![Exhaust Manifold](https://upload.wikimedia.org/wikipedia/commons/7/77/Exhaust_manifold.jpg)
In
automotive engineering
Automotive engineering, along with aerospace engineering and naval architecture, is a branch of vehicle engineering, incorporating elements of mechanical, electrical, electronic, software, and safety engineering as applied to the design, manufactu ...
, an exhaust manifold collects the
exhaust gas
Exhaust gas or flue gas is emitted as a result of the combustion of fuels such as natural gas, gasoline (petrol), diesel fuel, fuel oil, biodiesel blends, or coal. According to the type of engine, it is discharged into the atmosphere through an ...
es from multiple
cylinder
A cylinder (from ) has traditionally been a three-dimensional solid, one of the most basic of curvilinear geometric shapes. In elementary geometry, it is considered a prism with a circle as its base.
A cylinder may also be defined as an infin ...
s into one pipe. The word ''
manifold
In mathematics, a manifold is a topological space that locally resembles Euclidean space near each point. More precisely, an n-dimensional manifold, or ''n-manifold'' for short, is a topological space with the property that each point has a n ...
'' comes from the Old English word ''manigfeald'' (from the Anglo-Saxon ''manig''
anyand ''feald''
old and refers to the folding together of multiple inputs and outputs (in contrast, an inlet or
intake manifold
In automotive engineering, an inlet manifold or intake manifold (in American English) is the part of an engine that supplies the fuel/air mixture to the cylinders. The word ''manifold'' comes from the Old English word ''manigfeald'' (from the ...
''supplies'' air ''to'' the cylinders).
Exhaust manifolds are generally simple
cast iron
Cast iron is a class of iron–carbon alloys with a carbon content more than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its color when fractured: white cast iron has carbide impuriti ...
or stainless steel units which collect engine exhaust gas from multiple cylinders and deliver it to the exhaust pipe. For many engines, there are aftermarket tubular exhaust manifolds known as headers in
American English
American English, sometimes called United States English or U.S. English, is the set of variety (linguistics), varieties of the English language native to the United States. English is the Languages of the United States, most widely spoken lan ...
, as
extractor manifold
In an internal combustion engine, the geometry of the exhaust system can be optimised ("tuned") to maximise the power output of the engine. Tuned exhausts are designed so that reflected pressure waves arrive at the exhaust port at a particular t ...
s in British and
Australian English
Australian English (AusE, AusEng, AuE, AuEng, en-AU) is the set of varieties of the English language native to Australia. It is the country's common language and ''de facto'' national language; while Australia has no official language, Engli ...
,
[''The Design and Tuning of Competition Engines'', Philip H. Smith, pp. 137–138] and simply as "tubular manifolds" in
British English
British English (BrE, en-GB, or BE) is, according to Lexico, Oxford Dictionaries, "English language, English as used in Great Britain, as distinct from that used elsewhere". More narrowly, it can refer specifically to the English language in ...
. These consist of individual exhaust headpipes for each cylinder, which then usually converge into one tube called a
collector. Headers that do not have collectors are called
zoomie headers.
The most common types of aftermarket headers are made of mild steel or stainless steel tubing for the primary tubes along with flat flanges and possibly a larger diameter collector made of a similar material as the primaries. They may be coated with a ceramic-type finish (sometimes both inside and outside), or painted with a heat-resistant finish, or bare. Chrome plated headers are available but these tend to blue after use. Polished stainless steel will also color (usually a yellow tint), but less than chrome in most cases.
Another form of modification used is to insulate a standard or aftermarket manifold. This decreases the amount of heat given off into the engine bay, therefore reducing the intake manifold temperature. There are a few types of thermal insulation but three are particularly common:
* Ceramic paint is sprayed or brushed onto the manifold and then cured in an oven. These are usually thin, so have little insulatory properties; however, they reduce engine bay heating by lessening the heat output via radiation.
* A ceramic mixture is bonded to the manifold via
thermal spraying
Thermal spraying techniques are coating processes in which melted (or heated) materials are sprayed onto a surface. The "feedstock" (coating precursor) is heated by electrical (plasma or arc) or chemical means (combustion flame).
Thermal sprayi ...
to give a tough ceramic coating with very good thermal insulation. This is often used on performance production cars and track-only racers.
* Exhaust wrap is wrapped completely around the manifold. Although this is cheap and fairly simple, it can lead to premature degradation of the manifold.
