BASF's heat resistant plastic debuts on the Alfa Romeo Giulia's 2.0L turbocharger system

CORBETTA, Italy and SOUTHFIELD, Mich., May 9, 2017 /PRNewswire/ -- By 2020, predictions indicate that 70 percent of light vehicles worldwide will use turbocharged engine technology¹. As a result, BASF is introducing the use of its Ultramid Endure polyamide with high heat aging resistance up to 220° C in these engines. There are two new powertrain applications utilizing the company's high heat resistant Endure thermoplastics; the air intake manifold with integrated charge air cooler, and hot-side turbo duct. Both debut on the 2017 Alfa Romeo Giulia with the new 2.0L GME engine.

Turbochargers provide high pressure air to the engine that makes fuel burn efficiently – delivering greater engine power while consuming less energy. However, most standard thermoplastics cannot maintain desired performance under the high heat and pressure developed in a turbocharged engine, which is why BASF developed the Ultramid Endure portfolio of engineered resins. The Endure grades offer high heat aging resistance, good processability, excellent weld line strength and are available for production in North America, Europe, and Asia to support global Original Equipment Manufacturer (OEM) programs.

The Ultramid Endure portfolio can be used in many air induction applications of the turbocharged system including the air intake manifold, charge-air ducts, resonators, intercooler end caps and throttle bodies. It can also achieve long-term service temperatures of 220° C, and withstand peak temperatures of 240° C. Its notable heat aging behavior results from an innovative stabilization system, which greatly reduces oxygen attack on the polymer surface.

"We predict that about 20 percent of all turbocharger applications will require a high heat resistant plastic as engine temperatures increase due to downsizing," said Mike Chiandussi, Powertrain Market Segment Specialist at BASF. "BASF is able to deliver not only the innovative materials necessary for these applications, but also the design and welding expertise and know-how to ensure that suppliers and automakers can incorporate them successfully into their turbocharger system parts." 

Hot-Side Turbo Duct

BASF collaborated with ABC Group Inc. to develop the hot-side turbo duct for the Alfa Romeo Giulia. For this application, ABC Group used BASF's Ultramid Endure D5G3 BM, a 15 percent glass fiber reinforced blow molding grade, which has a high melt strength and superior heat aging resistance.

ABC Group leveraged BASF's material and joining technology expertise to optimize the infrared (IR) welding parameters for this part. It was crucial to achieve strong welds to insure the long-term durability of the duct.

"After conducting numerous resins trials through molding, welding and vigorous validation testing, we were able to use an industry-first material and meet the significant requirements for this application," said Mary Anne Bueschkens, CEO of ABC Group. "The part requires many weld connections, and our engineers worked closely with BASF's material and joining experts to understand the unique requirements, allowing us to fine tune our infrared welding technology, and assuring success of the welding process for this demanding high temperature duct."

Air Intake Manifold with Integrated Charge Air Cooler

BASF worked with Magneti Marelli to develop the air intake manifold with integrated charge air cooler for the Alfa Romeo Giulia. The need for materials to withstand a 200°C continuous use temperature made this air intake manifold a prime candidate for the Ultramid Endure D3G7, a 35 percent glass fiber injection molding grade.

The air intake manifold has a burst pressure requirement; therefore, Magneti Marelli needed a solution that offered reliable weld strength at elevated temperatures. Using BASF's design, material and processing expertise, Magneti Marelli could achieve the required burst strength and durability targets for the assembly.

"BASF's technical support was useful to ensure the application passed the burst requirement," said Marcello Colli, Product Manager Throttle Bodies, at Magneti Marelli. "Their material and welding experience ensured that we could use this heat resistant material and meet long-term durability targets."

As heat under-the-hood increases, the Ultramid Endure portfolio of solutions enables automakers to achieve engine downsizing and turbocharging without sacrificing performance.

This Alfa Romeo-exclusive engine debuts in the new 2017 Alfa Romeo Giulia and Giulia Ti premium mid-size sedan. The 2.0-liter Alfa Romeo engine delivers 280 horsepower and 306 lb.-ft. of torque, allowing it to launch from 0-60 mph in 5.1 seconds, and achieve a top speed of 149 mph.

For more information, visit www.automotive.basf.com

¹ Source: Honeywell, a global developer of automotive turbochargers

For press photos, click on the link below:

https://www.basf.com/en/company/news-and-media/news-releases/2017/05/p-17-211.html

About BASF

BASF Corporation, headquartered in Florham Park, New Jersey, is the North American affiliate of BASF SE, Ludwigshafen, Germany. BASF has more than 17,500 employees in North America, and had sales of $16.2 billion in 2016. For more information about BASF's North American operations, visit www.basf.us.

At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. The approximately 114,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into five segments: Chemicals, Performance Products, Functional Materials & Solutions, Agricultural Solutions and Oil & Gas. BASF generated sales of about €58 billion in 2016. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (BAS). Further information at www.basf.com.

About ABC Group Inc.

Founded in 1974, ABC Group Incorporation is one of the world's leading, full-service automotive suppliers of thermoplastic components and systems to Original Equipment Manufacturers (OEM's). Our global headquarters is in Toronto, Canada, with 36 domestic and international locations across Canada, United States, Mexico, Brazil, Germany, Spain, Poland, Japan and China. For further information about ABC Group Inc., please visit www.abcgroupinc.com.

About Magneti Marelli

Magneti Marelli designs and produces advanced systems and components for the automotive industry. With 86 production units, 12 R&D centres in 19 countries, approximately 43,000 employees and a turnover of 7.9 billion Euro in 2016, the group supplies all the major car makers in Europe, North and South America and the Far East. The business areas include Electronic Systems, Illumination, Powertrain, Suspension and Shock Absorbing Systems, Exhaust Systems, Aftermarket Parts & Services, Plastic Components and Modules, Motorsport. Magneti Marelli is part of FCA.

SOURCE BASF

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