Federal Mogul is best positioned to implement truly innovative solutions in response to the global CO₂ challenge. As world technology leaders in powertrain efficiency, Federal Mogul engineers have fine-tuned and developed new technologies that are aimed at reducing CO₂ emissions and upping engine performance with OEM-approved solutions.

A little less than one third of heat released during operation actually produces torque. The rest is dissipated in heat transfer, friction, and gas exchange. Federal Mogul understands the potential in these wasted energies and, with a range of solutions, is turning theoretical performance boosting approaches into useable technologies that are redefining the concept of efficiency.

Direct solutions

The overall reduction of friction with optimised product designs has a major effect on engine efficiency. Typically, power cylinder assemblies (pistons and piston rings) account for 40% of engine friction losses and dissipate useful energy in the form of heat. Federal Mogul has optimised the designs of pistons, piston rings, and piston coating technologies; providing a significant reduction of frictional horsepower losses and improving fuel economy.

When these technologies are implemented on a typical 170 g/km CO₂ petrol vehicle on the New European Driving Cycle (NEDC), this suite of technologies reduces CO₂ emissions by up to 4.4 g/km. The application of similar technologies to a typical diesel vehicle with a base emission of 150 g/km CO₂ can lead to CO₂ improvements of 2.5 g/km.

The use of new innovations in cylinder heads and gaskets, such as Federal Mogul’s flagship Payen® brand, can also help minimise bore distortion. This translates into a ring pack design with less friction, lowering CO₂ emissions. Federal Mogul designs have also improved sealing and bearing technologies. This contributes to a further reduction in friction – offering high-performance dynamic sealing for low torque that can be used for front and rear seals, as well as for transmission and axle applications. Efficient seals enable a reduction of more than 0.5 g/km CO_2, as based on the NEDC test cycle.

Out-dated spark plug technology that sees a large gap growth over extended use is another area where Federal Mogul has implemented its high-end engineering skills for reduced CO₂ emissions. Using iridium technology in the production of extremely durable “fine wire” centres and ground electrodes, engineers have been able to expose the cylinder’s air-fuel mixture to a larger spark plug gap for a brighter ignition with higher voltage. The Federal Mogul-developed alumina ceramic helps assure high-voltage and high-temperature operation of spark plugs.

With a combination of higher spark energy and engine recalibration, testing has shown reduction of up to 2.4 g/km in CO₂ emissions. In diesel engines, superior afterheating performance by Federal Mogul-engineered glow plugs has also been measured – showing that engines can meet Euro VI requirements without the need for ceramic materials.

The Federal Mogul endeavour to find every component that can be optimised to deliver lower CO₂ emissions has even led to design changes of windscreen wipers and lighting. The company has developed flat-blade wipers which reduce mass and energy required for operation – while still providing superior wiping performance.

By converting lighting sources to LEDs and focusing them more efficiently with Federal Mogul-developed lighting systems, mass, power draw and copper wiring requirements can be reduced. This solution gives users a cost-effective alternative that, as a result of lighter weight, also reduces CO₂ emissions.

All Federal Mogul components are designed to be as lightweight as possible. The company also recognises that, when considering dynamic components, reduced weight also means a reduction in counter weights – which results in greatly lowered vehicle mass for reduced strain on engines. This translates directly into lower CO₂ emissions.

Enabling solutions

High performance gained from Federal Mogul-engineered technologies allows OEMs to increase cylinder pressure drastically. This enables engines and powertrains to have better performance, fuel economy, and reduced CO₂ emissions.

Federal Mogul offers other enabling solutions that bring the possibilities of high-temperature operating conditions to the market, such as a range of heat shields for thermal protection. Advanced valve seats and guide materials also allow for the use of ethanol-based fuels which lack the lubricity of conventional petroleum and result in lower CO₂ emissions.

Driver solutions

As the international automotive industry begins to use Federal Mogul efficiency technologies, even further reductions in CO₂ emissions are achievable by making a few adaptations to one’s driving style:

• Drive with closed windows to reduce unnecessary drag which slows the vehicle and burns more fuel.
• Service vehicles regularly.
• Ensure correct tyre pressure to help minimise drag on the road surface.
• Accelerate slowly.
• Avoid, when possible, driving with a full fuel tank as the weight could increase consumption.

Photo: Flange bearing

• Flange bearing: Hard-wearing flange bearings help keep engines operating efficiently.

• GDC Ring: GDC Rings help create tight seals for better performance and lower emissions.

• IMG 2100.jpg: Good gaskets are central to maintaining high compression ratios. The better compression is preserved, especially in older engines, the easier it is to maintain low CO2 emissions.

• Iridium single: With recent improvements in spark plug technologies, higher efficiency engines are becoming standard around the world.

Photo: Nural piston

• Nural-Piston: Precise piston designs create minimal friction with maximum performance; the key to efficiency and low CO2 emissions.