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DSM and KACO cut weight and costs for next-generation Volkswagen engines

News International-French

6 Sep 2013

Royal DSM, the global Life Sciences and Material Sciences Company, together with its automotive component specialist partner KACO, has taken an important step in improving fuel efficiency in cars. The two companies have developed a lightweight multi-functional crankshaft cover in EcoPaXX, DSM’s bio-based polyamide 410, for the latest generation of diesel engines developed by the Volkswagen Group.

This EcoPaXX cover incorporates integral seals in PTFE and liquid silicone rubber (LSR), as well as various metal inserts. It will be used on Volkswagen’s new MDB modular diesel engine platform, implemented across its Audi, Seat, Škoda and VW brands. Volkswagen, along with all major automobile producers, is in a constant search for new ways to increase the sustainability of its products, and the new bio-based crankshaft cover is an excellent example of solutions that it is implementing.

Compared with covers made in aluminum, system costs for the EcoPaXX cover are considerably lower, thanks in part to the use of an integrated, fully automated production cell for the component at KACO. Weight has been reduced considerably too, since the EcoPaXX grade is 45% less dense than aluminum.

The development represents a significant step forward in terms of sustainability, from material production to the vehicle on the road. DSM’s EcoPaXX polyamide 410 is 70% derived from renewable resources, and the polymer is certified 100% carbon neutral from cradle to gate. In component production, KACO uses the highly energy-efficient production cell to not only mold the crankshaft cover, but also integrate two separate seals: the first, in PTFE, is placed into the mold by a robot, and EcoPaXX is over-molded onto it; the second, in LSR, is then molded directly into the part using a 2K process. This results in reduced energy consumption during production, as well as zero material waste. Finally, because the finished cover weighs so much less than an aluminium version, it makes the vehicle run more efficiently, saving fuel and reducing carbon dioxide emissions throughout its lifetime.

Thermoplastic crankshaft covers are still uncommon, with polyamide 6 or 66 being the favoured material. The very tight dimensional specification of the VW version, as well as the high loads it has to withstand, made the challenge of producing it in thermoplastic particularly severe. DSM and KACO met the challenge, thanks to the overall performance of EcoPaXX— good mechanical properties at elevated temperatures, in combination with toughness—and KACO’s skills in integrating static and dynamic seals into the part in a highly intelligent way.

Genesius adds that a key to the successful launch of the crankshaft cover after an extremely short development period was the strategic joint development with key partners, including DSM, in the areas of part design, material development, process design and bonding of the different materials.

The crankshaft cover is a masterpiece of engineering design. Fiber orientation, the number and position of gating points, and the design and integration of the various inserts have all been optimized to minimize warpage and ensure tight seals between the cover and the engine block and oil sump. The cover also has to resist tightening of bolts fixing it to the engine block and the sump (each of which is built to different tolerances), as well as from tools used to fix the position of the FEAD (Front End Accessory Drive) belt.

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