click for larger view

Exhaust Heat Recovery Manifold (EHRM)

Co-developed with Ford Motor Company, the Exhaust Heat Recovery Manifold (EHRM) is designed specifically for gas-electric hybrids. The EHRM integrates the heat recovery function into the exhaust manifold, capturing heat directly from the engine rather than down the line in the exhaust system, so it is able to collect a greater proportion of the exhaust heat than other systems can, while operating more efficiently. This is achieved by enabling the engine coolant to flow through the manifold inner and outer skin via a dedicated rail.

With EHRM, in cold weather the hybrid’s passenger compartment heats up to 50 percent more quickly than configurations where this system is not employed, so the vehicle can switch from its gas-burning thermal engine to its electric powertrain earlier, thereby reducing fuel consumption and emissions.

EHRM components are produced by hydroforming for optimal packaging. The EHRM is assembled by using Faurecia brazing technology, in which a filler metal is heated and distributed between two or more close-fitting parts by capillary action. Brazing can make a component lighter by enabling the use of thinner materials (as thin as 0.6 mm, or 1/32 of an inch) that cannot be joined easily by gas metal arc welding.

read more »

click for larger view

A customized complete exhaust system for Ferrari

Faurecia’s one-of-a-kind, 45 kg complete exhaust package for Ferrari is a compact system. It measures just 1,377 mm long x 1,121 mm wide x 423 mm high (54.2 in. x 44.1 in. x 16.7 in.), with two branches, one for each side of the V-8 engine with its large cylinders. The wide-diameter pipe carries exhaust gases from each side of the engine all the way through to the triple tailpipe encapsulated within the central portion of the rear bumper. The exhaust moves from a fabricated manifold that narrows the flow gradually from four streams ultimately to just one so as to preserve higher torque.

The constraints on the exhaust system are massive, since it must withstand extreme variations from high engine revolutions (up to 9,000 RPM), as well as provide less backpressure and offer the signature Ferrari V8 sound. A pneumatically actuated acoustic valve is integrated into each of the system’s two mufflers to enable the sound to be designed to match the vehicle’s image and performance.

click for larger view

Manifold and close-coupled converter

Faurecia supplies the exhaust manifold for the BMW 4-cylinder 2L turbo gasoline engine (245hp), as well as the close-coupled converter of this state-of-the-art engine. This manifold, roughly 20 percent lighter than a cast alternative, withstands gas temperatures of up to 980°C (1180°F), allowing for high-performance driving.

This manifold is integrated with the turbine housing in a twin-scroll configuration allowing for an optimal pairing of low-speed response and high-end power.