schulamid 612 presentation

Nylon 612: Viable Alternative TubingConstructions in Fuel Systems

ITB Automotive Energy Storage Systems 2013Novi, MIMarch 6-7, 2013

FAST FORWARD YOUR INNOVATIONTM

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A. Schulman – A Global Solutions Provider

• $2.1 BN revenue 2012• 5 integrated business segments

Masterbatch Solutions (35%) Custom Performance Colors (7%) Specialty Powders (16%) Engineered Plastics (26%) Distribution Services (16%)

• 34 manufacturing facilities• 3,300 associates in 25 countries• 4 technology centers - Americas and Europe• Strong innovation model for growth

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A. Schulman – Engineered Plastics

• Most diverse portfolio of multi-polymerand multi-functional compounds

• Serving Mobility, Electrical &Electronics, Sport & Leisure markets

• Strong commitment to the Automotivemarket

• Wide range of OEM and regulatory material approvals

• Technology centers in US, Mexico, Germany

PolypropyleneTPOPolyamidePolyesterPolyoxymethylenePolypthalamideIonomersBlends & AlloysFlame Retardant CompoundsThermoplastic ElastomersLong Glass Fiber ThermoplasticsBio-filled CompoundsSpecialty Masterbatches

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A. Schulman – High Performance Polyamides

• Wide range of PA chemistries• PA production in US, Mexico, Brazil,

Germany and China• Global technology platform for Fluid

Management applications• Wide range of OEM approvals• Proven performance in Automotive

fuel and brake systems• Virtually integrated nylon producer with

ability to customize at the molecular level

Nylon 6Nylon 66Nylon CopolymersNylon 610Nylon 612

UnfilledMineralGlass FiberGlass BeadCarbon FiberAramid FiberCarbon NanotubeMineral + FiberPlasticizedLubricatedFlame RetardantCustom ColorsBlends & Alloys

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Fuel Systems Performance: Key Drivers

• Fuel Evolution- ethanol-rich blends- biodiesel / biofuels- diesel

• Powerplant Evolution- increased hp/displacement- hybrids

• Legislative Evolution- CARB LEV III- EPA Tier 3- CAFE 2025- CO2 emissions reduction

• Supply Chain Evolution- PA12 / other disruptions- Raw material price volatility- New material alternatives

Ref: Kuraray

Raw materials and system design constructions must evolveto keep pace with the evolution of performance!

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Schulamid® and SchulaTubeTM Technology

• Objectives– Develop new materials

innovative to the market– Develop new tubing constructs

innovative to our customers– Enable development trials in-

house with our suppliers and customers

– Conduct seminars for training our customers

• Key Deliverables– Leverage our global expertise in

polyamide compounds– Commercialize innovation faster– Develop competitive products

which provide value to our customers and the market

SchulaTubeTM …Speaking the language of our customers and the market

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A. Schulman Academy

• Applications Center – Kerpen, Germany• SOTA 3-Extruder Multilayer Tubing Line• Smooth and Corrugated Capability• Beta-Laser Dimensional Measurement• Layer Microscopy Workstation• Burst Pressure Testing Chamber

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PA612 Performance

• Higher heat resistance than PA610 and PA12 (40 C higher melt temperature)

• Can be plasticized to be as flexible as PA12• Comparable moisture uptake to PA12, and

less than PA610• Excellent salt (zinc chloride) corrosion

resistance• Excellent resistance to H2SO4 solution• Demonstrated acceptable fuel and

chemical resistance• Minimal oligomer extraction which can

foul injectors

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PA612 Performance

ExcellentGoodFairPoor

ExcellentGoodFairPoor

Dimensional Stability

Gasoline/Diesel/Biodiesel Resistance

Salt Resistance

Heat Resistance (DTUL)

General Chemical Resistance

Hydrolysis/Moisture Resistance

Notched Impact Strength

Elongation

Flexural Strength/Modulus

Tensile Strength/Modulus

Specific Gravity

Nylon 66Nylon 6Nylon 12Nylon 612

Dimensional Stability

Gasoline/Diesel/Biodiesel Resistance

Salt Resistance

Heat Resistance (DTUL)

General Chemical Resistance

Hydrolysis/Moisture Resistance

Notched Impact Strength

Elongation

Flexural Strength/Modulus

Tensile Strength/Modulus

Specific Gravity

Nylon 66Nylon 6Nylon 12Nylon 612

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SchulaTubeTM FS: Test Protocol (AIAG)

I. Short-Term Validation - Straightforward, High Confidence Level (Tubing and Assemblies)

1. SAE J2044, J2045, or J2260 spec or OEM spec equivalent (must have comparison data for product being replaced). It is assumed that all assemblies prepared for the testing will be leak tested per SAE J2045 prior to test and that this leak test data will be reported. For assemblies, connections tested must include production intent technologies.

A. Burst (conduct with quick-connectors, also test tubing without connectors if test result is quick-connector blow-out)

B. Hi-Temp Burst (conduct with quick-connectors, also test tubing without connectors if test result is quick-connector blow-out)

C. AdhesionD. Cold ImpactE. Kink ResistanceF. Tensile TestG. Elongation TestH. Zinc Chloride Test if the outer layer is not an alternative PA12.

