BorgWarner has developed a new turbocharger design that it claims will help reduce diesel emissions. One of the methods used to reduce emissions of nitrogen oxides from diesel engines is to recirculate some of the exhaust gases (EGR). Low pressure EGR helps to reduce the combustion temperatures and thus the production of NOx. However injecting the exhaust gases upstream of the turbo compressor has caused problems in the past as the exhaust particles and high temperature of the exhaust have caused metal fatigue. Downstream injection requires higher pressures. BorgWarner has developed new materials and coatings that can better withstand low pressure EGR and resist particulate deposits on the compressor wheels. Two European manufacturers are expected to introduce the new turbochargers on their U.S. diesel engines in 2008. Volkswagen, BMW and Mercedes Benz are introducing new clean diesels this year.

[Source: BorgWarner]

Ford's Derrick Kuzak

It's interesting how the overall tenor of the presentations and speeches changes depending on which conference, which collection of auto industry people, one attends. You'd think there'd be some consistency, but the reality is that the auto industry is mighty varied. We shine a light on one corner here at ABG, but there's a lot more to what's going on than just green tech.

To wit: the SAE World Congress opened this morning with five speakers in a session titled "Climate for Change." Featuring keynote speaker Frank Klegon, executive vice president of product development for Chrysler and panelists Derrick Kuzak, Ford's global product development group vice president, Timothy Manganello, chairman and CEO of BorgWarner, Edward Mantey, the vice president of engineering design at the Toyota Technical Center and Donald Walker, co-chief executive officer at Magna International, the session was billed as a gathering of minds on how the industry is changing. The sad news for green car fans is that increased fuel efficiency and reduced emissions are not necessarily at the top of everyone's list. I've written up what each of the five speakers said after the jump. There's audio, too.

BorgWarner has just opened up a second plant at their facility in Amstadt, Germany to produce dual clutch transmission modules. BorgWarner and other suppliers like Getrag have been experiencing huge growth in demand for dual clutch transmissions as demand for increased fuel efficiency and reduced CO₂ emissions drives adoption. BorgWarner is the supplier of dual clutch systems to Volkswagen Group for their DSG transmissions. VW recently sold their one millionth DSG-equipped vehicle. By the time all of BorgWarner's currently announced programs reach full production they expect to be producing 2.3 million units a year. The dual clutch transmissions can provide a 10-15 percent improvement in efficiency compared to a conventional automatic.

[Source: BorgWarner]

With internal combustion engines set to continue playing a major role in automotive drivetrains for some time to come, technologies that can help improve efficiency are growing in demand. Two of the most popular at the moment are turbochargers and dual clutch transmissions (DCT). Both are seen as means to achieve significant improvements in efficiency at much lower cost than alternatives like hybrids. One of the chief suppliers of both of these components is BorgWarner.

BorgWarner has been the supplier of DSG transmissions to Volkswagen, which just recently passed the one million installation mark. With Ford set to produce upwards of 500,000 turbocharged direct injection engines annually within the next few years and many manufacturers looking to follow a similar path BorgWarner is well positioned to benefit from the shift. The company expects revenues to rise by 10 percent this year in spite of falling U.S. sales.

[Source: Detroit Free Press]

BorgWarner has broken ground for a second manufacturing plant in Arnstadt Germany to build their DualTronic transmission modules. The DualTronic clutch system is the heart of the renowned Volkswagen/Audi DSG gearbox. The clutch system can be used with most conventional manual transmissions to allow them to function as either fully automatic or sequential shift manual transmissions. The system takes advantage of the inherent mechanical efficiency of a conventional manual gearbox but allows two-pedal driving. The new plant will be finished in November and will double BorgWarner's existing capacity.

[Source: BorgWarner]

If you don't think your Toyota Highlander Hybrid is fast enough, try adding a turbocharger. The AirWerks program at BorgWarner Turbo & Emissions Systems has developed a turbo in partnership with Toyota for the Highlander Hybrid. Early testing shows a 20 percent power increase. The K24.2 turbo is specifically designed for the Highlander application. It features a forged billet compressor wheel, ni-resist turbine housing and a water-cooled bearing housing.

BorgWarner, a Michigan based automotive supplier, announced a partnership with the US Environmental Protection Agency (EPA), to further develop Clean Diesel Combustion (CDC). CDC is a technology developed and patented by EPA, and is a possible approach to meeting EPA's future diesel emissions standards for cars, SUVs, and trucks. The partnership will focus on the development of advanced air-boosting systems, since the currently available turbo- and super-chargers are insufficient to achieve clean and highly efficient diesel engines. EPA also has similar agreements with Ford Motor Company and International Truck and Engine to further develop CDC.

[Source: BorgWarner]