What is Fireball XMC Coating ?Fireball XMC exhaust coating is a proprietary thermal insulating coating for diesel engine exhaust manifold components. XMC was developed from the thin film ceramic coating technology used by the performance racing industry for 30 years.
Fireball XMC Coating, What does it do?XMC reduces heat loss from the exhaust gas, (manifold surface temperatures are 4250F lower) and smoothes the ID surfaces of the manifold, increasing exhaust flow by 8%. Benefits for trucking industry: The result is 7% more available horsepower and torque which can be used by the driver to reduce fuel consumption.
How does XMC Coatings Work ?The heat energy normally lost by conduction and radiation from the exhaust manifold is kept in the exhaust gas by the high thermal insulation properties of XMC. The hotter exhaust gas flows faster and has more kinetic energy which spins the turbo faster generating more boost and horsepower. The smooth XMC ID surface reduces turbulence thereby permitting higher exhaust gas flow which allows the engine to breathe better. This in turn reduces back pressure and improves scavenging and engine efficiency.
Fireball XMC Coating Improves Fuel Economy A long haul transport truck with a 12L 6 cylinder 465 hp diesel engine achieved an overall average 11.0% increase in fuel economy over 4 months. The improvement in fuel economy is statistically significant at the 99.5% confidence level
Since fuel consumption varies with the weight hauled, if load weight is taken into account the fuel economy increase averages 14.5%, 9.5% at 8,000 lbs, up to 18.7% at 40,000 lbs. See graph and tables below.
Fuel Monitoring Details
The trial truck is a 2000 Volvo model VN truck with a 2003 rebuilt Volvo VED12-465 engine. It makes 2 runs per week from Toronto to Charlotte NC, 1,200km (750 mi) one way. The before coating (normal) data covers Feb 1 to Mar 2, 2007, for a distance of 25,584 km (15,274 mi) and the after (coated) data covers Mar 5 to June 28, 2007, for a distance of 83,900km (52,132 mi).
XMC Effect on Horsepower and Torque
Chassis dynamometer testing shows a 7.4 % increase in peak Rear Wheel hp and 7% increase in peak RW torque in the cruise rpm range, 1100 to 1375 rpm (48 to 65 mph) after the XMC manifold was installed, see the HP and torque curves below.
XMC Increases Exhaust Manifold Air Flow
Air flow tests before and after coating showed an 8.3% increase in CFM passing through the XMC manifold. The coating makes the ID of the manifold smoother, see photographs below, which reduces the resistance to exhaust gas flow.
The ID surface of a cast exhaust manifold is very rough, see photo below. The rough surface generates excessive turbulence in the exhaust gas flow, increasing backpressure and restricting the flow of exhaust gas through the manifold.
XMC Coating Cost
For a 12L 6 cylinder diesel engine exhaust manifold (3-piece) and hot side turbo housing, XMC coating costs $1,200 CDN. The cost of parts and installation is extra. For the trial truck 3 hours of shop time was needed to remove the old parts and install the coated manifold and turbo housing. The installation cost was $525 including parts, labour & taxes for a total coating & installation cost of $1,725.
XMC Coating Payback
After 4 months on the road, 83,900km (52,132 mi), the Owner/Operator’s fuel spending was reduced by $2,624 CAN ($2,493 US). He averaged a savings of approximately $39 CAN ($37 US) per fill up. The average fuel price for the time of the trial was $0.760 CAN/L ($2.73 US/USG).
The fuel savings = $0.031 CAN/km ($0.046 USD/mile).
The coating and installation cost is paid back after 55,645 km (34,556 mi) which represents less than 3 months working time for this Owner/Operator.