Engineering Plastics and Polyurethane Systems for engine, powertrain and chassis components

When it comes to the development of challenging components and materials for powertrain and chassis, BASF has been a globally reliable and accepted partner for the automotive industry for decades. The use of engineering plastics, polyurethane systems and additives leads to advantages like weight reduction, functional integration, improved NVH-performance (NVH=noise, vibration, harshness) and cost savings.

Engineering Plastics and Polyurethanes

Engineering plastics such as Ultramid^®, Ultradur^® and Ultraform^® as well as polyurethane systems like Elastoflex^® and Elastofoam^® are particularly suitable for components around the engine and along the chassis: With these materials, components along the entire charge-air duct can be designed, but also cylinder head covers, oil pans, engine mounts, transmission and front end carriers, engine covers, different chassis parts as well as components in the cooling circuit and within the fuel system. BASF plastics contribute significantly to fulfilling the diverse and increasing demands of lightweight construction, functional integration, acoustics and safety.

The BASF polyamide Ultramid^® is particularly suited for components in the engine compartment and in the chassis as it meets further demands of the automotive industry: global specification of uniform materials from local production, tailor-made grades for different temperatures, pressures and loadings, a high product quality as well as technical support for part simulation, application development and realistic parts testing.

Powertrain: Tailor-made polyamide portfolio for the charge air duct in modern combustion engines

Ultramid^® grades for various demands on pressure and resistance up to 220°C
Selected polyamides available with globally consistent specifications, locally manufactured

The reductions in fuel consumption and emissions which are prescribed by law in many countries are forcing the automotive industry to act. Besides developing alternative drives, the optimization of traditional combustion engines continues to play a key role. Downsizing results in higher pressures and temperatures, especially in components that carry air behind the turbocharger. BASF is responding to this development in engine designs with a consistent portfolio of PA6 and PA66 grades that meet the higher demands on the materials, their mechanical properties and temperature resistance. Depending on the base polymer and stabilization system, the materials are resistant to heat aging up to 220°C and show excellent burst pressure and weld strength. This means the part developer can be provided with the optimum material for each of the different components in the charge-air duct that offers the best value for money. Selected grades are based on global specifications: They are supplied worldwide from local manufacturing facilities, with uniform material properties and a high level of quality.

Ultramid^® Endure has already been successfully used in several automobiles

Our versatile PU systems for powertrain parts

With their versatile properties, our PU systems can make powertrain parts safer, lighter and more robust. BASF polyurethanes can be adjusted to many different densities, they can be flexible or stiff, they resist hot and cold temperatures as well as many aggressive media.

Powertrain: Engineering plastics for fuel cells

Alongside the continued development of cars with more efficient internal combustion engines, chemistry is making an important contribution to a number of different electric drive concepts. Further progress is also being made in the field of fuel cells. In close cooperation with Joma-Polytec and Mercedes-Benz Fuel Cell GmbH, a subsidiary of Daimler AG, the engineering plastic Ultramid^® has successfully been used to manufacture a number of fuel cell system components. This innovative solution is being used as standard in the new Mercedes GLC F-CELL, which combines a fuel cell with a rechargeable lithium-ion battery.

Plastics increase efficiency – not only in hybrid, plug-in and electric vehicles but also in internal combustion engines. The high quality and safety requirements in the automotive industry place huge demands on materials. With versatile and sophisticated polyamides (Ultramid^®), polybutylene terephthalates (Ultradur^®), polyphthalamides (PPA), and the plastics polyoxymethylene (Ultraform^®) and polyethersulfone (Ultrason^®), BASF is able to keep pace with car manufacturers’ latest developments, while also setting innovative trends. Technical properties and high functionality are key here. For the Mercedes GLC F-Cell, it is the all-round excellence of Ultramid’s properties that counts: good thermal and chemical resistance, dynamic stiffness, impact strength, and good long-term performance.

