materials | 3D printing
PA6 powders are capable of performing reliably in a conventional metal turbocharged engine, where radiant temperatures can reach as high as 121°C (250°F). However, the plenum in the Polimotor 2 concept will encounter lower temperatures of 66-93°C (150-200°F), due to the low thermal conductivity of the engine’s largely plastic composition.
Above: An extrusion line for production of 3D print filaments at ColorFabb in the Nether- lands
as well as significantly reducing the tendency to warp. According to Covestro, Polymaker PC has high heat
Right: Covestro worked with
Polymaker to develop its PC-Plus and PC-Max
polycarbonates for 3D printing applications
resistance compared with existing 3D printing materi- als. The products can withstand temperatures of more than 100°C, making it suitable for lighting, engineering and all types of applications that require good structural stability when exposed to heat. The material is said to retain good mechanical strength under nearly all different deformation modes while also exhibiting high impact resistance and hardness. Polymaker PC can be post-processed by sanding, coating or other methods. Additional advantages include intrinsic flame retardance, optical transparency and resistance to chemi- cals and solvents. Polymaker PC-Max adds improved mechanical properties - increased toughness, in particular - making it suitable for mechanically demanding applications. Solvay is the principal material sponsor for
the Polimotor 2 project that aims to design and manufacture an all-plastic engine for competitive racing in 2016. The project target is to develop a four-cylinder, double-overhead cam engine that weighs between 63-67 kg (138-148 lbs), or about 41 kg (90 lbs) less than today’s standard production engine. The Polimotor 2 engine is to feature a 3D printed
Right: The
plenum for the experimental Polimotor 2
all-plastic race car engine is printed in a 3D-printable PA6 powder grade from Solvay
22
plenum chamber fabricated through selective laser sintering (SLS) using Sinterline Technyl polyamide 6 (PA6) powder from Solvay Engineering Plastics reinforced with 40% glass beads to enhance dimen- sional stability. The plenum is the pressurised chamber that uniformly distributes the air flow between the engine’s inlet and cylinders. The plenum in the Polimotor 2 engine will share similar specifications to those in production car engines, which are typically injection moulded in polyamide with 2-3 mm wall thickness to withstand the 2-4 bar of positive air pressure inside. Solvay says parts printed from Sinterline Technyl
COMPOUNDING WORLD | May 2016
PEEK performance Solvay Specialty Polymers’s KetaSpire PEEK is also to be used in the Polimotor 2 engine for a 3D printed fuel intake runner, which is fabricated by Arevo Labs using reinforced filament fusion technology. Used in both racing and production cars, intake runners are typically integrated with the engine’s plenum and provide a transition piece between the cylinder head and the plenum chamber. The intake’s function is to inject fuel into the air stream just as it enters the engine and its performance has a direct influence on the engine’s horsepower. Replacement of the original aluminium runner
with PEEK reduced the part’s weight by 50%. The specific material chosen for the Polimotor 2 is a custom-formulated grade of KetaSpire KT-820 PEEK reinforced with 10% carbon fibre. The material is claimed to offer good chemical resistance to automotive fuels as well as reliable mechanical performance at continuous-use temperatures up to 240°C (464°F). These qualities made it a highly suitable candidate for the Polimotor 2 fuel intake runner, which will encounter tempera-
tures close to 150°C (302°F) near the pistons. In addition to these two applications, the
programme will use Solvay polymers to develop up to ten engine parts. These include a water pump, oil pump, water inlet/outlet, throttle body, fuel rail and other high-performance components. Lehmann&Voss has developed its Luvosint materi-
als for laser sintering applications and claims to occupy a unique position in the market. “We are the first machine-independent material supplier for laser sinter powders,” says Dr Marcus Rechberger, Market Development Luvosint. “Our focus is on industrial
www.compoundingworld.com
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