BorgWarner has developed a new series of multi-platform exhaust gas recirculation coolers that it says offer manufacturers needed durability and flexibility.

The company’s modular cooler family includes four adaptable standard designs for flexibility across a range of engine sizes from 2L-16L displacement. The EGR solution offers resistance to thermal fatigue and improved coolant distribution for durable performance, even with minimum coolant flow, while reducing NOx 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 and 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.”

Featuring hybrid tube heat transfer technology and a floating inner core, BorgWarner’s EGR coolers are designed to resist high levels of thermal load. BorgWarner integrated a thermomechanical 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.

When the system is operated at an exhaust gas temperature of 1,562 degrees (850 degrees Celsius), the inlet gas box temperature is kept below 392 degrees (200 degrees Celsius), compared to more than 1,292 degrees (700 degrees Celsius) without cooling, according to BorgWarner.

The four new coolers allow the standardization of most of the components from one application to another, with the exception of the housing and the mounting fixtures, resulting in better adaptability.