Innovation Spotlight: DuPont™ Zytel® XT and DuPont™ Vamac® 

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Turbocharger Twin Outlet T-joint

Application Description

A lightweight, cost-effective twin turbocharger outlet T-joint engineered using molded plastic, replacing the cast aluminum/thermoset rubber incumbent material. Developed by Hyundai and Hwaseung R&A Co., Ltd., for use in a Hyundai luxury sedan.

Unmet Need

Turbocharger components offer an area of focus for vehicle lightweighting, but material choices must be capable of enduring significant physical stresses, including vibration, extreme heat and aggressive chemicals.

Challenges

  • Meet severe flow load, static/dynamic engine load, chemical resistance and vibration performance requirements
  • Reduce cycle time

Solution

The injection-molded plastic outlet was assembled using a novel combination of infrared and vibration welding to reduce cost and minimize potential contamination in the finished component. Concentrated stress areas including bolting, leg were designed using an optimized rib pattern. The T-joint:

  • enables significant weight and cost reductions 
  • reduces air flow pressure drop rate by 8kPa through optimized design
  • enables NVH performance gains, including lower radiation noise versus aluminum in the range of 3,000 ~ 6,000Hz as 1 ~ 2dBA

DuPont Material Chosen and Why

DuPont™ Zytel® XT was chosen for the T-joint component of this application because it offers:

  • high strength
  • broad temperature toleration
  • stiffness and fatigue resistance over a wide range of temperatures, chemicals and moisture exposure

DuPont™ Vamac® was chosen for the hose components of this application because it provides:

  • flexibility  
  • longevity in powertrain and air management applications 
  • resistance to chemical exposure over a broad temperature range

WINNER, 2017 SPE AUTOMOTIVE INNOVATION AWARDS, POWERTRAIN CATEGORY