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Charge Air Cooler with Plastic End Caps

High-Heat-Resistant PA Replaces Metal

Royal DSM has partnered with automotive system supplier, Mahle GmbH, Stuttgart, Germany, to replace metal end caps with high-heat-resistant plastics in charge air cooler (CAC) applications. This change has led to improved engine performance, better fuel efficiency and reduced system costs.

For the water-cooled charge air cooler of the VW Crafter Stanyl Diablo OCD2300 was the only material that could fulfill the OEM’s requirements (© DSM)

Metal end caps in CAC applications must withstand continuous temperatures up to 230°C, which limits the material choices. For this project, DSM’s Stanyl Diablo OCD2300 (a PA46 with 50% glass fiber) was used for Volkswagen’s Crafter light commercial vehicle.

The VW Crafter project required a water-cooled charge air cooler mounted directly on the engine, resulting in shorter cold charge air ducts, leading to improved engine performance. Stanyl Diablo OCD2300 offers an excellent combination of high mechanical performance, long-term heat aging at extremely high temperatures and good chemical resistance which made it “the” choice for this application. Jessica Wolf, Mahle Behr project manager for the Crafter ICAC, 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 back-up scenario was to design in metal, which would have higher costs and add significant weight.”

DSM engineered the Diablo technology specifically for extremely high continuous use temperatures and is available with different glass fiber contents. The latest grade - Stanyl Diablo HDT2700 - offers a best-in-class heat deflection temperature (HDT) under load of 267°C, which exceeds that of existing Stanyl Diablo grades. This material can deliver a 3000 hour, continuous use temperature 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.

As under the hood requirements become more extreme, especially for new developed engines to fulfill the EU7 requirements, Stanyl Diablo materials deliver not only robust performance, but also function integration and design flexibility while eliminating the need to return to metals. Stanyl provides up to 40% weight reduction versus aluminum, and its excellent processing characteristics reduce material and production costs.

Company profile

Royal DSM

P.O. Box 6500
Tel.: +31 45 578-2421
Fax: +31 45 578-2230

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