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engineering thermoplastics | Innovation


overcome with the Pulse GX50 PC/ABS blends, which produce parts with low gloss. Pulse GX50 has a density around 4% less than other


Above: DSM is targeting its heat resistant Diablo PA4,6 and PA6,6 grades at automotive under bonnet applications


portfolios are aimed at applications in automotive engine compartments where the drive to create more fuel-efficient designs has resulted in reduced space and higher temperatures under the hood. DSM says this more demanding environment is due, in part, to the inclusion of features such as improved pedestrian impact protection and the increasing use of turbocharg- ers and superchargers. Diablo technology provides a significant improve-


ment in long-term temperature resistance in compo- nents such as air intake manifolds with integrated inter- coolers, ducts, charge air cooler end caps, mixing tubes and resonators used in the latest car engines. The latest HD2700 version of Stanyl Diablo polyamide 4,6 is able to withstand a continuous use temperature of 230°C, while the new Akulon Diablo HD2500 withstands a 220°C continuous-use temperature. Both also have improved resistance to short-term high temperature peaks as measured by deflection temperature under load (DTUL): 267°C for Stanyl Diablo HD2700, 245°C for Akulon Diablo HD2500. DSM says the new grades also have improved


Right: Mercedes uses Pulse


GX50 PC/ABS blend from


Trinseo in its C-Class interiors


resistance to chemicals and gases in EGR (exhaust gas recirculation) systems. They provide good processing properties and create finished parts with high burst pressure weld-line strength as well as very good surface finish. At Trinseo, European vice president for performance


plastics Dagmar van Heur highights the global trend in automotive to eliminate the costly painting step in production of high-visibility plastics interior parts wherever possible. “You need a material that gives a robust surface even without the paint,” he says, adding that Trinseo offers a high-flow PC/ABS blend, Pulse GX50, for such parts. While van Heur says PC/ABS is still the “material of


choice for car builders” in terms of fit and finish, he adds that in the past the inherent high gloss and challenges in terms of hydrolytic stability and UV resistance made painting a neccessity. That has been


68 COMPOUNDING WORLD | July 2015 www.compoundingworld.com


blends, which translates down the line into fuel savings. Weight reduction was the main aim of the original development, but Van Heur says the advantage of the total system cost saving through elimination of the painting step – up to around 35% – is more compelling for automotive specifiers. The new grade is intended mainly for interior applications, but its good laser-weld- ability resulted in its selection as the backing material for the “’Airbumps” on the Citroen C4 Cactus (see the article on page 76 of the February 2015 issue of Compounding World for more details of this application).


Integrated processes Meanwhile, Bayer MaterialScience is developing additional grades of polycarbonate and PC-based blends for a variant of in-mould decoration (IMD) where thermoplastic injection moulding is combined with poly- urethane reaction injection moulding (RIM) to provide the surface. In recent years, Engel and Krauss-Maffei have both demonstrated this hybrid technological solution for production of automotive parts such as instrument panels and the like. Eckard Wenz, director of marketing for polycarbonates for global mobile applications, says the Bayblend T85SG (Skinning Grade) is formulated to provide good adhesion to the PUR decorative coating. Wenz says conventional PUR coating systems, even


water-borne ones, contain some solvent to get an interpenetrating layer between the substrate and the paint. “With IMD, you are working with 100% polyure- thane, so there is no chance to include something to increase adhesion by, for example, swelling the substrate,” he says. “Therefore, something else needs to be done to increase adhesion. You need to balance the system from the PUR and the TP side, so you can get adhesion that will pass tough long-term tests for


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