Valve cover for Volkswagen 1.6 and 2.0 l
Valve Cover for Diesel Made by Foam Injection Molding
Valve covers for vehicle engines must comply with strict specifications concerning mechanical properties and dimensional stability. For components used in the engine compartment, high quality of surfaces has recently been added to these basic requirements. ElringKlinger AG in Dettingen an der Erms, Germany, produces the valve cover for Volkswagen 1.6 and 2.0 l Common Rail Diesel. Thanks to foam injection molding, the company has been able to master all problems in terms of technology and economy.
To achieve the necessary mechanical properties, an easy-flowing type of polyamide was employed as a basic material. The MuCell process (license: Texel Inc. in Woburn, Massachusetts, USA) makes sure the component’s dimensional stability is adhered to. This is important for two reasons: Firstly, a flat and warpage-free valve cover in place helps keep engine performance to a constant level. Secondly, the product consists of two parts joined by hot-gas welding, which would be difficult to carry out in case there was any warpage in the parts. Additionally, this combination of process and material makes high surface quality possible.
To ElringKlinger, the economic benefits involved in the MuCell process are at least just as important. Because the clamping force applied is below that of conventional injection molding processes, only smaller machines are required. Microcellular foaming – i.e. exactly measured quantities of nitrogen and carbon dioxide are added to the melt – means significant reduction in cycle times. Before the end of the year, ElringKlinger will start serial production of further types of MuCell valve covers.
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