Super Structural Plastics Continue to Push the Frontier of Metal Replacement Authors:
Joiji Homma - DuPont Engineering Polymers, Japan, Clive Robertson - DuPont Engineering Polymers, USA, J Y Lee - DuPont Engineering Polymers, Korea
Abstract:
DuPont has developed SuperStructural plastics using combinations of high performance polymers and high loadings of short or long glass fibers. These plastics, depending on the grade, offer one or more of higher stiffness, lower creep, greater impact strength, thereby allowing further cost effective replacement of metals in automotive components.
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Nano-reinforced Polymers Author:
Hunter Ficke - Director, DuPont Central Research and Development, Wilmington DE, USA
Abstract:
The development of Nylon 6 based nanocomposites by Toyota Central R&D Labs during the late 1980's has ignited the interest of the materials science community. At low nanofiller loadings, these nanocomposites were demonstrated to exhibit dramatic improvements in flexural and tensile modulus, flexural and tensile strength, Heat Deflection Temperature, gas barrier properties, and unique rheological properties. These properties arise from the high interfacial area generated by the nanoscale dispersion of the filler particles in the polymer matrix. Our efforts have focused on the development of nanocomposite materials using a range of polymer matrices to generate a fundamental understanding of the requirements for a nanoscale dispersion to occur and the properties that result. In addition, we are attempting to modify the interfacial region and alter the volume fraction and properties of the interphase to tailor the ultimate properties of the overall nanocomposite material. Early results from these studies have resulted in a novel and useful family of well defined nanocomposites in a number of polymer matrices aside from the well known Nylon and Epoxy nanocomposite systems. These new nanocomposites exhibit increased flexural and tensile modulus, elevated Heat Deflection Temperatures, excellent impact properties, reduced flammability, and improved moldability.
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Trends in Thermoplastic Materials for Powertrain Applications Authors:
Gian Luigi Molteni - DuPont Engineering Polymers, USA, Y. Ohashi - DuPont Engineering Polymers, Japan, G. Sul - DuPont Engineering Polymers, Korea
Abstract:
The auto industry is looking for engines with more power, continuous improvement of emissions, lower fuel consumption and lower NVH. In the process of developing components and/or systems where alternative materials and more specifically engineering thermoplastic resins are used, there are two major dynamics which take place: productivity and performance. In productivity there is, at least in most cases, not a real control over profitability because there is no real control over pricing. However, manufacturing productivity does indeed influence the long term profitability. Thus, we need to work on all tangible and more subtle factors which do influence directly and indirectly the manufacturing process. In performance, advanced materials, innovative design and material technologies, sometime with high degree of complexity, are the key elements for enabling functioning. We will examine the powertrain sub-segments and critical applications within: air induction systems, oil management systems, transmission components, in addition to the already established high volume applications like AIM and rocker covers. We will better understand how high-performance materials, combined with innovative design, advanced manufacturing and integrated processes can boost engine power and performance, reduce NVH and significantly lower the total part and/or system weight. As we aimed to advance functionality and quality we will also allow for significant economical gains. Even though the end-use requirements for each application might be of significant differences, the same design principles do apply. Only the combination of innovative design, manufacturing control, optimization and new technology will lead to successful developments. Every material has its properties reported in technical datasheets. The key is how to achieve high material characteristics, which are the properties exhibited after material processing (transformation). Thus, we see how in even mature applications, like the air intake manifold or rocker covers, new and higher level of end-use performance can be achieved, or significant design integration can enhance multifunction assembly. The understanding of market needs and customer requirements are the fundamentals for determining the material selection and the feasibility. A successful development is reached when we are able to satisfy all needs at lowest possible cost. We must look beyond our own expertise and reach out for new boundaries that move technologies forward. This indeed requires synergies and cooperation of the entire supply chain.
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