in Fluoropolymers Dyneon your preferred partner 3M Advanced Materials Division 3M Dyneon Fluoroelastomers in Automotive Applications

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Darleen Powell
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3 Why using fluoropolymers in automotive applications? Industry Growth Global estimate 250 Million vehicles Automotive industry continues to grow Population increase & regional expansions Automobile remains our preferred mode of transportation. Climate Considerations Global/Regional legislations on CO2 emission reduction Need to improve fuel economy Alternative engine concepts & fuel types Hybrid, Electric, Fuel Cell Combustion Engine will remain the most popular at least for next decade. Emissions targets met with combinations of alternate fuels, light weight solutions & new innovations. 3

4 Why using fluoropolymers in automotive applications? Good mechanical properties Excellent temperature resistance Outstanding chemical resistance Excellent weatherability and ozone resistance Very low permeation Good flame resistance Low impact resilience 4

5 Fluoropolymers by market segment - automotive Others Fuel Systems Air Management Powertrain 5

6 FKM by application segment - automotive Metal Coated Gaskets Hoses O-Rings Valve Stem Seals Shaft Seals Fuel Injector O-Rings Molded Goods/Gaskets 6

7 Automotive Application Structure Fuel Systems Powertrain Air Management Chassis Electronics Misc. Fuel Cap Engine Air Intake Sys. Suspension Wire & Cable Tank Transmission Exhaust System Brakes Fuel Transport Turbocharger Wheel Steering Fuel Injection 7

8 Automotive Application Structure Fuel Systems Powertrain Air Management Chassis Electronics Misc. Fuel Cap Engine Air Intake Sys. Suspension Wire & Cable Tank Transmission Exhaust System Brakes Fuel Transport Turbocharger Wheel Steering Fuel Injection 8

9 Fuel System Segment Definition Fuel Tank Fuel Injection Fuel Transport 9

Fuel System Application Overview Fuel Cap 1 2 9 5 4 6 3 8 7 11 1 2 Fuel Cap Main Seal Fuel Cap Pressure Relief Valve Seal 10 11 Fuel Transport Fuel and Vapor Lines Quick connector O-rings 10 Fuel

10 Fuel System Application Overview Fuel Cap Fuel Cap Main Seal Fuel Cap Pressure Relief Valve Seal Fuel Transport Fuel and Vapor Lines Quick connector O-rings 10 Fuel Tank Fuel Injection (Engine) Fuel Filler Hose Fuel Tank Fill Limit Vent Valve Seal In-tank Fuel Supply Hose Fuel Pump Seal Fuel Filter Seal Sender Seal Fuel Tank Rollover Valve Seal Fuel Rail Seal Fuel Rail Crossover Line Fuel Injector Seals 10

contact Some OEMs introduce capless systems = seal is attached to the tank lid Trend to higher fluorine FKM 1 Relevant Specifications: BMW:

11 Fuel System Fuel Cap Main Seal Application Requirements: Resistance against fuels / fuel volatiles Low temp performance down to -40 C High temp performance not critical Permeation Resistance Trends impacting the application: New fuels / biofuels Shift from NBR to FKM in case of direct fuel contact Some OEMs introduce capless systems = seal is attached to the tank lid Trend to higher fluorine FKM 1 Relevant Specifications: BMW: GS to 3 (General Spec) Opel: GMW15176; GMW15983, VW: VW Material: Part Function: Dyneon FKM Terpolymers Sealing of tank cap against filler neck 11

12 Automotive Application Structure Fuel Systems Powertrain Air Management Chassis Electronics Misc. Fuel Cap Engine Air Intake Sys. Suspension Wire & Cable Tank Transmission Exhaust System Brakes Fuel Transport Turbocharger Wheel Steering Fuel Injection 12

13 Powertrain Segment Definition Combustion Engine Transmission 13

Powertrain Application Overview 15 16 19 20 21 Cylinder Head Gasket Valve Stem Seal Valve

Crankcase Ventilation (PCV) Hose Oil Pump Seal 15 16 17 18 TRANSMISSION Differential Shaft

14 Powertrain Application Overview Cylinder Head Gasket Valve Stem Seal Valve Cover Gasket COMBUSTION ENGINE Cam Shaft Seals Crankshaft Seal Positive Crankcase Ventilation (PCV) Hose Oil Pump Seal TRANSMISSION Differential Shaft Seal Wheel Shaft Seal Transmission Seal Rings Transmission Shaft Seal

Powertrain Crankshaft Seals Application Requirements: Good thermal resistance up to 150 C Chemically resistant against engine oils and blow by gas Excellent metal

targets Alternative technologies in use: FKM / PTFE Compounds FKM > design is changing to f-less types (no spring) Relevant Specifications: VW TL 52304, VW

