminum designs are prone to leakage in this area.
- Better impact resistance – Tests show that the hubcap body in Zytel® provides at least nine times more resistance than aluminum units to repeated impact from stones and other debris.
- Lower assembly costs – Insert molding permits one-step assembly with no screws and fewer parts.
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