STEVENAGE: Japanese automakers used DupontTM MinlonTM and TMZytelTM to supply their 2.5-liter Turbodies for their Pathfinder and Navara, respectively, at the initial stage of Nissan's use of metallic alternatives to manufacture engine bonnets. The engine manufactures rocker covers and front covers.
The rocker cover (front, left) and front cover (back, right) of the Pathfinder and Navara's 2.5-liter turbo diesel engine from Nissan Motor were cast by DuPontTM MinlonTM and DuPont TMZytelTM, respectively. By selecting high-performance polymers from DuPont, Spanish injection molding Maier S. Coop can reduce weight and cost, reach their aluminum equivalent value, and maintain good performance to meet Nissan's stringent standards.
These two parts were developed by two companies belonging to MCC Mondragon Corporacion Cooperativa: Fagor Ederlan, from Eskoriatz in northern Spain, a region that traditionally manufactures engine parts, transmissions and aluminum or iron body manufacturing. Maier, a manufacturer of plastic parts from Spain Gernika, automotive and other industries. This strategic alliance can provide a variety of technical (plastics-metal) solutions based on market requirements. By selecting high-performance polymers from DuPont, Maier can reduce production costs, and reduce the weight of the parts by 30% under the premise of the specified aluminum equivalent value, and maintain good performance to meet the strict standards of Nissan.
The rocker cover is approximately 47.5 centimeters long, 22.5 centimeters wide and weighs approximately 1,250 grams. It is molded from mineral-filled and glass-reinforced nylon 66. With a very high hardness, strength, low thermal deformation rate and excellent shape stability? These features can be used to make seals to protect the valve control system or prevent oil leakage. The material can also withstand operating temperatures up to 150 °C and hot oil resistance or other chemicals.
The front cover of the engine is about 44 cm long, 20 cm wide (the longest part) and weighs 500 g. It has similar protection and sealing functions as the rocker cover. Because of its shorter dimensions, the stability is relatively unimportant. The raw material is 30% glass fiber reinforced Zyteln® nylon resin. The ability to withstand heat and chemicals, as well as the mechanical strength that can withstand the assembly process, were key factors in the selection of raw materials—that is, the bolted connections on the engine and the vibrations that occur each day when the engine is used.
This project was developed by Maier, a technology center known for its innovative efficiency, MTC and Fagor Ederlan, and proved to be more cost effective and less weight than other materials. Ordonez, who is responsible for new materials at Maier, stated: “By using DuPont's high-performance polymer castings, we can achieve the same size and performance of the original aluminum parts, but at a reduced cost of 30-35% and 40% weightâ€. Based on his experience in developing aluminum rocker covers, Fagor Ederlan provided technical support related to product functionality.
The rocker cover (front, left) and front cover (back, right) of the Pathfinder and Navara's 2.5-liter turbo diesel engine from Nissan Motor were cast by DuPontTM MinlonTM and DuPont TMZytelTM, respectively. By selecting high-performance polymers from DuPont, Spanish injection molding Maier S. Coop can reduce weight and cost, reach their aluminum equivalent value, and maintain good performance to meet Nissan's stringent standards.
These two parts were developed by two companies belonging to MCC Mondragon Corporacion Cooperativa: Fagor Ederlan, from Eskoriatz in northern Spain, a region that traditionally manufactures engine parts, transmissions and aluminum or iron body manufacturing. Maier, a manufacturer of plastic parts from Spain Gernika, automotive and other industries. This strategic alliance can provide a variety of technical (plastics-metal) solutions based on market requirements. By selecting high-performance polymers from DuPont, Maier can reduce production costs, and reduce the weight of the parts by 30% under the premise of the specified aluminum equivalent value, and maintain good performance to meet the strict standards of Nissan.
The rocker cover is approximately 47.5 centimeters long, 22.5 centimeters wide and weighs approximately 1,250 grams. It is molded from mineral-filled and glass-reinforced nylon 66. With a very high hardness, strength, low thermal deformation rate and excellent shape stability? These features can be used to make seals to protect the valve control system or prevent oil leakage. The material can also withstand operating temperatures up to 150 °C and hot oil resistance or other chemicals.
The front cover of the engine is about 44 cm long, 20 cm wide (the longest part) and weighs 500 g. It has similar protection and sealing functions as the rocker cover. Because of its shorter dimensions, the stability is relatively unimportant. The raw material is 30% glass fiber reinforced Zyteln® nylon resin. The ability to withstand heat and chemicals, as well as the mechanical strength that can withstand the assembly process, were key factors in the selection of raw materials—that is, the bolted connections on the engine and the vibrations that occur each day when the engine is used.
This project was developed by Maier, a technology center known for its innovative efficiency, MTC and Fagor Ederlan, and proved to be more cost effective and less weight than other materials. Ordonez, who is responsible for new materials at Maier, stated: “By using DuPont's high-performance polymer castings, we can achieve the same size and performance of the original aluminum parts, but at a reduced cost of 30-35% and 40% weightâ€. Based on his experience in developing aluminum rocker covers, Fagor Ederlan provided technical support related to product functionality.
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