Alexei Volkov
Plastic intake manifolds are integrated assemblies that sit atop an engine, distributing air to each cylinder. They are typically mounted on top of the engine between both cylinder banks. While plastic intake manifolds are widely used, with many major car manufacturers adopting them, there are some drawbacks to their use. Early designs were prone to failure due to leaks, warpage, and cracks caused by intense heat. Additionally, noise control has been an issue with plastic intake manifolds, and they may not be suitable for forced induction engines. Despite these challenges, plastic intake manifolds are expected to gain popularity due to their lightweight, low-cost, and smooth interior surfaces, which can enhance engine performance.
| Characteristics | Values |
|---|---|
| Material | Plastic, Aluminum, Iron |
| Function | Distribute fresh outside air to each cylinder for proper engine performance |
| Location | Mounted on top of the engine |
| Issues | Leaks, Warpage, Cracks, Noise |
| Advantages | Lighter, Less Expensive, Smoother Interior Surfaces |
| Use | Common in modern cars, especially in Europe and North America |
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What You'll Learn
Plastic intake manifolds are durable and reliable
Plastic intake manifolds have become increasingly popular since the 1990s, when automakers began to manufacture them in a form that was durable enough to survive initial testing. They are made from glass-reinforced nylon 6/6, which is lighter and less expensive than metals such as aluminium. The interior surfaces of plastic intake runners are also smoother, which results in less turbulent airflow through the tubes and, in turn, more horsepower.
Plastic intake manifolds are also more durable and reliable than their metal counterparts. For example, they are less susceptible to corrosion from old coolant, which can eat away at the walls of the tubes carrying antifreeze inside the manifold. Plastic intake manifolds are also less likely to leak or crack due to their ability to withstand the expansion and contraction that occurs with changes in temperature. Gaskets that provide a seal between an intake manifold and a metal cylinder head must be flexible and durable enough to withstand serious pulling and twisting forces, which plastic intake manifolds are better equipped to handle.
Additionally, plastic intake manifolds have proven to be reliable over time. For instance, GM's use of Nylon 66 for its intake manifolds has been around for a while and has proven to be reliable. While some early plastic intake manifolds were prone to failure, modern replacements have corrected these issues, and plastic intake manifolds are now known for their durability and reliability.
Despite the benefits of plastic intake manifolds, there are still some drawbacks. One issue is noise control, as the thinner wall thickness of plastic manifolds can result in unpleasant noises. However, companies like DuPont, the world's largest producer of nylon for intake manifolds, are working to address this issue through acoustical analysis. Overall, plastic intake manifolds offer improved durability and reliability compared to metal manifolds, and their popularity is expected to continue to grow.
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Plastic is a cheaper alternative to metal
Plastic is generally a cheaper alternative to metal. The raw materials for most plastics are derived from petroleum and are relatively inexpensive. The manufacturing processes for plastic, such as injection moulding, are highly efficient and cost-effective, especially for large-scale production. Each additional plastic part can be produced at a very low cost, often just a few cents per unit. This is in contrast to metal parts, which are more expensive to produce due to higher production costs and the energy-intensive process of extraction. For example, aluminium is derived from bauxite ore, which requires a significant amount of energy to extract.
However, it is important to note that the decision between using plastic or metal is not solely based on cost. Both materials have their advantages and unique properties that make them suitable for specific applications. Metal is known for its strength, durability, and weight-bearing capabilities, making it ideal for structural parts. On the other hand, plastic offers lightweight options, corrosion resistance, chemical resistance, and impact resistance.
In the automotive industry, the use of plastic intake manifolds is a notable example of cost-saving measures. Original plastic intake manifolds were designed with low manufacturing costs in mind, and early designs were prone to failure due to a lack of knowledge about their long-term performance. Plastic intake manifolds are also criticised for their noise and potential for leaks and cracks under intense heat. Despite these drawbacks, plastic intake manifolds are expected to become more common due to their lightweight and cost-saving benefits.
While plastic is generally cheaper than metal, there are exceptions. For high-value, durable items where longevity and recyclability are important, metal may be more cost-effective in the long run due to its superior physical properties and environmental benefits. Additionally, the cheapest metal to manufacture is typically steel, particularly low-carbon or mild steel, due to its wide availability and optimised production processes.
In summary, plastic is often a cheaper alternative to metal due to lower raw material costs and less energy-intensive production methods. However, the specific product, production volume, market conditions, and environmental considerations can also impact the overall cost comparison between plastic and metal.
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Plastic is lighter than metal
The use of plastic for car intake manifolds has been a topic of debate, with some people expressing their dislike for the idea of plastic intakes. However, it is important to note that plastic intake manifolds offer several advantages over their metal counterparts. One of the primary benefits of plastic intake manifolds is their lightweight nature. Plastic is substantially lighter than metal, which translates to greater fuel efficiency and lower fuel costs for vehicles. This weight advantage is one of the main reasons for the metal-to-plastic conversion in the automotive and aerospace industries.
The weight difference between plastic and metal is significant. A thermoplastic part, for example, can be up to six times lighter than the same part made from steel. Even when compared to aluminium, which is known for its lightweight properties, plastic still retains its weight advantage, being half the weight of an aluminium part. This weight difference makes a substantial impact on the overall weight of a vehicle, and subsequently, its fuel efficiency.
The weight advantage of plastic becomes even more pronounced when considering the strength-to-weight and strength-to-stiffness ratios. Modern plastic composites have made significant strides in terms of strength and can now compete with, and even surpass, the strength characteristics of metal. Plastics tend to have higher strength-to-weight and strength-to-stiffness ratios, meaning they can endure more stress before failure and are more resistant to deformation under stress. This makes plastic a more durable choice, especially when considering the weight savings.
Additionally, the use of plastic for intake manifolds can lead to smoother interior surfaces, resulting in less turbulent airflow through the tubes. This, in turn, can lead to increased horsepower and improved engine performance. Beyond just weight and performance, the use of plastic in car intake manifolds also offers other advantages, such as lower production costs, faster production times, and the ability to accommodate more complex designs.
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Plastic intake manifolds are prone to failure
Plastic intake manifolds are a crucial component in modern automotive engines. They are responsible for distributing air and fuel to the engine cylinders for efficient combustion and power generation. The use of plastic in manufacturing these manifolds has become increasingly popular in recent years due to its lightweight, cost-effectiveness, and ability to produce complex shapes. However, despite these advantages, plastic intake manifolds are prone to failure.
One of the main reasons plastic intake manifolds fail is due to cracking. The nylon-filled polymers used to make plastic intake manifolds lack the strength of cast aluminum or iron intake manifolds. As a result, plastic manifolds can easily crack due to mishandling, over-tightening fasteners, excessive bending, flexing, overheating, vibration, or an engine backfire. Cracks in plastic intake manifolds can cause various problems, including idle, fuel mixture, drivability, and emission issues.
Another issue with plastic intake manifolds is their susceptibility to damage from heat and high-pressure conditions. If exposed to temperatures or pressures beyond their design limits, plastic manifolds can warp or crack, leading to engine failure. Additionally, some types of plastic can be more prone to chemical damage from certain types of fuel or oil. Coolant that is old and deteriorated can also be corrosive to plastic, gradually eating away at the walls of the tubes carrying antifreeze inside the manifold.
Early designs of plastic intake manifolds also had issues with leaks. The gaskets between the intake manifold and the metal cylinder head must be flexible and durable enough to withstand serious pulling and twisting forces. However, early designs were not adequately designed, which led to leaks and warpage under intense heat that eventually caused cracks. While modern replacements have corrected many of these issues with improved materials and construction, plastic intake manifolds can still be prone to failure if not properly designed and manufactured.
In conclusion, while plastic intake manifolds offer several advantages over metal manifolds, they are susceptible to failure due to cracking, heat and high-pressure damage, chemical damage, and leaks. Proper design, manufacturing processes, and regular maintenance are crucial to mitigate these issues and ensure the reliable performance of plastic intake manifolds in modern automotive engines.
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Plastic intake manifolds can be noisy
Plastic intake manifolds are a common feature in many modern cars. They are usually made of glass-reinforced nylon 6/6 and are substantially lighter and less expensive than metal manifolds. They also have smoother interior surfaces, which result in less turbulent airflow and increased horsepower.
However, one drawback of plastic intake manifolds is that they can be noisy. DuPont Automotive, the world's largest producer of nylon for intake manifolds, acknowledges that noise can sometimes be an issue with plastic manifolds, mainly because the walls tend to be thinner than those of metal manifolds. The thinner walls can result in unpleasant noises as air whooshes through the complex vortices of the manifold.
In one example, the Porsche Boxster engine experienced an unwanted resonant frequency during early testing, which threatened to distract from the engine's characteristic sound quality. DuPont experts were able to pinpoint the source of the noise and correct the problem, demonstrating that it is possible to address noise issues in plastic intake manifolds.
Another factor contributing to noise in plastic intake manifolds is their lower rigidity and density compared to aluminum manifolds. This can result in increased vibration and noise radiation, particularly in inline 4-cylinder gasoline engines.
Some car manufacturers, like Mercedes, have opted to use magnesium instead of plastic for their intake manifolds to reduce noise and achieve a more desirable sound quality. However, plastic intake manifolds are still expected to dominate metal in most new engine programs due to their weight and cost advantages.
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Frequently asked questions
No, not all cars have plastic intake manifolds. While plastic is a common material for intake manifolds, some cars may have metal ones made from aluminum or iron. Additionally, forced induction engines may be an exception and use non-plastic intake manifolds.
Plastic intake manifolds are often used because they offer a balance between cost-effectiveness and lightweight construction. Plastic manifolds are usually cheaper and lighter than metal ones, and they can also provide a smoother interior surface, resulting in less turbulent airflow and increased horsepower.
Plastic intake manifolds are generally considered reliable and are used by many major car manufacturers, including Lexus, Toyota, and Acura. They typically last the life of the car, and modern designs have addressed issues found in earlier plastic manifolds. However, like any part, they can fail, and there have been reports of problems such as cracking and leaks in some older plastic manifolds.
