World first: Air intake manifold with integrated charge air cooler made from PA46

• 40% glass fibre reinforced polyamide 46
• Continuous-use temperature of 220°C
• CAC (Charge Air Cooler) integrated in AIM (Air Intake Manifold)

Royal DSM has taken another step forward in the use of thermoplastics in automotive high-heat zones. A recently-introduced hybrid sports car features the world’s first high-heat plastic air intake manifold (AIM) with integrated charge air cooler (CAC) in Stanyl Diablo, DSM’s high temperature resistant polyamide 46.

Peak temperatures up to 250°C

The injection moulded manifold operates at 220°C and withstands pulses of high internal pressure. DSM worked closely together with a leading system supplier to develop the AIM/CAC combination. The part is made in Stanyl Diablo OCD2100, which contains 40% glass fibre reinforcement as well as a specially developed and patented heat stabilizer. This grade has a continuous-use temperature of 220°C and is able to withstand peak temperatures up to 250°C.

Charge air cooler (CAC) integrated: reduction in air duct length and improved engine responsiveness

The engine makes use of an extremely high turbo pressure that results in a very high internal air temperature. To cool down the air stream, the engine developer has made use of one of the latest developments in turbo charging systems: a liquid cooled charge air cooler (CAC) which is integrated into the air intake manifold and delivers higher efficiency than an equivalent air-to-air cooler.

Integrating the CAC into the AIM reduces the air duct length and improves engine responsiveness. This makes it possible to deliver higher performance while still meeting the latest gas emission requirements. However, integrating the cooler into the AIM drives the internal air temperature up to 220°C in continuous use, with peaks up to 250°C. Integrated high temperature AIM/CACs have been produced before, but they have typically incorporated metal components for the manifold.

40% weight reduction versus aluminum

Stanyl Diablo polyamide 46 provides a weight reduction of up to 40% versus aluminum. It combines very good mechanical performance with high temperature resistance, retaining its high stiffness even under continuous-use temperatures of up to 220°C.

The AIM/CAC is assembled from several moldings using hot gas welding. Due to the material’s weld strength, the assembly is highly resistant to pressure pulsation loads. In addition, parts show good dimensional stability, and Stanyl Diablo OCD2100 produces parts with good surface finish, despite the high level of glass reinforcement.