DSM develops all-new plastic CAC end cap

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DSM, in collaboration with supplier Mahle, has developed a high-heat-resistant plastic for use in charge air cooler applications. The technology enables the ability to replace metal end caps, meaning better performance, efficiency and system costs.

Thanks to innovative materials in the DSM Stanyl Diablo OCD2300, including 50% glass fiber, the end cap can withstand continuous temperatures of up to 230°C. The component will be first introduced in to the Volkswagen Crafter.

With OEMs constantly looking for ways to improve engine performance and fuel efficiency, the company claims its thermoplastic technology in the Akulon and Stanyl Diablo offers high mechanical performance, long-term heat aging, as well as chemical resistance. This means that OEMs can reduce fuel consumption and carbon emissions, while retaining excellent tensile strength retention and impact resistance.

Jessica Wolf, project manager at Mahle, said, “For this project, we needed a material that could withstand continuous 230°C with excellent creep and fatigue performance. Stanyl Diablo OCD2300 was a perfect fit for the requirements given by the OEM. The only backup scenario was to design in metal, which would have higher costs and add significant weight.”

DSM engineered the Diablo technology specifically for use at extremely high continuous temperatures and is available with different glass fiber contents. The material can deliver a 3,000 hour, continuous use of up to 230°C, making it ideal for components such as welded air ducts, resonators and LCCAC integrated air intake manifolds where aging performance of the weldline is critical.

Kurt Maschke, air management at DSM, said, “Our complete portfolio of high-temperature plastics, combined with world-class technical support, allows us to serve customers with the best price/performance combination for extreme temperature requirements for all applications in the charge air system, such as charge air ducts, resonators, air intake manifolds and CAC end caps.”

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Dean has been with UKi Media & Events for over a decade, having previously cut his journalistic teeth writing and editing for various automotive and engineering titles. He combines extensive knowledge of all things automotive with a passion for driving, and experience testing countless new vehicles, engines and technologies around the world. As well as his role as editor-in-chief across a range of UKi's media titles, he is also co-chair of the judging panel of the International Engine of the Year Awards.

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