In view of the unique material structure, and on the basis of intensive material analyses of the chemical and mechanical resistance, the partners ultimately decided on the tailor-made Ultramid^® grades A3WG10 CR and A3EG7 EQ. Following successful testing of all components, the two glass fiber-reinforced Ultramid^® grades are now being used as standard to manufacture the anode- and cathode-end plate in fuel cells. Ultramid^® A3EG7 EQ is an ideal material, given the exceptional purity requirements associated with sensitive applications in the electronics industry. In the case of the media distribution plate and the water separator unit, which is exposed to a wide variety of media through the cooling water, air and hydrogen channel, this Ultramid^® grade offers excellent resistance, while at the same time meeting all requirements regarding the purity of the material.

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Watch the animation on our solutions for fuel cell applications.

Chassis: Lighweight design through metal substitution and functional integration

Highly filled polyamides for engine carriers and top mounts, frontends and structural stiffeners

Cellasto<sup>®</sup> and Ultramid<sup>®</sup> Top Mount

World's first top mount with polyurethane bearing and polyamide housing

BASF combines plastic specialties Cellasto^® and Ultramid^® for the first time
Globally available top mount is 25 percent lighter than aluminum die-cast version with rubber

BASF is now expanding its expertise in top mounts to enable car manufacturers an optimum combination of weight savings, pleasant acoustics and vibration damping. The unique NVH (noise, vibration, harshness) solution is made possible by combining two of BASF's plastic specialties: the micro-cellular polyurethane elastomer Cellasto^® and the highly glass-fiber reinforced polyamide Ultramid^® A3WG10 CR. The top mount with the Cellasto^® element and the Ultramid^® housing is around 25 percent lighter than conventional aluminum die-cast versions with rubber. It was developed and optimized for serial production using BASF's simulation tool Ultrasim^®.

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Specific Ultramid^®Grades

Further Ultramid^®specialties for powertrain and chassis parts

Brochure

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First top mount made of Cellasto^® and Ultramid^®

Computer Simulation with Ultrasim^®

Ultrasim^® – the Versatile, Flexible CAE Tool from BASF for Innovative Parts Using BASF Plastics!

Our assessment of component concepts ranges from the selection of suitable BASF materials and the corresponding material models to the virtual prototype, to the optimal production process, to the finished serial component. Ultrasim^® allows you to design your components for specific requirements – for high-stress, efficient, and light components and your long-term market success!

Ultrasim^®

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Wide Product Range

We offer a comprehensive range of products with a broad variety of property profiles. Find the right product for you!

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Basotect^®

Sound absorption, fire resistance, thermal insulation or abrasiveness: Basotect^® combines many requirements for a high-performance foam in one product. In the construction, automotive and transport sectors, but also in consumer applications, Basotect^® provides a great variety of options.

Elastofoam^®

Elastofoam^® is especially distinguished for its decorative surface finish. The integral foam is extensively employed in the automotive and furniture industries producing seats, steering wheels, gear shift knobs as well as in engine compartment heavy duty uses for cable sheathing, grommets and gaskets in filter elements.

Elasturan^®

Elasturan^® cold-cast elastomers are two-component PU high-performance systems. Elasturan^® HP is also a new PU system is an extremely efficient material for manufacturing specialised parts in especially high-load areas of industry.

Ultradur^®

Ultradur^® is BASF’s brand name for its line of partially crystalline, thermoplastic, saturated polyesters derived from polybutylene terephthalate (PBT). They are employed as materials for high-quality technical components in many industry sectors.

Ultradur^® HR

Hydrolysis-resistant PBT for hot-damp environments

Ultraform^®

Ultraform^® is the brand name for BASF’s polyoxymethylene product range. It comprises engineering plastics designed for use in sophisticated components. Ultraform^® is suitable for many applications in automotive manufacturing, in medical technology, for household and recreation, but also for machine and plant construction.

Ultramid^®

The engineering plastic Ultramid^® is based on PA6 and PA66 as well as on various co-polyamides such as PA66/6. The range also includes PA610 and partially aromatic polyamides such as PA6T/6. Ultramid^® is noted for its high mechanical strength, stiffness and thermal stability.

Ultramid^® Endure

Ultramid^® Endure is a glass fiber-reinforced polyamide that combines excellent heat aging resistance with the good processing properties of PA 66.

Successful Customer Projects

Proven in practice: These case studies demonstrate the successful use of our products in customer projects.

Engineering Plastics and Polyurethane Systems for engine, powertrain and chassis components