15 Powertrain Crankshaft Seals Application Requirements: Good thermal resistance up to 150 C Chemically resistant against engine oils and blow by gas Excellent metal bonding Low friction / low wear Acceptable dry running properties Trends impacting the application: Weight reduction Friction reduction needed for achieving CO 2 targets Alternative technologies in use: FKM / PTFE Compounds FKM > design is changing to f-less types (no spring) Relevant Specifications: VW TL 52304, VW , VW DBL 6251 BMW: GS to 3 (General Spec) Material: Part Function: Dyneon FKM Di-/Terpolymers Dyneon PTFE Compounds Keep oil in the engine block 23 15

16 New SealingTechnology 3M Dyneon PTFE & TFM PTFE A new class of high performance 3M Dyneon Dyneon CompoundsNew 3M Compounding innovative Expertise Your Benefit! filler systems

17 The world of fillers becomes spheric Standard Glass Fillers New Microspheric Fillers

18 Benefits Serving Rotary Seal Applications Optimised seal thickness Remarkably low leakage Optimised friction & wear behaviour Improved physical properties Smoother surface finish higher production yield enviromentally friendly longer service life & less fuel consumption better performance easy to process * compared to: 3M Dyneon PTFE Compound TF 4105 freeflow 25% glass fibres

19 Application properties Rotary shaft seals with reduced thickness (> 10%) Friction torque Wear resistance Leakage 25% Improvement* 18% Improvement* 70% Improvement* * compared to: 3M Dyneon PTFE Compound TF 4105 freeflow 25% glass fibres

20 Automotive Application Structure Fuel Systems Powertrain Air Management Chassis Electronics Misc. Fuel Cap Engine Air Intake Sys. Suspension Wire & Cable Tank Transmission Exhaust System Brakes Fuel Transport Turbocharger Wheel Steering Fuel Injection 20

21 Air Management Segment Definition Air Intake Section (incl. Turbo Charger) Exhaust System 21

22 Air Management Application Overview 34 Throttle Seal 35 Muffler Seal(s) 36 Oxygen Sensor Seal 30 Turbo Charger Hose 31 Turbo Charger Hose Seal SCR Injector Seal 32 Turbo Charger Seal 38 EGR Stem Seal 33 Air Intake Manifold Gasket 39 EGR Flap Coating 22

Air Management Turbo Charger Hose Application Requirements: Good extrudability (co-extrusion) Excellent bonding to silicones Excellent resistance to fuels and oils Resistance to high temperatures (>

23 Air Management Turbo Charger Hose Application Requirements: Good extrudability (co-extrusion) Excellent bonding to silicones Excellent resistance to fuels and oils Resistance to high temperatures (> 200 C) Resistant to acetic acid and H 2 SO 4 Good tear propagation resistance: Trends impacting the application: Use of turbocharger is increasing due to downsizing of engines OEMs try to reduce length and thickness of TCH for cost reasons Integration of charge air cooler in air intake manifold Relevant Specifications: VW: TL 52600A, VW Mercedes: DBL 6251 Material: Part Function Dyneon FKM Terpolymers (BF6 or PO cure) Connecting the turbocharger to the charge oil cooler with a flexible connection 30 23

3M Dyneon Fluoropolymers Innovations Primer free

The Concept Processes Primer Free Overmolding Classic

2K overmolding concept Stanyl & 3M Dyneon

single process (from raw materials to a finished part

25 The Concept Processes Primer Free Overmolding Classic two step concept two machine overmolding principle New 2K overmolding concept Stanyl & 3M Dyneon Fluoroelastomers bonded parts can be produced in a single process (from raw materials to a finished part with one tool) Proven by DIK (German Institute for Rubber Technology)

26 Your Benefits Weight reduction Time saving Cost reduction Design freedom & New functions Increased sustainability Quality improvement

automotive industry Traditional elastomeric sealing

28 Changing Fuel Compositions Fossile fuels, made from crude oil, are finite and contribute to CO 2 emissions Alternative fuels, like Bio-ethanol and Bio-diesel, help to reduce CO 2 emissions as well as the dependency on fossile fuels and meet legal requirements of the automotive industry Traditional elastomeric sealing materials (e.g. nitrile butadiene rubber) show limitations related to alternative fuels in sealing and barrier performance Where other elastomer products fail, 3M Dyneon Fluoroelastomers are able to provide safer sealing solutions 28

29 Fuel test conditions Volume Swell (%) of FE 5640Q (66% F Dipolymer) in FAM A over time Extrapolated C 40 C 60 C 70 C C 60 C C 40 C 29

30 Fuel test conditions Volume Swell (%) of FE 5840Q (70% F Terpolymer) in FAM A over time Extrapolated 23 C 40 C 60 C 70 C C 60 C C 40 C 30

