Dana's All-New Water-Cooled Charge Air Cooler Debuts on 2011 Ford F-Series Super Duty Trucks

Unique cooler design provides improvements in packaging, performance, fuel economy

Sep 21, 2010

HANNOVER, Germany, Sept. 21 /PRNewswire/ -- Dana Holding Corporation (NYSE: DAN) recently debuted its all-new water-cooled charge air cooler on the 2011 Ford F-250 Super Duty pickup truck.  The truck, which features Ford Motor Company's all-new 6.7 liter Power Stroke® V-8 turbocharged diesel engine, provides improved torque, power, and fuel economy.  

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Dana is showcasing its unique cooler design at IAA Commercial Vehicles Expo, through Sept. 30, in Hannover (Hall 17, Booth B27).

"As the demand grows for vehicle makers to produce engines that are both downsized and turbocharged, Dana is delivering innovative, lightweight solutions such as its water-cooled charge air cooler that provide optimal fuel economy benefits and greater vehicle performance," said Ted Zielinski, director of advanced thermal engineering at the Dana Power Technologies Group.

Key to the water charge air cooler's success is its highly compact packaging design. Unlike air-to-air coolers, which typically must be packaged in front of the radiator,  Dana's efficient cooler design can be accommodated to fit smaller spaces and can be packaged anywhere within the engine compartment.

The water-cooled charge air cooler is constructed using stacked dish technology.  The stamped alternating plates, constructed entirely of aluminum, provide lightweight  benefits, which translate to improved durability and fuel economy – key features of the new Ford Super Duty engine.  

The cooler provides additional performance benefits for the Ford engine, thanks to Dana's enhanced rolled tiered offset fins.  The unique design of the fin helps to transfer heat more efficiently than current industry offerings.  Dana also utilizes its turbulizer rolling process to construct the fins, which is more cost-effective and flexible when compared to standard stamping.

Dana utilized its proprietary fluxless continuous flow brazing process to assemble the cooler.  The result is a clean part with no residue, which is critical for optimal engine performance.  Current flux brazing offerings often leave residue on the part, which can cause detrimental interaction with the engine coolant.

"This cooler's innovative stacked dish design, combined with Dana's proprietary manufacturing processes, demonstrates our ability to provide thermal solutions that meet highly demanding performance standards in today's vehicles," said Dwayne Matthews, vice president and general manager of the Dana Power Technologies Group.

Dana is manufacturing the water coolers at its Mount Forest, Ontario, Canada facility.

About the 63rd IAA Commercial Vehicles Expo

The IAA Commercial Vehicles Expo is the most established and longest running commercial vehicle trade fair for mobility, transportation, and logistics around the world.  Held bi-annually in Hannover, Germany, by the German Association of the Automotive Industry (VDA), the theme for this year's conference is "Commercial vehicles: efficient, flexible, future-proof."

About Dana Holding Corporation

Dana is a world leader in the supply of driveline products (axles and driveshafts), power technologies (sealing and thermal-management products), and genuine service parts for light and heavy manufacturers.  The company's customer base includes virtually every major vehicle manufacturer in the global automotive, commercial vehicle, and off-highway markets.  Based in Maumee, Ohio, the company employs approximately 22,000 people in 26 countries and reported 2009 sales of $5.2 billion.  For more information, please visit www.dana.com.

SOURCE Dana Holding Corporation