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AMODEL PPA REPLACES ALUMINUM IN FUEL-AIR RAIL SEVERE OPERATING ENVIRONMENT DEMANDS STRENGTH & DURABILITY
Heat resistance was a major consideration in the selection of the AMODEL PPA, because of the fuel rail’s proximity to the cylinder head, whose operating temperature can be as high as 160°C. AMODEL AS-1133 HS offered Synerject engineers excellent heat resistance, featuring heat-deflection temperatures as high as 285°C (@ 1.8 MPa) and 297°C (@ 0.45 MPa) as well as continuous-use temperatures of 185°C for 5,000 hours and 165°C for 20,000 hours. Injection molding the part reduced its cost compared to machining it from aluminum and achieved some weight savings as well. In addition to high-temperature performance, Synerject engineering included vibration resistance, storage of the scooter at ambient low temperatures, and thermal cycling as factors in the choice of a polymer. Synerject also cited the fact that AMODEL PPA had demonstrated performance in a production automotive fuel rail. AMODEL AS-1133HS is a glass-reinforced, heat-stabilized material that exhibits the dimensional stability and strength that are necessary in this pressurized application. PPA outperforms conventional nylons in its resistance not only to heat, but also to swelling caused by absorption of moisture or fuel. The combined resistance to heat, impact, and chemicals gives this material the life-ofvehicle durability that is demanded in contemporary automotive applications. The fuel-air rail is molded and assembled by SMT, L.L.C. in Naperville, Illinois. SMT worked with Synerject to develop the tooling and processes for converting the previous aluminum part to an injection-molded design. SMT molds an O-ring seat separately to hold specified flatness; the seat is then vibration welded to its location. Threaded brass inserts are also heat-staked to the part, and two compression limiters are press-fit into the assembly. AMODEL 1000-series PPAs are designed to be molded with oil cooling to control crystallization during processing and assure performance of the part in operation. http://www.solvayadvancedpolymers.com
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