Exhaust Gas Recirculation (EGR) Line Custom

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EGR Line Manufacturers

EGR Line is a critical piping system that cools a portion of the engine's exhaust gas before redirecting it to the intake manifold. This system significantly reduces combustion temperatures, lowers nitrogen oxide (NOx) emissions, and improves fuel economy. We are committed to providing highly reliable, low-emission EGRLine solutions to global automakers.

Product Features:

Short-Path Design: Minimizes the exhaust recirculation path, improving system response and reducing pressure drop.
Integrated Cooling: The laser-welded, high-efficiency EGR cooler offers excellent corrosion resistance. A bypass valve can be used to shut off the cooling function during cold starts, allowing for rapid warm-up.
Modular Piping: Standardized connectors and quick-release clips facilitate on-site assembly and subsequent maintenance. High-Strength Materials: Main piping is constructed of 304/316L stainless steel or high-strength alloys to withstand high-temperature and high-pressure operating conditions.
Smart Valve: Utilizes solenoid or linear valves, offering fast opening/closing times of 50-100ms, supporting precise ECU control.
System Integration: Multiple piping routing options are available to accommodate various engine layouts (inline, V-type), supporting dual-circuit designs for high-pressure (HP-EGR) and low-pressure (LP-EGR).

NINGBO JIATIAN AUTOMOBILE PIPE CO.,LTD.

About JIATIAN

As a EGR Line Manufacturers and EGR Line Factory, The company is located in Wanhou, Zhanqi Town, Yinzhou District, Ningbo City. It is 25 kilometers away from Ningbo Liushi Airport and 5 kilometers away from Ningbo Coastal Industrial Zone. The surrounding area is beautiful with convenient transportation. The company was established on the basis of the development of Ningbo Xingxin Metal Products Factory (established in 1995), and is a high-tech enterprise specializing in the production of automotive pipe fittings. The company's area is 32,000 square meters; the factory area is 26,000 square meters.

The main products of the company are: manufacturing and development of automotive corrugated pipes. Currently, there are 10 CNC fully automatic pipe bending machines, 2 large-scale brazing furnaces assembly lines, 10 various specifications hydraulic internal forming machines (with the maximum processing length of 1.5 meters and diameters ranging from ￠10 to ￠80), 1 800T hydraulic water expansion machine, 4 fully automatic laser welders, 4 sets of welding robots, 8 large-scale machining centers, 6 Panasonic arc welding machines, and over 30 various supporting pipe forming machines. The company has its own R&D and processing centers. The water expansion corrugated pipe equipment and technology of the company are currently at the industry leading level. A comprehensive laboratory has been established.

The company is committed to creating the world's leading automotive bellows with outstanding quality and innovative technology, ensuring that each product can perform well in various environments and promoting the progress of the industry.
NINGBO JIATIAN AUTOMOBILE PIPE CO.,LTD.

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News and Information

Exhaust Gas Recirculation (EGR) Line Industry knowledge
In modern automotive powertrains, Exhaust Gas Recirculation (EGR) Line and fuel injection piping are critical components that directly impact engine performance, emissions compliance, and operational safety.
  • EGR Piping Systems: As a core emission-control component, EGR piping redirects a controlled portion of cooled exhaust gas back into the engine’s intake manifold. This process lowers combustion chamber temperatures, reducing nitrogen oxide (NO?) emissions by up to 35% (per industry testing data) and improving fuel efficiency by 5-8% for diesel engines. Without reliable EGR piping, engines cannot meet global emission standards (e.g., Euro 6, EPA Tier 3, China VI).
  • Fuel Injection Piping: Responsible for delivering high-pressure fuel from the fuel rail to injectors, this piping ensures precise fuel metering and atomization. Its integrity directly affects engine power output, idle stability, and fuel economy – a single leak or pressure drop can cause a 15% reduction in engine efficiency and increased hydrocarbon (HC) emissions.
For automotive manufacturers, partnering with a specialized piping supplier like Jiatian (with 20+ years of precision manufacturing heritage since its predecessor Ningbo Xingxin Metal Products Factory was founded in 1995) is critical to meeting regulatory and performance benchmarks.
The two piping systems perform distinct but complementary functions to optimize engine operation:
System Type Key Core Functions
EGR Piping 1. Cool and recirculate exhaust gas to suppress NO? formation
2. Enable rapid cold-start warmup via bypass valve control
3. Support dual HP/LP-EGR loop integration for flexible emission management
4. Maintain stable pressure with minimal pressure drop (≤2kPa at full load)
Fuel Injection Piping 1. Deliver fuel at pressures up to 2,500 bar (common rail systems)
2. Ensure uniform fuel distribution across cylinders
3. Resist pulsation and vibration to prevent fatigue failure
4. Comply with strict leakage and durability standards
Automotive piping systems face extreme and variable operating environments that test material and structural integrity:
  • Temperature Extremes: EGR piping endures continuous exposure to exhaust gas temperatures of 600-850℃, while fuel injection piping operates in -40℃ (cold start) to 150℃ (engine bay) temperature ranges.
  • Pressure & Vibration: Fuel injection piping sustains cyclic high pressure (up to 2,500 bar), and EGR piping handles exhaust backpressure of 1-3 bar, combined with engine vibration (10-2,000 Hz) that causes fatigue over time.
  • Corrosive Media: EGR gas contains acidic condensates (e.g., sulfuric acid), and fuel piping contacts corrosive additives (e.g., ethanol blends), leading to material degradation without proper protection.
  • Space Constraints: Engine bays have limited installation space, requiring piping to feature complex bends (achieved via Jiatian’s CNC bending machines) and compact modular designs.