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SchulaTubeTM FS: Constructions

Construction: monolayer, non-conductive, smooth, 6.35mm ID

SchulaTubeTM FS 102

100% Mono Layer: Schulamid 612 FS 4004 Black

612 FS 4004: High molecular weight, high impact

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SchulaTubeTM FS: Gasoline Testing

SAE J2260 – DVP&R Results

Procedure Conditions Result Pass/Fail

7.1 Room Temp Burst 23 °C, 7 MPa/min 7.1 MPa Pass7.2 High Temp Burst 115 °C, 7 MPa/min 2.4 MPa Pass7.5 Cold Temp Impact -40 °C, 75% retention 7.2 MPa PassA.4.1 Tensile Strength 50 mm/min to failure 39.4 MPa PassA.4.1 Elongation 50 mm/min to failure 365% Pass7.12 Zinc Chloride Test 50% ZnCL2, 23 °C, 200 hrs 5.3 MPa Pass

(No cracks)7.6 Fuel Recirculation* Expose, test to Sec 7.5 4.1 MPa Pass7.8 Sour Gas Expose, test to Sec 7.5 4.0 MPa Pass

*CM15A Fuel

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Construction: 3-layer, non-conductive, smooth, 8mm x 1mm

SchulaTubeTM FS 301

50% Outer Layer: Schulamid 612 FS 4104 Black

10% Middle Layer: Kuraray EVAL FP101B (EVOH)

40% Inner Layer: Schulamid 612 FS 5004W Natural

SchulaTubeTM FS 312



40% Inner Layer: Schulamid 612 FS 4104 Natural

612 FS 4104: High molecular weight, super high impact612 FS 4004: High molecular weight, high impact612 FS 5004W: High molecular weight, high impact, plasticized

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Long Term PeakInside Temperature: -40°C to +110°C max. +130°CAmbient Temperature: -40°C to +135°C max. +170°C

Operating Pressure: Inside 0.5 – 8.0 bar (max. 10.0 bar)Fuel: Various, with and without ethanol

Specifications: VW TL 52345, BMW QV 16006, DIN 73378

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SchulatubeTM FS 301 SchulatubeTM FS 312

Operating Performance (VW) Pass (Approved) -Operating Performance (BMW) - Pass (Approved)Processing Good GoodLayer Adhesion Very good Very goodCold Impact (-40°C), Charpy 7.5J No break No breakCold Impact (-40°C), Ball 880g / 650 mm No break No breakZnCl2 Resistance (with connector) Very good Very goodBurst Pressure (+23°C) > 100 bar > 100 barBurst Pressure (+23°C) after 10X to failure > 80 bar > 80 barBurst Pressure (+115°C) > 40 bar > 40 barTensile Strength > 30 MPa > 30 MPaElongation > 230 % > 250 %

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Oligomer Extraction:

Exposure at 23 °C24 hr dryingE85 fuel SchulaTube® FS 312

< 2 mg/m² 9 mg/m²

After 200 hrs After 500 hrs

VW and BMW Specification: < 10 mg/m2 after 500 hrs

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Construction: non-conductive, smooth, 8mm x 1mm

SchulaTubeTM FS 101

100% Mono Layer: Schulamid 612 FS 4004 Black

SchulaTubeTM FS 301



40% Inner Layer: Schulamid 612 FS 5004W Natural

612 FS 4004: High molecular weight, high impact

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SchulaTubeTM FS: Diesel Testing

Long Term PeakInside Temperature: -40°C to +120°C max. +140°CAmbient Temperature: -40°C to +150°C max. +170°C

Operating Pressure: Inside 0.5 – 5.0 barFuel: Various, with and without bio content

Specifications: BMW QV 13032

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SchulatubeTM FS 101

Processing Very goodCold Impact (-40°C), Charpy 7.5J No breakCold Impact (-40°C), Ball 880g / 650 mm No breakZnCl2 Resistance Very GoodBurst Pressure (23°C) > 100 bar

Burst Pressure (120°C) > 20 barBurst Pressure (135°C) > 15 barBurst Pressure (150°C) > 10 barTensile Strength (unconditioned) 29 MPaE-Modulus (unconditioned) 462 MPaElongation (unconditioned) > 250 %Tensile Strength (after 1500h at 90°C with B20, 5 bar) 29 MPaE-Modulus (after 1500h at 90°C with B20, 5 bar) 577 MPaElongation (after 1500h at 90°C with B20, 5 bar) > 180 %Burst pressure (23°C, after 1500h at 90°C with B20, 5 bar) 58 bar

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Oligomer Extraction:

72 hrs at 60 °CB20 and B30 fuels

SchulaTube® FS 301

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Evaluations are proceeding with these tubing structures:

• PA612 / adhesive / EVOH / adhesive / PA612• PA612 / EVOH / PA612• PA612 / ETFE / PA612• PA612 / ETFE / PA6

Various barrier polymer grades Various layer thicknesses

Measurables:

Fuel permeation Burst strength Layer adhesion quality Conductivity Extrusion processability Connector / tubing sealing

SchulaTubeTM FS: Next Steps

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• PA612 is a viable polymer for use in automotive fuel systems• PA612 compounds are currently approved and in use with

at least 6 global OEMs• The viability of PA612 in fuel systems depends on the

PA612 resin and compound formulation design• Innovation in tubing constructions offers potential for balancing

performance with cost reduction

SchulaTubeTM FS: Conclusions

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Special thanks for their kind assistance and contributions to this presentation:

• Thilo Stier A. Schulman Germany• Peter Sebö A. Schulman Germany• Tom Jacques A. Schulman US

Appreciation

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ThankThank you for your attention!you for your attention!

Contact:Jeff McCoyManager, Business DevelopmentEngineered Plastics Americas(330) [email protected]

schulamid 612 presentation

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