Detroit radiator corporation | 800-525-0011 | 15385 Pine • Romulus, MI 48174

Detroit Radiators revolution series
EGR improvement process

Since the EGR cooler was introduced, it has become the single most replaced part on a diesel engine. With an average failure rate of 100,000 miles, it has become a very costly part to maintain. Detroit Radiator has recognized this issue and over the past 3 years have developed a patent pending EGR improvement process with a life expectancy 2.7 times the O.E.M.

Finding the problem

Engineers found that common failure is in the tube to header joint	After close examination of this joint, the brazing process was inconsistent leaving gaps

Developed Solution

	Detroit Radiator has a proprietary brazing alloy that fills the gaps and strengthens the tube to header joint.
	Our patent pending reinforcing clip provides additional support for the tubes.
	After the back brazing alloy and clips are put into place, we then vacuum braze the unit at over 2000 degrees.

Proving the process

To prove this process will improve performance of the EGR Cooler, Detroit Radiator developed a custom testing rig. This test rig forces 900 degrees of air into the cooler while cold water is on the coolant side, simulating thermal shock.

Test Results

• TYPICAL O.E.M. FAILED AFTER 989 CYCLES
• TYPICAL REVOLUTION EGR FAILED AFTER 2739 CYCLES