New EGR Cooler

Preventative Maintenance is Vital

BorgWarner’s modular compact floating-core new EGR cooler series provides durable performance, high robustness against thermal fatigue and reduced emissions for a wide range of commercial vehicle applications.


In developing technological solutions to meet current and future emissions regulations, BorgWarner has developed a new series of multi-platform exhaust-gas recirculation (EGR) coolers featuring a compact floating core. Unlike conventional solutions that must be specifically designed for each application, this modular cooler family includes four adaptable standard designs flexible enough to cover a range of engine sizes from two to 16 litres.


The new EGR solution is robust against thermal fatigue and has enhanced coolant distribution for improved performance even with minimum coolant flow, while reducing nitrogen oxide emissions.


“With lower production volumes and high durability requirements, the commercial-vehicle segment needs an EGR solution that provides outstanding performance and reduces complexity at the same time,” said Joe Fadool, President and General Manager, BorgWarner Emissions & Thermal Systems. “Offering high flexibility and durability, our newly developed EGR coolers have already piqued the interest of several manufacturers that see the potential for a cost-effective solution to help meet increasingly stringent emissions regulations.”


The new EGR technology features hybrid tube heat transfer technology and a floating inner core, and the coolers are designed to resist high levels of thermal load. In addition, the system provides enhanced coolant distribution, improving performance even with minimum coolant flow.


BorgWarner integrated a thermo-mechanical damper into the design to facilitate complete decoupling of the shell and inner core components, to absorb longitudinal and angular differences for improved durability. The damper also provides some initial extra cooling for the inlet gas to reduce thermal shock and allows better gas distribution to the tubes to resist thermal fatigue.


Cooling the damper and inlet gas box reduces the overall temperatures achieved, which in turn significantly lowers thermal stress. When the system is operated at an exhaust gas temperature of 850°C, the inlet gas box temperature is kept below 200°C, compared to more than 700°C without cooling.


The new design is said to minimise the effect of the engine transients over the EGR cooler’s durability. The four new coolers allow the standardisation of most of the components from one application to another, with the exception of the housing and the mounting fixtures, resulting in improved adaptability.