Material Innovations

Material Type Application Scenario Key Advantages
304/316L Stainless Steel EGR Piping Main Body High corrosion resistance, temperature resistance up to 900℃, low cost
High-Strength Nickel Alloys EGR Cooler Headers Withstands 850℃+ temperatures and acidic exhaust condensates
Titanium Alloys High-End Fuel Injection Piping 40% lighter than steel, high pressure resistance (up to 3,000 bar)
PTFE-Coated Steel Fuel Piping for Alternative Fuels Chemical resistance to ethanol/hydrogen, low friction for reduced wear

FAQs:

Q1: What are the differences in adaptability between HP-EGR and LP-EGR systems under different operating conditions?

A: The HP-EGR gas extraction point is at the exhaust manifold upstream of the turbocharger, where exhaust gas is at high pressure and temperature. At low engine speeds and loads, it can more precisely control the exhaust gas recirculation ratio, avoiding combustion instability caused by overly lean mixtures. The LP-EGR gas extraction point is downstream of the turbocharger; exhaust gas is cooled and depressurized by the turbocharger and aftertreatment system, making it more suitable for high engine speeds and loads. It reduces the impact on turbocharger efficiency and lowers particulate matter content in exhaust gas. The combination of the two systems achieves a balance between emissions and power across the full operating range.

Q2: What is the correspondence between the pressure rating of fuel injection piping and the pressure of the engine fuel system?

A: The pressure rating of fuel injection piping must be much higher than the normal working pressure of the engine fuel system to cope with pressure fluctuations and peak pressures in the system. For example, the working pressure of a conventional diesel common rail system is approximately 1,600-2,500 bar, while the burst pressure of fuel injection piping typically needs to be 1.5-2 times the working pressure (i.e., above 4,000 bar). It must also withstand long-term cyclic pressure impacts to prevent leakage or rupture due to fatigue.

Q3: What media mainly cause EGR piping corrosion, and what chain effects do they have on the engine?

A: EGR piping corrosion is mainly caused by acidic condensates in exhaust gas, such as sulfuric acid from sulfur combustion and nitric acid from nitrogen oxide reactions, as well as oxidative corrosion from high-temperature exhaust gas. If EGR piping is corroded and leaks, on the one hand, the exhaust gas recirculation ratio will be out of control, leading to excessive engine NO? emissions that fail to meet regulatory requirements. On the other hand, corrosive media may infiltrate the engine compartment along with leaked exhaust gas, corroding surrounding components. It may even affect the engine's air-fuel ratio due to exhaust gas leakage, causing power loss, idle jitter, and other faults.

Q4: What are the main approaches to automotive piping lightweighting, and what technical bottlenecks are faced?

A: There are three main approaches to automotive piping lightweighting: first, material substitution, such as using titanium alloy or high-strength aluminum alloy instead of traditional carbon steel, or adopting composite piping of engineering plastics and metals; second, structural optimization, achieving thin-wall and integrated designs through processes like hydraulic internal forming to reduce redundant components such as piping joints; third, process innovation, such as using laser welding instead of traditional welding to reduce material accumulation at welds. The technical bottlenecks are that lightweight materials often have high costs, and some lightweight materials lack sufficient high-temperature resistance, high-pressure resistance, and corrosion resistance; thin-wall designs may reduce the fatigue resistance and pressure-bearing capacity of piping, making it difficult to balance lightweighting and reliability.

Q5: What new requirements will the popularization of alternative fuels (such as hydrogen and methanol) bring to fuel injection and EGR piping?

A: For fuel injection piping, hydrogen has a small molecular volume and is prone to leakage, and high-pressure hydrogen causes hydrogen embrittlement in piping materials, requiring piping to have higher sealing performance and hydrogen embrittlement resistance. Alcohol fuels such as methanol are highly corrosive and can damage seals and pipe walls of traditional piping, necessitating special corrosion-resistant materials (e.g., PTFE-coated steel). For EGR piping, although some alternative fuel engines (such as hydrogen engines) have no NO? emissions and do not require EGR systems, methanol engines still need EGR to assist in emission reduction. Formaldehyde and other substances produced by methanol combustion will exacerbate piping corrosion. Additionally, changes in the operating characteristics of alternative fuel engines require EGR piping to have more flexible flow regulation capabilities.

Q6: How to identify early failures of EGR piping and fuel injection piping?

A: When EGR piping has early failures, the engine may experience idle instability, power loss, and illumination of the emission warning light. Some models may also have abnormally increased fuel consumption. If the piping has minor leaks, a faint exhaust odor can be detected after the engine warms up. Early failures of fuel injection piping are mostly characterized by insufficient engine power, weak acceleration, and jitter caused by unbalanced operation of cylinders, along with abnormal fluctuations in fuel pressure. If there is a minor leak, oil stains will appear at piping joints, and the vehicle's fuel consumption will increase significantly.