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A cool boost to turbocharger performance

Since the advent of the forced-induction engine, we have been looking for ways to get every drop of performance we can. There are many approaches to getting additional power using better intercooling, water injection, or even adding nitrous oxide. One take on a short instant burst of power is being researched by Mahle and involves providing supercooled air to an engine, which allows it to burn a leaner fuel mixture and produce more power. The supercooling idea is not new and was examined by Ford in 1993 on the Mustang Mach III concept car, then brought up again in 2003 with the SVT F-150 Lightning concept. Ford called its system the SuperCooler; it was designed to work with any turbocharged or supercharged engine equipped with a water-to-air intercooler. The system on the Lightning concept used a small tank of antifreeze that was hooked up to the truck air conditioning compressor. The air conditioning compressor cooled the antifreeze down to about 30 degrees. The other side of the tank was hooked up to the air-to-water intercooler, which usually had a temperature over 100 degrees. Once the antifreeze was circulated from the tank into the intercooler, it would lower the intercooler temperature and provide for a cooler, denser air charge into the engine; the result was around 50 extra horsepower for a burst of about 30 seconds to a minute, depending on the size of the tank. The system for the Lightning was to be offered as a $750 option and would have been targeted towards drag racers and the like, as it could be used for a run down the drag strip and then re-cooled by the time the truck was back in line. The system was fairly non-intrusive – it only weighed about 25 pounds and did not require a new compressor or intercooler. But as with many concepts, it was ultimately scrapped. The technology was always stuck in the back of my mind, but with larger and more powerful engines being produced it could not find its place. With the advent of new fuel economy standards, we have seen small-displacement turbocharged engines pop up and they seem like the perfect candidate for this type of technology. Ford's EcoBoost 1.0-liter three-cylinder turbocharged engine, as used in the Fiesta and Focus, is one such candidate for this technology. It would add a negligent amount of weight but could provide a boost of 10 to 20 horsepower when needed, like merging onto the highway or catching up to traffic.

Now you can 3D print your favorite new Ford

Ford is letting people build their own cars, offering digital files so people can print 3D versions of their favorite models. This is way cooler than any old Matchbox or Hot Wheels toy. Ford this week started offering printable files for the F-150 Raptor, Shelby GT350R, Focus ST and Fiesta ST. Folks can order the 3D models in 1:32 scale in plastic (that'd make the mighty large pickup truck about eight inches long) but the digital files let users tweak the scale to the their liking. Once people have the digital files, they can print out their own miniature versions of the cars, made out of soft plastics, sandstone, and even some metals. Ford says it expects demand for such files to grow as sales numbers for desktop 3D printers surges to 1 million units in 2018. That's up from about 44,000 last year. Ford already offers digital files for its company logo, the 1.0-liter engine block, and two older Mustang models. But these new models take this to a totally different scale. Check out Ford's press release below. PRINT YOUR FAVORITE FORD VEHICLE AT HOME: FORD FIRST AUTOMAKER TO OPEN ONE-STOP 3D SHOP ONLINE - Consumers can now download digital images and 3D-printable files of Ford vehicles at the first-ever automaker-licensed, one-stop 3D shop online - The Ford 3D Store offers printable files of F-150 Raptor, Shelby GT350R, Focus ST and Fiesta ST; more models will become available later - Online store is powered by TurboSquid.com, the leader in providing automotive digital imaging and 3D-printable files Want to 3D-print a Shelby GT350R at home? Or would you prefer to simply purchase an F-150 Raptor 3D digital image for a presentation? How about both? Ford fans can now download digital images for Ford vehicles at the first-ever, automaker-authorized one-stop online store for 3D-printable vehicle files. The Ford 3D Store, 3d.ford.com, allows customers to use advanced technology to make their own models of Ford vehicles of the size and material they desire, or simply opt to purchase a 3D digital file from a growing library of more than 1,000 Ford images. "3D printing at home is a growing trend, and it makes sense for us to offer our customers a chance to make their own 3D Ford models," said Mark Bentley, licensing manager, Ford Global Brand Licensing.

Ford recalls 90,736 vehicles due to engine valve issue

Ford will recall 90,736 vehicles as engine intake valves in the vehicles may break while driving, the National Highway Traffic Safety Administration (NHTSA) said on Saturday. The recall impacts certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine, the NHTSA said. According to documents posted by NHTSA and sourced from the automaker, "The engine intake valves may break while driving, which can result in engine failure and a loss of drive power." Following an investigation that started in January, 2022, Ford found 22 instances where "the engine intake valves fractured and fell into the combustion chamber of the engine causing catastrophic engine damage." The automaker's analysis continues: "Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after October 31, 2021." Fixing the problem will require replacement of the entire engine. "Dealers will inspect each vehicle to determine its cumulative number of engine cycles. For vehicles that do not meet the engine cycle threshold, dealers will accumulate high revolutions per minute (rpm) engine cycles per a service procedure. Engines will be replaced on vehicles that do not pass the engine cycle accumulation," Ford says.