31 Fuel test conditions Question: will an o-ring exposed to fuel from only one side swell as much as a fully emerged o-ring? FC MT 23 C 1000 hrs FAM A Volume Swell 17% FAM A air Volume Swell 12% C 1000 hrs

the fluorine content permeation and volume swell in fuels reversibly change with temperature the ultimate

32 Fluoroelastomers are specially designed to meet the challenges of demanding applications. Facts: volume swell in regular gasoline and biodiesel is generally low for all fluoroelastomers depending on the fluorine content permeation and volume swell in fuels reversibly change with temperature the ultimate swell in regular gasoline of a fluoroelastomer sealing is achieved after >1.000 hrs at room temperature or after 168 hrs at 60 C 32

Fuel Resistance Aggressive Gasoline 60 Volume Swell (%) after 168 hrs at 60 C 50

Content Bisphenolic curable Medium Fluorine Content Bisphenolic curable Low

33 Fuel Resistance Aggressive Gasoline 60 Volume Swell (%) after 168 hrs at 60 C FPO 3731 MIP 8740 FE-5530 FE-5830Z Peroxide curable High Fluorine Content Bisphenolic curable Medium Fluorine Content Bisphenolic curable Low Fluorine Content Bisphenolic curable High Fluorine Content FAM B CE10 CE50 CE85 CE22 CM30 33

34 Chemical Resistance of Fluoroelastomers Physical Effects Percent of Fluorine Weight % Fluorine 66% 68% 70% Fluid with low Physical Effects e.g. ASTM oil Nr. 3 2,5 % 2 % 1,8 % Volume Swell, % ( C) Fluid with strong Physical Effects e.g. Methanol 100 % 35 % 5 % Volume Swell, % ( C) TR 10, C (ASTM D 1329) -18 C -11 C - 5 C 34

35 Chemical Resistance of Fluoroelastomers Physical Effects Crosslinking Density on volume swell (immersed C Methanol) DyneonTM Dipolymer (66% F) Curing Agent (Bisphenol AF) Standard Formulation A B C ODR 177 C, 3 ARC, Micordie, 100 CPM MH (inch.pounds) 7,3 14,7 22,6 Volume Swell in Methanol (after C) 214 % 108 % 70 %

36 Methanol + Water vs. FKM MeOH Volume Swell 168 hrs at 23 C FC 2174 FX ,1 0,25 0,5 1 2,

37 Methanol + Water vs. FKM MeOH Volume Swell 168 hrs at 60 C FC 2174 FX ,1 0,25 0,5 1 2,

38 Methanol + Water vs. FKM Structure of Methanol CH 3 CH 3 O O H H H Solubility parameter (cal /cm3) Methanol as polyether structure: ~ 10 Methanol (at elevated temp.): 14,5 O CH 3 n Fluoroelastomer low fluorine: 8,7 Fluoroelastomer high fluorine: 7,1 38

permeation The swell of fluoroelastomers in methanol is higher at lower than at increased temperatures Ethanol and butanol

39 Fluoroelastomers are specially designed to resist alternative fuels. Facts: Traditional sealing materials like nitrile rubber do not fulfill the requirements and present challenges related to permeation The swell of fluoroelastomers in methanol is higher at lower than at increased temperatures Ethanol and butanol containing fuels (e.g. CE 22) do not reduce the sealing performance of fluoroelastomers High fluorine containing fluoroelastomers resist methanol containing fuels (e.g. FAM B) 39

40 Fuel Resistance Biodiesel (RME & SME) FPO Volume swell C RME Hardness change RME Volume swell C SME Hardness change SME FPO 3741 FE 5830Z 40

volume swell in contact with degraded biodiesel or fuel residuals Even at elevated temperatures selected 3M Dyneon Fluoroelastomers do not

41 Fluoroelastomers are specially designed to perform in biofuels. Facts: Biodiesel (RME / SME) starts to degrade under influence of temperature, air exposure and water Standard fluoroelastomers show higher volume swell in contact with degraded biodiesel or fuel residuals Even at elevated temperatures selected 3M Dyneon Fluoroelastomers do not compromise on sealing performance, independent if the fuel contains RME or SME Fluoroelastomer formulations without acid acceptors can lead to higher volume swell of the seal in ammonia or urea solutions (e.g. ad blue) 41

42 The Right Choice 3M Dyneon Fluoroelastomers are the right choice for demanding current and future fuel system applications 42

3MTM DyneonTM Fluoroelastomers. Fluoroelastomers for SCR systems. Improved performance in AdBlue systems at high temperatures.

3MTM DyneonTM Fluoroelastomers Fluoroelastomers for SCR systems. Improved performance in AdBlue systems at high temperatures. Introduction Why AdBlue technology? In the past few years there has been a