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BorgWarner Technology Boosts Growth of Gasoline-Engine Turbocharging


March 2007
 Filed under: FUEL AND ECONOMY Car News | FUEL AND ECONOMY Headlines
AUBURN HILLS, Mich., March 14 /PRNewswire-FirstCall/ -- Advances in turbocharger design, manufacturing and materials are expected to boost the growth of turbocharged gasoline direct injected engines by 30% over the next five years, according to industry experts and BorgWarner, a leader in turbocharging technology.

"Gasoline-engine turbocharging is not focused exclusively on increasing engine output, but also on combining exceptional engine performance with fuel economy," said Roger Wood, President and General Manager, BorgWarner Turbo & Emissions Systems. "These are among the most important challenges facing automakers all over the world. BorgWarner is at the forefront of the industry in terms of providing the technology solutions that enable our customers to meet the challenges of improving fuel economy and engine performance. In addition to conventional turbochargers, variable turbine geometry (VTG) technology will play a significant role in gasoline engines."

Several automakers around the globe are exploring application possibilities for VTG technology in gas engines. BorgWarner is leveraging its expertise in air management technology to ensure that the company is well- positioned to make the most of these opportunities. Worldwide, the use of turbocharged gasoline direct injected engines is expected to grow to 2 million engines in 2011 from about half a million in 2006. About 70% of these engines are expected to be produced in Europe, with the rest of the production in Japan, China and North America.
Downsized gasoline engines with VTG technology can achieve the same output and dynamic engine response as normally aspirated engines with a larger displacement. At the same time, these improvements are achieved with much lower fuel consumption. Fuel savings is estimated at 15 and 20 percent compared to a larger traditional or port injected gasoline engine without a turbocharger.

Until recently, VTG technology was limited to diesel engines. The technical challenge lay in developing materials capable of withstanding the much higher exhaust gas temperatures that are generated in gasoline engines. In cooperation with Porsche, BorgWarner Turbo & Emissions Systems succeeded in developing the first turbocharger with VTG technology for the Porsche 911 Turbo.

The key feature of the turbocharger is its adjustable guide vanes. The innovative design means that at low engine speeds and low exhaust gas flow rates, the vanes in a closed position develop a high boost pressure. This pressure falls as the vanes are opened. As a result, the bypass system with the wastegate valve that is a feature of conventional turbochargers can be eliminated. The entire exhaust gas flow can then pass through the turbine wheel and be immediately converted into increased boosting. This considerably improves engine response in the lower rpm range, compared to a conventional turbocharger with a wastegate typically used in gasoline applications.

To address the challenge of high exhaust temperature, BorgWarner used high- temperature-resistant alloys for the VTG cartridge and vanes, materials which are also used in aviation and space technology.

Following the successful debut of its gasoline VTG unit in the Porsche 911 Turbo, BorgWarner Turbo & Emissions Systems expects this technology to become established on a broad number of applications over the next ten years.

BorgWarner Turbo & Emissions Systems is a leading global producer of turbochargers and other engine air management systems for passenger cars, light trucks and commercial vehicles. These systems are designed to improve fuel economy, reduce emissions and enhance vehicle performance.

Auburn Hills, Michigan-based BorgWarner Inc. (NYSE:BWA) is a product leader in highly engineered components and systems for vehicle powertrain applications worldwide. The FORTUNE 500 company operates manufacturing and technical facilities in 63 locations in 18 countries. Customers include Ford, VW/Audi, DaimlerChrysler, General Motors, Toyota, Renault/Nissan, Hyundai/Kia, Honda, BMW, Caterpillar, Navistar International, and Peugeot.

The Internet address for BorgWarner is: http://www.borgwarner.com/

Statements contained in this news release may contain forward-looking statements as contemplated by the 1995 Private Securities Litigation Reform Act that are based on management's current expectations, estimates and projections. Words such as "expects," "anticipates," "intends," "plans," "believes," "estimates," variations of such words and similar expressions are intended to identify such forward-looking statements. Forward-looking statements are subject to risks and uncertainties, many of which are difficult to predict and generally beyond the control of the Company, that could cause actual results to differ materially from those expressed, projected or implied in or by the forward-looking statements. Such risks and uncertainties include: fluctuations in domestic or foreign automotive production, the continued use of outside suppliers by original equipment manufacturers, fluctuations in demand for vehicles containing the Company's products, general economic conditions, as well as other risks detailed in the Company's filings with the Securities and Exchange Commission, including the Risk Factors identified in its most recently filed annual report or Form 10-K. The Company does not undertake any obligation to update any forward-looking statement.

Source: BorgWarner Inc.

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