Powertrain and Engineering Plastics

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1 Powertrain and Engineering Plastics Materials to Reduce Mass and Boost Performance Patrick Granowicz DuPont Automotive Engine Covers Segment Manager Troy, MI Franz Spitznagel DuPont Automotive Oil Pan Global Segment Manager Germany What we ve learned, where we can go together

2 Engine Design and Function a 30 Year Revolution in Engineering Plastics 2 We ve come a long way!

3 3 Engineer s Dreams Plastics Possibilities Add function, not mass... Lower tooling cost.. Achieve 100% reliability. Integrate parts for low cost.. Beat the heat... Improve ease of assembly... Improve performance. Weight reduction ~ 40% <½ the tooling cost Predictive Engineering Multi-function design ease Integrated engine cooling Snap fits, packaging via complex geometries Improve fuel economy with lower emissions, reduce NVH

4 4 Engineering Plastics Firsts in Powertrain DuPont materials examples for ICE from the past to the future New AIM Oil Pan Front cover Integrated AIM-EGR Emissions Canister Fan GOR and Shrouds Expansion Tanks Cyl. Head Covers AC Pulley Air ducts Resonators Air Intake Manifolds Hot-side Air Ducts Water Pumps Turbo chargers Exhaust EGR Cooling Muffler System AIM

5 Zytel vs. Metal - Weight Factor Wall thickness Density Weight factor (SG*Th) Sheet Metal Al sand cast Aluminum die cast Mg ZYTEL 35% GF

6 6 Cost and Productivity Comparison Tooling Investment Flexibility Part cost lifetime production unit in production T-Plastic Die Cast AL Sand Cast AL Quantity dependant Die Cast Mag Sheet Metal * * high quantities f.e > 1MM Key: + higher; - lower

7 Powertrain Engine Cylinder Covers 7 Chrysler First Rocker Cover prototype already in 2k Porsche Boxster- First EU Rocker Cover Fastest SOP ever 30% weight saving Adequate cost saving BMW M52 -First high mass, high complex system 30% weight saving Attractive cost saving New generation 2k gasket for radial sealing?? Mucell Technology

Air Intake Manifolds are One of the Highest Volume Applications for

prototypes and installs lost core process in Troy lab GM introduces

Porsche launches 1 st European AIM In DuPont Zytel World s largest

to integrate more functions and high EGR temps for thinner walls,

8 Air Intake Manifolds are One of the Highest Volume Applications for Engineering Plastics DuPont Troy machines prototypes and installs lost core process in Troy lab GM introduces 3800 Manifold in DuPont Zytel with 2 piece welded design. Porsche launches 1 st European AIM In DuPont Zytel World s largest AIM for Ford Mustang In DuPont Zytel Air intake manifold in HTN PPA to integrate more functions and high EGR temps for thinner walls, higher temperature. VW: The charge-air cooler is incorporated into the intake manifold

9 Continuous Improvement in Weight, Cost Savings with Performance Increases for Oil Pans 9 o First prototypes in U.S. Functional prototypes in E.U. First commercial part for Daimler made by Bruss 2nd generation with functional integration made by Elring Klinger 3rd generation module with full integration made by Mann+Hummel

10 Air ducts, from - 40 C to C Hytrel and Zytel blow molding - great tools for cost and weight 10 Bracket Assy. Hose Assy. Pipe Duct Assembly Total Weight 2.8kg Clamp Hose

11 6-8 Speed Transmissions - Real Need for Weight-Savings 11 Electronic transmission control system & modules Zytel 70G35 HSLX Transmission oil pan Zytel 70G35 GM 6-Speed transmissions use Hytrel for ATF baffle and seal to reduce fluid aeration and allow fluid-fill for life. Seals in Vespel parts

12 New Opportunities for Weight Saving with High Performance Plastics 12 Front cover, Zytel ; Zytel HTN PPA EGR Cooler units Zytel HTN - PPA Turbocharger housing Super-tough Zytel + Zytel HTN PPA Zytel Toyota Prius HTN51G35HSLR Plastic muffler in Zytel HTN PPA

13 13 New Powertrain Trends CO2 / Emissions Influence Change Small engines - down to 2 cylinder Effective ICE fuel consumption Bio-fuel HEV, EV, Hybrid diesel plus clean fuel Turbos/Bi-turbos for small diesel and fuel engines Modular approach for efficiency & savings (VW approach)

14 14 DuPont Technical Support Material Development Process Development and Processing Support Application Development SI Process Design Assistance Design Innovative System Solutions Processing Material Formulation

15 15 DuPont Engineering Polymers CAE Resources Modeling Unigraphics Solid-Works PATRAN ANSA HYPER MESH CATIA Moldflow Analysis ABAQUS ANSYS MARK LS-DYNA Moldflow Hardware Local Workstations High Performance LINIX Cluster

16 16 DuPont Engineering Polymers CAE Solutions Injection Molding Analysis Filling Cooling Shrinkage Fiber Orientation Warpage Structural Analysis Static Stress Dynamic Stress Impact NVH Analysis Acoustic Frequency Response Noise Radiation Noise Penetration

World s 1 st Pass-Car Oil Pan in Nylon Winner 2008 SPE Most Innovative Use of Plastics Award Daimler 4 cylinder diesel engine oil pan DuPont Zytel 70G35

17 World s 1 st Pass-Car Oil Pan in Nylon Winner 2008 SPE Most Innovative Use of Plastics Award Daimler 4 cylinder diesel engine oil pan DuPont Zytel 70G35 HSLR A4 17 Integration in future oil pan models could include: oil pick-up pipe, oil level switch, oil filter and other oil return components or oil pumps.

