Auto Powertrain Trends Solving the materials selection puzzle June 27, 2006
2 What is the industry looking for? Rocker cover The productivity quest Manufacturing (to a large degree) Most cases there is no real control over profitability, since there is no control over pricing Manufacturing productivity is a key influence to long term profitability Tangible (hard money) Capitalized productivity (high yield) Material productivity Labor productivity Intangibles (soft money) All factors that do influence material process ability (i.e.: cycle time, mold complexity, automatization, etc. ) The performance want Constant improvement of emissions and fuel consumption More power Lower consumption Lower emission Design, high performance materials and materials technologies that can influence: Noise reduction (vibration and harshness) Withstand higher operating temperatures and harsher environment (I.e.: coolant and oil resistance) Integration (components and functions) Reduce weight Packaging and handling Logistic Air intake manifold Water jacket spacer
3 Segmentation of Powertrain AIS Turbo Air Duct Intercooling System ACIS Air Control System Control System EGR ECU Exhaust Evaporation Oil Management System Oil Filtration Cam System Oil Pan/Storage Sealed Cover Transmission Front Cover Shift Folk Control Module Other AT comp
4 Air Intake Manifold and fuel management Rocker cover Worldwide applications All majors OEMs New technology (LWT) Welding (LWT) Bonding Managing high T and coolant (EGR) Zytel HTN PPA Integration Rocker cover? Throttle body? Air cleaner? VIS SCV
5 Air Intake Manifold: gaskets, sealing technologies Dodge Magnum RT with a 5.7L Hemi Multi-Displacement V8 engine bows with integrated air fuel module from Siemens VDO Automotive using DuPont Zytel nylon Materials, Technology to Ensure Top Performance Air Intake Manifold Leadership 12 years, 75 commercial programs and 400 billion miles of performance - 20 million trips around the world - delivering: Weight savings - Gasoline consumption reduced by 360 million gallons Cost savings - More than $2 billion in cost eliminated throughout the value chain Powertrain Integration Opportunities Air fuel delivery modules, sealed and non-sealed covers, engine cooling, ignition systems, gaskets and sealing technologies Permeation reduction technologies - NEW - No postcure DuPont Dow Elastomers Viton fluoroelastomer for gaskets helps meet LEV II and PZEV emissions regulations Savings based on LCA performed on F-150 truck by University of Michigan New No Postcure Viton for AIM Applications Improves OAT Coolant Resistance APA Designed No Postcure DuPont Dow Elastomers Viton fluoroelastomer for gaskets Improved Coolant Resistance of Viton GBL-S vs. 66%F FKM Elongation (solid) & Modulus (dashed) after 135 C Coolant Aging Outstanding coolant resistance Excellent for air intake manifold carrier gasket overmolding 100 New No Postcure Viton for AIM Applications Delivers Good Compression Set in Air and Coolant Improved Coolant Resistance of Viton GBL-S v. 66%F FKM Compression Set in Air @ 150 C and Dexcool OAT Coolant @ 135 C 500 7.0 450 M50 6.0 80 Elongation at Break [%] 400 350 300 250 200 150 100 Eb M50 5.0 4.0 3.0 2.0 Stress @ 50% Strain - M50 [MPa] Compression Set [%] 60 40 20 1.0 50 Eb 0 0.0 0 500 1000 1500 2000 2500 3000 0 336 672 Time [hrs] 1008 2016 Time at 135 C in Dexcool OAT Coolant [Hrs] Viton GBL-S Eb 66%F FKM Eb Viton GBL-S M50 66%F FKM M50 Viton GBL-S Air Viton GBL-S Coolant 66%F FKM Air 66%F FKM Coolant
6 Engine covers Rocker cover Non-sealed cover (I.e.: Beauty/Noise Covers) Sealed covers (I.e.: Rocker Covers) Renewing the application lifetime
7 Engine covers Rocker cover Sealed covers (I.e.: Rocker Covers) Oil separator integrated (oil baffle welded) Valve system (simple) Centrifugal system (more complex and costly) The new challenges Cam shaft bearing integration structural/heavy loads Sealing tolerances Oil lubrification Water cross-over Fixation systems Structure of OCV/VVT HC Tight dimensions and tolerances Cam shaft bearing Oil separator Valve system DCX I4 World Engine 2.0L and 2.4L by Bruss NA MB I6 Diesel by Mann+Hummel Oil separator centrifugal system
8 Engine covers Rocker cover Sealed covers (I.e.: Rocker Covers) Gasket systems Elastomer type and volume Carrier technology Thermoplastics Self curing Glue? New gasket technology 2K process Zytel /ETPV Fixation systems Number and type of screws Screws with micro-encapsulation To keep fixation moment over T and replace inserts Decoupling Inserts Assembly Radial sealing (fundamental change) Reduction and/or elimination of bolts fixation due to: Advanced materials LFT (long fiber technology) Improved gaskets Oil separator Valve system Oil separator centrifugal system
9 Front, side and rear sealed covers Engine Covers (Sealed) Rocker Cover Sealed covers, rear, front and side Front Cover Module with integrated air filter