The goal of performance exhaust headers is mainly to decrease flow resistance (
back pressure
Back pressure (or backpressure) is a resistance or force opposing the desired flow of fluid through pipes, leading to friction loss and pressure drop. The term ''back pressure'' is a misnomer, as pressure is a scalar quantity, so it has a magnit ...
), and to increase the volumetric efficiency of an engine, resulting in a gain in power output. The processes occurring can be explained by the
gas laws, specifically the
ideal gas law
The ideal gas law, also called the general gas equation, is the equation of state of a hypothetical ideal gas. It is a good approximation of the behavior of many gases under many conditions, although it has several limitations. It was first stat ...
and the
combined gas law
The ideal gas law, also called the general gas equation, is the equation of state of a hypothetical ideal gas. It is a good approximation of the behavior of many gases under many conditions, although it has several limitations. It was first sta ...
.
Exhaust scavenging
When an engine starts its exhaust stroke, the piston moves up the cylinder bore, decreasing the total chamber volume. When the exhaust valve opens, the high pressure exhaust gas escapes into the exhaust manifold or header, creating an "exhaust pulse" comprising three main parts:
# The high-pressure ''head'' is created by the large pressure difference between the exhaust in the combustion chamber and the atmospheric pressure outside of the exhaust system
# As the exhaust gases equalize between the combustion chamber and the atmosphere, the difference in pressure decreases and the exhaust velocity decreases. This forms the medium-pressure ''body'' component of the exhaust pulse
# The remaining exhaust gas forms the low-pressure ''tail'' component. This tail component may initially match ambient atmospheric pressure, but the
momentum
In Newtonian mechanics, momentum (more specifically linear momentum or translational momentum) is the product of the mass and velocity of an object. It is a vector quantity, possessing a magnitude and a direction. If is an object's mass an ...
of the high and medium-pressure components reduces the pressure in the combustion chamber to a lower-than-atmospheric level.
This relatively low pressure helps to extract all the combustion products from the cylinder and induct the intake charge during the overlap period when both intake and exhaust valves are partially open. The effect is known as "scavenging". Length, cross-sectional area, and shaping of the exhaust ports and pipeworks influences the degree of scavenging effect, and the engine speed range over which scavenging occurs.
The magnitude of the exhaust scavenging effect is a direct function of the velocity of the high and medium pressure components of the exhaust pulse. Performance headers work to increase the exhaust velocity as much as possible. One technique is tuned-length primary tubes. This technique attempts to time the occurrence of each exhaust pulse, to occur one after the other in succession while still in the exhaust system. The lower pressure tail of an exhaust pulse then serves to create a greater pressure difference between the high pressure head of the next exhaust pulse, thus increasing the velocity of that exhaust pulse. In V6 and V8 engines where there is more than one exhaust bank, "Y-pipes" and "X-pipes" work on the same principle of using the low pressure component of an exhaust pulse to increase the velocity of the next exhaust pulse.
Great care must be used when selecting the length and diameter of the primary tubes. Tubes that are too large will cause the exhaust gas to expand and slow down, decreasing the scavenging effect. Tubes that are too small will create exhaust flow resistance which the engine must work to expel the exhaust gas from the chamber, reducing power and leaving exhaust in the chamber to dilute the incoming intake charge. Since engines produce more exhaust gas at higher speeds, the header(s) are tuned to a particular engine speed range according to the intended application. Typically, wide primary tubes offer the best gains in power and torque at higher engine speeds, while narrow tubes offer the best gains at lower speeds.
Many headers are also
resonance
Resonance describes the phenomenon of increased amplitude that occurs when the frequency of an applied periodic force (or a Fourier component of it) is equal or close to a natural frequency of the system on which it acts. When an oscillatin ...
tuned, to utilize the low-pressure reflected wave
rarefaction pulse which can help scavenging the combustion chamber during valve overlap. This pulse is created in all exhaust systems each time a change in density occurs, such as when exhaust merges into the collector. For clarification, the rarefaction pulse is the technical term for the same process that was described above in the "head, body, tail" description. By tuning the length of the primary tubes, usually by means of resonance tuning, the rarefaction pulse can be timed to coincide with the exact moment valve overlap occurs. Typically, long primary tubes resonate at a lower engine speed than short primary tubes.
