BASF announced its Ultramid Endure polyamide with high heat aging resistance up to 220 degrees C is being used in two new powertrain applications for FCA's 2017 Alfa Romeo Giulia – the air intake manifold with integrated charge air cooler, and hot-side turbo duct. Both debut with the new two-litre GME engine.

BASF claims Ultramid Endure portfolio engineered resins 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 OEM model programmes.

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"We predict that about 20% 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. "We are able to deliver the innovative materials necessary for these applications and also the design and welding expertise to ensure that suppliers and automakers can incorporate them successfully into their turbocharger system parts." 

BASF collaborated with ABC Group to develop the hot-side turbo duct for the Giulia. For this application, ABC used Endure D5G3 BM, a 15% glass fibre reinforced blow moulding grade which has a high melt strength and claimed superior heat aging resistance.

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

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"After conducting numerous resins trials through moulding, 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."

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BASF worked with Magneti Marelli to develop the air intake manifold with integrated charge air cooler. The need for materials to withstand a 200 degree C continuous use temperature made this air intake manifold a prime candidate for Endure D3G7, a 35% glass fibre injection moulding grade.

"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."