10 Air-flow management Air ducts for turbo engine and intercooling systems Rocker cover Requirements High Temperature Gasoline Engines: 120 150 C (248 302 F) Diesel Engines: 140 170 C (284 338 F) with peaks up to 200 C (392 F) Typical ambient under hood temperature from 85 120 C (185 248 F) Chemical resistance to: Oil, blow-by gas, petrol and other under hood fluids Coolant resistance Pressure range: 1.0 2.5 bar (14.5 36.3 psi) NVH Turbo outlet and high temperature (T 130-200 C) Pressure in air ducts Oil mist in air ducts Vacuum in air ducts Dirty air and low temperature (T 100 C) A Vacuum in air ducts Clean air and low temperature (T 80-130 C) B C Intercooler D Inlet manifold Air intake manifold Exhaust manifold C Exhaust Charge air outlet with pressure and high temperature (T 80-150 C) Pressure in air ducts Oil mist in air ducts Fresh Air Turbo charger A Air filter B Engine life up to 3000-4000hrs Absorb engine movements Flexible for (de-) assembly D
11 Air-flow management Air ducts for turbo engine and intercooling systems Rocker cover Materials for air ducts (non-turbo) EPDM ( low swell ) Hypalon (CSM) Chlorinated Polyethylene (CPE) Epichlorohydrin (ECO) Silicone (VMQ) Blow Molded Plastics (TEEE, TPO, PA, PP, TPV) Meeting the design and technology development capabilities 3D Blow Molding Zytel EFE7340 BK VSB bellows QC integrated to the BM part
12 Air-flow management Air ducts for turbo engine and intercooling systems Rocker cover Materials for Turbo Ducts (hot side) Vamac Viton Veneer/VMQ Cover Silicone Zytel PA66 Zytel HTN PPA Renault Turbo-diesel Hot side Duct PA6 15% GR Vamac Rubber Connection Renault Hot side Turbo-diesel Duct Hytrel 4275 BK316 Rubber cuffs on both ends
13 Oil systems Rocker cover Oil pan - first commercial application (DC Actros Truck) Oil baffle - growth Oil baffle module (windage tray) - first commercial application Oil pan sealing and gasket - first commercial application Transmission oil pan - first commercial application (BMW 7 series) Oil modules - first commercial application (Audi) Oil delivery parts Oil suction - growth Oil pre-filtration parts - growth Oil pump - concept Oil filters - growth High pressure oil tank Oil separator Valve system Oil separator centrifugal system
14 Oil Systems Oil pan Critical application Sheet metal due to low cost Al pan without stiffness function for instance Engine support due to stiffness Engine Al block (light, more vibrations) Rear wheel drive Vs. front wheel drive Challenging oil pans in metal
15 Oil Systems Oil pan Application critical criteria Economics (total assembly cost) Common components Assembly and packaging Part weight Chemical resistance Hot oil Corrosion Temperature resistance (130 C-170 C) Sealing and fastening No leak under air pressure (20 Psi 1min) Dimensional stability thermal, flatness, creep High impact resistance Off road NVH Confidential
16 Oil Systems Oil pan Design features for integrated solutions Pan, pick-up tube and screen assembly Windage tray carries seal Hybrid bottom for additional load and impact capability Stiffness Local reinforcement impact Confidential
17 Transmission Rocker cover Recent commercial applications Shift solenoids bobbins Mat.: HTN 51G35HSL Benefits: Control modules Transmission oil @135 C Dielectric and mechanical properties retention RYN 935 ZYT 70G30 (in Europe) Transfer Case Fork Mat: Crastin* SK605 Borg Warner Benefits: Balance of Strength & Rigidity withstand ATF temp at 125 C Oil separator Valve system Cam shaft bearing Oil separator centrifugal system
18 Transmission Transmission Gravity Filter (With Composite Pan / Filter) ONE-PIECE COMPOSITE TRANSMISSION OILPAN PRESS-IN PLACE GASKET PRESS-IN PLACE GASKET PICK-UP TUBE DRAWS CLEAN ATF IN PAN NON WOVEN FILTER MEDIA IN COMPOSITE FRAME TRAPS CONTAMINANTS ON DRAIN BACK VALVE BODY Metal ATF Oil Pan Start with DuPont VIBRATION WELD JOINT CLEAN ATF IN PAN COMPOSITE TRANS. OIL PAN Metal plastic ATF filter ZYT 70G33HSL
19 Other powertrain Secondary air pump (concept) Water and air pump Lower housing Impeller Water pump electrical (concept) Upper housing outlet Inlet Main structural components Pulley thermostat Expansion tank Water pump mechanical (concept) Electric water pump Intake shutters hoses Source;- Valeo
20 Other powertrain High T water and coolant x-over Thermostat housing Water x-over WJS
21 Other powertrain High T and coolant/egr management ACTUATORS Control variable turbo charger Control EGR valve Control tunable AIM Intelligent and accurate system Actuator control module
22 Other powertrain 4 3 Other applications 1. Compressor Resonator and actuator in Zyt*HTN PPA 2. Time chain system 3. ABS wheel speed sensor 4. ABS control unit housing 2 1
23 Diesel engines Rocker cover Diesel engine technology will continue to grow Europe ~60% market share today NAM expected 15% market share by 2020 Direct injection diesel technology Inclusive particles filter Temperature will increase up 700 C The heat generate by the burn will influence all powertrain components High performance materials will be needed New applications trend Secondary air pump Additional fresh air in cold phase Reduce emission Heat shield-resonator Sophisticated filtration systems Audi air duct First AIM in HTN in EUR (Audi 4.2L TDI
24 Heat shield resonator Diesel engines New applications trend Liquid filter system Rocker cover Audi air duct Integrated air filtration system Secondary air pump
Gianluigi Molteni Gian-luigi.molteni@usa.dupont.com 001-248-583-8104 DuPont Zytel, Crastin, Rynite, Delrin, Hytrel, Vamac, Viton, DuPont ETPV, DuPont ACE, Hypalon, Alcryn, are a trademark and registered trademarks of E.I. DuPont de Nemours and Company