Some modern exhaust headers are available with a ceramic coating. This coating serves to prohibit rust and to reduce the amount of heat radiated into the engine bay. The heat reduction will help prevent intake manifold heat soak, which will decrease the temperature of the air entering the engine.
Why a cross plane V8 needs an H or X exhaust pipe
Crossplane V8 engine
A V8 engine is an eight-cylinder piston engine in which two banks of four cylinders share a common crankshaft and are arranged in a V configuration.
The first V8 engine was produced by the French Antoinette company in 1904, developed and us ...
s have a left and right bank each containing 4 cylinders. When the engine is running, pistons are firing according to the engine firing order. If a bank has two consecutive piston firings it will create a high pressure area in the exhaust pipe, because two exhaust pulses are moving through it close in time. As the two pulses move in the exhaust pipe they should encounter either an X or H pipe. When they encounter the pipe, part of the pulse diverts into the X-H pipe which lowers the total pressure by a small amount. The reason for this decrease in pressure is that the fluid (liquid, air or gas) will travel along a pipe and when it comes at a crossing the fluid will take the path of least resistance and some will bleed off, thus lowering the pressure slightly. Without an X-H pipe the flow of exhaust would be jerky or inconsistent, and the engine would not run at its highest efficiency. The double exhaust pulse would cause part of the next exhaust pulse in that bank to not exit that cylinder completely and cause either a detonation (because of a lean
air-fuel ratio (AFR)), or a misfire due to a rich AFR, depending on how much of the double pulse was left and what the mixture of that pulse was.
Dynamic exhaust geometry
Today's understanding of exhaust systems and
fluid dynamics
In physics and engineering, fluid dynamics is a subdiscipline of fluid mechanics that describes the flow of fluids— liquids and gases. It has several subdisciplines, including ''aerodynamics'' (the study of air and other gases in motion) an ...
has given rise to a number of mechanical improvements. One such improvement can be seen in the
exhaust ultimate power valve ("EXUP") fitted to some Yamaha motorcycles. It constantly adjusts the back pressure within the collector of the exhaust system to enhance pressure wave formation as a function of engine speed. This ensures good low to mid-range performance.
At low engine speeds the wave pressure within the pipe network is low. A full oscillation of the
Helmholtz resonance
Helmholtz resonance or wind throb is the phenomenon of air resonance in a cavity, such as when one blows across the top of an empty bottle. The name comes from a device created in the 1850s by Hermann von Helmholtz, the ''Helmholtz resonator'', wh ...
occurs before the exhaust valve is closed, and to increase low-speed torque, large amplitude exhaust pressure waves are artificially induced. This is achieved by partial closing of an internal valve within the exhaust—the EXUP valve—at the point where the four primary pipes from the cylinders join. This junction point essentially behaves as an artificial atmosphere, hence the alteration of the pressure at this point controls the behavior of reflected waves at this sudden increase in area discontinuity. Closing the valve increases the local pressure, thus inducing the formation of larger amplitude negative reflected expansion waves. This enhances low speed torque up to a speed at which the loss due to increased back pressure outweighs the EXUP tuning effect. At higher speeds the EXUP valve is fully opened and the exhaust is allowed to flow freely.
See also
*
Cylinder head porting
*
Fusible core injection molding
Fusible core injection molding, also known as lost core injection molding, is a specialized plastic injection molding process used to mold internal cavities or undercuts that are not possible to mold with demoldable cores. Strictly speaking th ...
*
Tuned exhaust
In an internal combustion engine, the geometry of the exhaust system can be optimised ("tuned") to maximise the power output of the engine. Tuned exhausts are designed so that reflected pressure waves arrive at the exhaust port at a particular t ...
*
Thermal spraying
Thermal spraying techniques are coating processes in which melted (or heated) materials are sprayed onto a surface. The "feedstock" (coating precursor) is heated by electrical (plasma or arc) or chemical means (combustion flame).
Thermal sprayi ...
*
Exhaust Heat Management
*
Thermal barrier coating
Thermal barrier coatings (TBCs) are advanced materials systems usually applied to metallic surfaces operating at elevated temperatures, such as gas turbine or aero-engine parts, as a form of exhaust heat management. These 100 μm to 2 mm ...
*
Zircotec
References
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Manifold
In mathematics, a manifold is a topological space that locally resembles Euclidean space near each point. More precisely, an n-dimensional manifold, or ''n-manifold'' for short, is a topological space with the property that each point has a n ...
Engine technology
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