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Senior Flexonics is a leader in EGR Cooler design and manufacture with design centers in North America, Europe and Asia. We serve the on/off Highway diesel markets with manufacturing centers in Gurugram, India. EGR products include Tube and Shell, Tube and Fin, Plate Type and our unique patented Co-Axial EGR Cooler. Our heat exchangers have up to 95% efficiency. In addition, they are highly resistant to fouling and are scalable to match performance requirements. Our products can be found in light/medium and heavy-duty vehicle platforms.
As the technology leader, Senior has developed unique corrugated thin-wall, flexible EGR tube designs to solve high-temperature durability and installation problems. Since our tubing is flexible, alignment of end fittings is also much easier. A one-piece design also eliminates high stress areas that are often the source of premature failures.
Senior has solutions for the Heavy-Duty Diesel engine market where durability is measured by uptime, as well as the automotive market where tight packaging and high efficiencies are required.
About EGR Coolers
As emissions-related engine components continue to expand both in quantity and complexity, the market is demanding solutions that provide full transparency to the end user. This zero-impact approach when adding complex components leaves no room for compromises in durability or performance. Senior Flexonics has taken this direction seriously and has developed the experience and tools necessary to deliver products that exceed even the most demanding customer requirements.
When evaluating EGR cooler durability, it is crucial to understand the different loading mechanisms and their causes within a general loading category – primarily thermal cycling. Thermal loading of EGR coolers falls into two levels that are typically referred to as thermal fatigue (high cycle) and thermal shock (low cycle).
Within all of Senior Flexonics’ EGR cooler designs, flexibility is the key feature. Metal expansion is a simple fact within the abusive environment EGR coolers are applied in. Senior Flexonics’ engineering team believes that, as with most things in life, it is far better to accommodate change than to resist it.