Rocket Ship Superalloy Technology Aids Ford Fusion 2.0-Liter
Turbo Durability

  • Modified superalloy used in Space Shuttle main engine helps performance and
    durability of Ford Fusion 2.0-liter EcoBoost® turbo

  • Material supports upper limit of temperature extremes for commercial
    turbochargers; used on Fusion and Focus ST EcoBoost turbos

  • Integrated exhaust manifold casting combines cylinder head with exhaust
    manifold to aid cooling, direct more energy to the turbo faster

DEARBORN, Mich., Aug. 21, 2012 – Enthusiasts will say the all-new
Ford Fusion equipped with the 2.0-liter EcoBoost® turbo
engine is a rocket ship. Fusion engineers will tell you parts of its engine
depend on technology from one.



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graphic to download PDF.



To prolong turbo life and combat thermal fatigue, powertrain engineers for
the new Ford Fusion, in conjunction with a team at supplier BorgWarner, went to
the upper limits of commercially available turbo materials when deciding on the
turbine wheel for the turbocharger fitted to 2.0-liter EcoBoost variants.



The same material has been tried and tested in outer space, as a version of
it was used on the Space Shuttle main engine’s high-pressure fuel turbo pump and
the blades of its high-pressure oxidizer turbo pump.



The upper temperature limit for the turbine wheel used on the 2.0-liter
EcoBoost engine in Edge and Explorer is 970 degrees Celsius (1,778 degrees
Fahrenheit). But in the sporty 2.0-liter EcoBoost for Fusion and Focus ST, the
addition of tungsten and cobalt gives the alloy an upper temperature limit of
1,050 degrees Celsius (1,922 degrees Fahrenheit).



The benefit of using such high-temperature alloy is that Fusion 2.0-liter
drivers can enjoy enthusiastic and spirited driving for the life of the car
without degrading turbo reliability or its mechanical integrity.



Fusion owners can highlight the fact that the BorgWarner K03 turbocharger
features both water and oil cooling; when the engine is running, it is primarily
oil-cooled, but after the engine is turned off, the water cooling system creates
a thermal water siphon to help draw heat away from the turbocharger.



As a bonus, they might explain their Fusion 2.0-liter turbo’s performance
is further strengthened by an integrated exhaust manifold design that combines
the cylinder head and exhaust manifold into one casting; this allows the
creation of smaller internal passageways (reduced plenum volumes) that direct
more exhaust gas energy into the turbo more quickly than a separate head and
manifold assembly.



The Fusion turbo, they also can claim, is designed to run safely at speeds
up to 190,000 rpm, and is the same turbo used in the new, high-performance
Ford Focus ST.



More information regarding the Fusion 2.0-liter can be found at http://www.ford.com/cars/fusion/2013/.



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About Ford Motor Company
Ford Motor Company, a global
automotive industry leader based in Dearborn, Mich., manufactures or distributes
automobiles across six continents. With about 168,000 employees and about 65
plants worldwide, the company’s automotive brands include Ford and Lincoln. The
company provides financial services through Ford Motor Credit Company. For more
information regarding Ford and its products worldwide, please visit http://corporate.ford.com.