XMC Coating
XMC Coatings Print E-mail

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.

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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).

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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.

 

 

XMC Test Results

Our XMC coating is tested for air flow gains and surface temperature improvements. The results speak for themselves.

View test data for XMC coatings

XMC Air Flow Test

XMC Exhaust Manifold Test

XMC Coatings Flow Bench TestingAir 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,  which reduces the resistance to exhaust gas flow. The ID surface of a cast exhaust manifold is very rough. The rough surface generates excessive turbulence in the exhaust gas flow, increasing backpressure and restricting the flow of exhaust gas through the manifold.

Before And After

Exhaust Manifold Before And After

Exhaust manifold before XMC coating
Before XMC Coating
Exhaust manifold after XMC coating
After XMC Coating

As you can see the exhaust manifold port is rough. The air flow through the manifold before coating is 306.6 CFM.

The XMC coating smoothes the rough texture of the cast iron. The air flow through the XMC coated manifold is 332.1 CFM, an increase of 25.5 CFM or 8.3%.

   

Surface Temperature

Surface Temperature

Surface Temperature DataSurface temperature measurements during dynamometer testing showed the reduction in the manifold and turbo surface temperature averages 2240C (4350F). The temperature difference actually ranged from 120 to 2980C (250 to 570 0F), see graph below. The reduction in temperature is statistically significant at the 99.9% confidence level. Other benefits include:

  • Under hood temperatures will also be reduced significantly
  • XMC surface temperatures are below ignition temperature of hydraulic fluid
  • The exhaust manifold cools off much faster, a bonus for mechanics

XMC Appearence

XMC Available Finishes - Black Satin and Polished

Manifold before coating
Before XMC Coating
 Manifold after coating
After XMC Coating
 Manifold in black satin finish
Black Satin Finish
Manifold on Volvo VED 12 - 465
Volvo VED 12 - 465
    
Fireball Performance Coatings - XMC Coatings
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