Ultramid^® Endure

Ultramid^® Endure with higher stiffness and heat aging resistance for even more metal replacement in the engine compartment

The high-performance plastic Ultramid^® Endure is to date the most heat-resistant, polyamide-based injection-molding material available in the market. For example, the grade Ultramid^® Endure D3G10 with 50 percent glass fibers offers a considerably increased stiffness at elevated temperatures:

Identifiable by its modulus of elasticity: Over a period of three months (approx. 2,200 hours) of heat aging, the stiffness of Ultramid^® Endure D3G10 remains stable at a high value of about 17,000 MPa, measured as a modulus of elasticity in accordance with ISO 527-2 (1993) at 23°C. Prior to the aging test, the material shows a modulus of elasticity of around 4,000 MPa at 220^°C, about 30% more than the less stiff D3G7 version.

Ultramid^® Endure is suitable for components close to the engine in the charge air duct of turbocharged engines in particular. The material offers a continuous-service heat resistance temperature of up to 220^°C for applications requiring maximum stiffness.

This means that even more metal can be replaced in the engine compartment. In contrast to high-priced specialty plastics, using Ultramid^® Endure results in a considerable reduction of the system costs.

Heat-resistant gap closure – Ultramid^® Endure now also available as a blow-molding grade

BASF is closing the gap between the turbocharger and the intercooler with the market launch of the blow-molding grade Ultramid^® Endure D5G3 BM. The new blow-molding grade with a glass fiber content of 15% has a level of heat aging resistance which is just as high as that of the injection-molding grade, is easy to process in the suction blowing method and also shows excellent acoustic properties.

Properties of the blow-molding grade Ultramid^® Endure D5G3 BM:

• Excellent heat aging resistance under continuous loading at up to 220^°C
• Excellent processability
• High hose stability
• Good swelling
• Outstanding surface
• Supply of regranulate without any noteworthy influence on the processing

Ultramid^® Endure – polyamide in continuous use in modern engine concepts

The trend towards increased efficiency in automotive construction leads to a continuous rise in the temperatures in the engine compartment. As a result, automotive manufacturers today are attempting to improve the energy efficiency of vehicles by various means including turbocharged engines. In turbocharged diesel engines, for example, operating temperatures of up to 220^°C and temperature peaks of up to 240^°C are common in the area between the turbocharger and intercooler.

Acoustics as a brand-defining factor

The subject of acoustics has now become a brand-defining factor and is therefore assuming a real significance in the automotive industry. New engine concepts and continuously rising demands from customers and legislators call for acoustically advantageous materials. Ultramid^® Endure boasts excellent damping behavior and is therefore ideally suited to solving acoustic challenges.

High-performance plastic as replacement for metal

The heat-resistant Ultramid^® Endure is an ideal alternative to metal and other plastics such as PPS. The high-temperature polyamide is suitable for all components which are exposed to a higher continuous thermal loading over a prolonged period of time.

Possible applications include all components of the charge air duct such as:

• Resonators
• Sensors and actuators
• Intercooler intakes
• Intake manifolds
• Charge air pipes