The combination of Stanyl® polyamide 46 from DSM and 3M™ Dyneon™ Fluoroelastomers has created a unique composite material to support the rising trend for lightweight automotive construction.
The lightweight vehicle parts are manufactured using an economical two-component injection moulding process followed by vulcanisation. Products made this way demonstrate high mechanical strength, are able to withstand high temperatures for extended periods and are resistant to the chemical impact of oil and fuels. This makes the lightweight construction composite ideal for use in the entire powertrain. It also eliminates the use of cleaning products, phosphating substances and bonding agents needed for traditional metal insert processing.
Watch an animation of the injection moulding process below:
Stanyl polyamide 46 from materials producer DSM N.V. and fluoroelastomers from Dyneon, a subsidiary of diverse technology company 3M, are high-performance materials that, when combined, form an excellent characteristic and performance profile for use in engines. Stanyl polyamide 46 retains its stable mechanical properties even at temperatures up to 200°C. With 80 percent less density than steel, it also substantially reduces the weight of vehicle applications.
The wide range of Dyneon Fluoroelastomers offers very high chemical resistance against oils, fuels and numerous other chemicals at temperatures up to 230°C. Stanyl polyamide 46 and Dyneon Fluoroelastomers are already used for many seals, gaskets and components in automotive powertrain and turbo applications.
Watch an animation of the molecular bonding concept below:
Simplified process through two-component injection moulding
The two-stage manufacturing process provides economic and environmental advantages. Suppliers currently process metal components using stamping processes, followed by chemical cleaning and various surface optimisation treatments. This requires cooling lubricants, cleaning agents, phosphate compounds and solvent containing primers.
Unlike time-consuming and labour intensive metal processing, it is possible to manufacture the new material combination using a two-component injection moulding process followed by vulcanisation. During this process the Stanyl polyamide 46 amino end groups enter into a chemically stable bond with the Dyneon Fluoroelastomers. This eliminates the cost of auxiliary materials as well as their disposal, and the simplified process increases quality consistency. During continuous production, the cycle time for the two-component process - as verified by the German Institute for Rubber Technology - is reduced to a mere 90 seconds per finished product. Including the post-vulcanisation process, the components are ready for installation after just two hours.
This makes the new material combination ideal for applications such as crankshaft covers, dynamic seals and gaskets. In addition, this innovation provides more freedom for new construction designs and assembly techniques as well as the integration of functions in the final application.
If you would like to know more about primer free bonding of FKM and PA 46, download the brochure by clicking below: