Development and characterization of fkm rubber-based composite materials resistant to high temperature and ambient conditions for turbocharger hoses

In this thesis, the development of the fluorocarbon elastomer rubber compound, which is the inner layer of the FKM/VMQ/AR/VMQ turbocharger hose used on the hot side in the automotive turbocharger system, has been studied. Firstly, design of rubber compound formulation were made for material development. In these designs, 4 different types of process aids were used without changing the peroxide curable fluorocarbon polymer and other materials. The production of testing compound according to the determined by rubber compounds formulation was made by the open mill process. Rheometer test was used to determine the curing properties of the test compound, and viscometer test was used to determine their fluidity. Standard test plates of 2mm thickness were prepared for the determination of physical, mechanical and thermal properties. Mechanical and thermal aging tests were carried out on test plates. In addition, the adhesion properties of the prepared mixtures with VMQ rubber were examined on the test plate. According to the test results, the test compound with the best material properties was determined. It has been determined that the type of process aids used in the FKM rubber compounds formulation affects the mechanical properties. It has been determined that the most suitable process aids type for FKM rubber is the type with a compounds of fatty acid and wax. In addition, it has been determined that the optimum amount of use in the formulation is 1 phr. In order to examine the effect of the newly developed FKM rubber compound on the turbocharger hose, hose production was carried out by extrusion and autoclave processes. Performance tests were carried out on the hose and the final product was evaluated.