18 CAE Tools for Daimler Oil Pan Mold Filling Impact Analysis 18 Accelerations Dynamic Structural Analysis Acceleration [m/s2] Order 2.5 Order 3 Order 4 Order 6.5 [rpm]

19 Materials: Where We Can Go With You CaCL resistance Dimensional stability Electrical friendly resins Flammability to V0 Greater heat resistance Hydrolysis resistance Renewably Sourced e.g.

19 19 Materials: Where We Can Go With You CaCL resistance Dimensional stability Electrical friendly resins Flammability to V0 Greater heat resistance Hydrolysis resistance Renewably Sourced e.g. Zytel RS 6,10 resin (47% renewable content) for radiator end tanks Super productivity materials OTHER NEEDS? More than 1/3 of our product offering is new over the past 5 years Denso radiator end tanks of Renewably Sourced Nylon 6,10

20 20 Materials Choice is Driven by Engineering Needs Performance Vamac /Viton Elastomer Zytel Hytrel Crastin Zytel HTN PPA Zenite Tefzel LCP PTFE Vespel PI Minlon Crastin PBT Rynite PET Cost

21 21 High Temperature Heat Aging - Polyamides High Performance resins family >220 C Zytel HTN PPA <220 C <200 C <190 C <180 C <160 C Zytel 70G35HSLRA4 Zytel Zytel 70G35 HSLX New DuPont PA material family coming in 2010 EFE DuPont resins for Powertrain

22 22 Choosing the Right Material for the Right Reasons Thoughness Processing window 10 8 Surface appearance Dimensional stability 6 4 AOA heat aging 170 C, 1000h Warpage 2 AOA heat aging 150 C, 3000h Chemical Resistance Glycol resitance Hot oil resitance HSLB HSLR HSLX HTN Zytel 70G35 grades, Zytel HTN 51G35

23 Superflow, Superstiff and Mucell Materials 23 Super flow material for thin wall technology Zytel 70 G35 HSLRA4

24 24 Superflow, Superstiff and Mucell Materials Super Stiff material for Structural Applications Zytel HTN 51LG50

25 25 Superflow, Superstiff and Mucell Materials 2 Mucell for weight savings and productivity gains

26 26 The World's First Hybrid Vehicle Tesla: the first full electrical sports car Lohner Porsche: the first hybrid vehicle Ferdinand Porsche built the first standard hybrid power unit in His Lohner-Porsche featured a combustion engine as well as an electric hub motor and could store energy in a battery. Stay Tuned for the Upcoming Segment Vehicle Electrification

27 27 Materials to Help Electrify Vehicles Hitoshi Shioya DuPont Automotive Global Electrical & Electronic Applications Segment Leader Paul Kane DuPont Automotive Global Electrical & Electronic Senior Development Programs Manager

28 28 Copyright 2009 DuPont. The DuPont Oval Logo, The miracles of science, DuPont, Zytel, Hytrel Vespel, Mucell, Tefzel, Minlon, Rynite, Zenite, Crastin, Vamac, and Viton are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. Because we cannot anticipate or control the many different conditions under which this information and/or products may be used, neither DuPont nor the authors guarantee the applicability or the accuracy of this information or the suitability of its products in any given situation. Users of DuPont products should make their own tests to determine the suitability of each product for their particular purposes. The data listed herein falls within the normal range of product properties but they should not be used to establish specification limits or used alone as the basis of design. Disclosure of this information is not a license to operate or recommendation to infringe a patent of DuPont or others. CAUTION: This product is not permitted to be sold for use in medical applications involving implantation in the human body or where contact with internal body fluids or tissues will equal or exceed 24 hours. For applications involving contact of less than 24 hours, see DuPont Medical Caution Statement, H or contact your DuPont sales representative.

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Hello, I am Paul Kane, the Americas leader for DuPont engineering plastics development activities in vehicle electrification systems.

Hello, I am Paul Kane, the Americas leader for DuPont engineering plastics development activities in vehicle electrification systems. DuPont Automotive Performance Materials to Help Electrify Vehicles DuPont Automotive Webcast hosted by SAE International Oct. 21, 2009 Hitoshi Shioya DuPont Automotive Global Electrical & Electronic Applications