The development of high performance turbocharging systems for the Ford F-150 is a longstanding tradition at BorgWarner. The company’s turbochargers have been helping the successful model from Ford achieve excellent driving characteristics with moderate fuel consumption since 2010. Most recently, BorgWarner supported Ford in implementing its innovative 6-cylinder 165 cubic inch (2.7 liter) EcoBoost engine, which has been available in the Ford F-150 since the end of 2014 (see TurboNews 1/2015).
However, focus now shifted to revising the 213 cubic inch (3.5-liter) V6 EcoBoost engine, which was also equipped with BorgWarner turbocharging systems. Ford had extremely high demands of the new drive. The objective was to improve response and performance, as well as fuel economy and exhaust emission values. The vehicle manufacturer also placed great emphasis on optimizing smooth running.
EcoBoost sets new standards
Close cooperation between Ford and BorgWarner led to a drive that eclipses even large-displacement V8 engines such as the previous 378 cubic inch (6.2-liter) unit and the 305 cubic inch (5-liter) engine that is still in production. The high-performance version of the new V6 EcoBoost engine generates 444 hp (331 kW) in the Ford F-150 Raptor and offers maximum torque of 509 lb-ft (691 Nm), which is available from 3,500 rpm. The basic version generates 370 hp (276 kW) and torque of 469 lb-ft (637 Nm) at 3,500 rpm. The two drives also offer significantly better fuel efficiency than the V8 engines.
Goodbye, V8: Two waste gate turbochargers from BorgWarner
help the new engine generate power of up to 444 hp (331 kW)
and torque of 509 lb-ft (691 Nm).
To squeeze this enormous performance out of displacement of just 213 cubic inches (3.5 liters), BorgWarner reworked the engine’s turbocharging systems from the ground up. The developers in Asheville collaborated closely with the Powertrain Technical Center in Auburn Hills and also received support from Kirchheimbolanden. Two waste gate turbochargers with electrical actuators are used. The particularly lightweight turbine wheels of the turbochargers are produced from an extremely heat-resistant alloy that was developed in the aerospace industry and guarantee spontaneous response even at low engine speeds. The turbos also employ ported-shroud impeller casings, which have previously only been used in diesel engines. This therefore represents a first in the gasoline engine market. This design allows the turbocharger to build up greater pressure at low revs and with less gas, while also improving the efficiency of the impeller wheel.
Turbo with exceptionally smooth running
Optimizing the NVH (noise, vibration, harshness) characteristics of the turbochargers also represented a complex task. Numerous changes were still being made to the engine until shortly before the start of production, which also had an influence on the NVH behavior of the turbocharging systems. However, thanks to very close collaboration with the developers at Ford, the turbocharger specialists were able to overcome this challenge. The new turbochargers have been optimized in such a way that they meet Ford’s high expectations and requirements in full. Beside the turbocharging systems, BorgWarner also provides the variable cam timing (VCT) and the complete camshaft drive system for the new engine. These components have also been optimized with regard to wear resistance, low-friction, and smooth running.
Partnership with growth potential
With the new V6 BiTurbo, the EcoBoost concept has been transformed to produce a genuine high-performance application that also impresses the discerning US customer with a predilection for largedisplacement engines. The orders placed for the engine are constantly on the rise and are actually beginning to overtake the production figures of the normally aspirated engines. The engine’s turbochargers have been produced at BorgWarner’s state-ofthe- art facility in Ramos since mid-2017. Due to the strong increase in demand being experienced, production capacities at this location are being increased in a step-by-step approach.
The turbochargers in the new EcoBoost engine are produced
at BorgWarner’s state-of-the-art facility in Ramos.
Foto: © BorgWarner