Clean-sheet concepts. Loaded with innovations. Engineered For Racing.
What kind of turbocharger would you build for your high-performance car? The engineers in BorgWarner’s Advanced Aftermarket Product group created a wish list of every notable design characteristic. They used materials that had never been combined into an aftermarket turbocharger. They delivered quick boost response, powerful performance and reliable durability.
The EFR (Engineered For Racing) turbochargers from BorgWarner offer an unprecedented combination of advanced technologies:
Boosting every INDYCAR. Track tested. Race proven.
BorgWarner’s materials expertise, aerodynamic techniques and innovative engineering are race proven. As the exclusive supplier of the Verizon IndyCar Series, BorgWarner EFR turbochargers boost every car on the starting grid. Their track record: over half a million miles during practice, test, qualifying and race events with no incidents.
EFR turbochargers also boosted winning cars in the Redline Time Attack and World Time Attack series as well as the American LeMans Series LMP2 champion for 2011, 2012 and 2013—all without incident.
High-revving vehicles endure punishing thermal stresses, vibration and pressure. Even in these extreme environments, EFR turbochargers deliver a winning combination of quick response, powerful performance and reliable durability.
2014 Verizon Indy Car champion Will Power boosted by twin EFR-7163 turbochargers
BorgWarner’s EFR turbochargers set new world standards in performance, convenient installation and high-tech features:
For details of the full EFR feature package, click the sectioned turbocharger below:
Compressors
Born from BorgWarner’s experience in highly boosted, highly efficient commercial engines, the compressors in EFR turbochargers offer exceptional efficiency, range/width and pressure ratio (boost) capability.
Turbines
EFR turbine wheels are made from titanium aluminide (or Gamma-Ti). Not quite ceramic and not quite metal, the material is very light-weight and demonstrates excellent strength at high temperatures. Because EFR turbine wheels weigh 50% less than typical turbine wheels, less energy is required to spin up the wheel, allowing the turbocharger to respond faster. BorgWarner EFR turbochargers also feature the newest “super back” and “fullback” turbine designs for high-boost, high-efficiency applications.
Pairing
BorgWarner engineers pair compressors and turbines to maintain optimal flow for the fastest response. In addition, a range of turbine housing A/R’s are available so that you can dial in your desired power range based on your application.
The chart below displays the rated peak horsepower capability for each EFR turbocharger (click to enlarge).
The compressor and turbine wheels have the greatest influence on the turbocharger’s operational characteristics. BorgWarner engineers perform finite element analysis to optimize wheel strength, calculate air and exhaust gas flows, and assess durability based on realistic driving cycles. Finally, aerodynamic components are tested on customized turbocharger test stands.
Click on a model below to see each turbocharger’s dimensions and its compressor map.
BW EFR Turbochargers
Simple. Scalable. Strong.
Airwerks turbochargers are designed for the competitive motorsports market as well as drivers retrofitting a naturally aspirated engine or looking for a little more performance from a factory turbocharged car.
Engineered specifically for drag racing, pulling and road racing, AirWerks turbochargers have earned a reputation as robust, brute-force induction systems. Looking for a no-frills replacement? Want to upgrade your turbocharger? Working with limited space? BorgWarner’s AirWerks turbochargers are the perfect go-to product for many applications.
With a twin hydrodynamic journal bearing design, AirWerks turbochargers feature an effective high-pressure ratio compressor stage, extended-tip technology and a high-efficiency turbine stage. The configuration provides ultra-fast response and more than 70 PSI of boost.
Team Turbo4 dragster boosted by a single AirWerks S400SX3 turbocharger
BorgWarner’s first performance turbocharger. Designed to race. Built to win.
Designed to Race
Deeloped as a joint effort between BorgWarner and GM’s in-house racing program in 2004, AirWerks turbochargers were designed to create reliable and consistent boost for GM’s Pro FWD (front-wheel drive) sport compact racecars. After several meetings with the GM Racing team, basic design and performance targets were established. The first units were built as prototypes, and the suffix “X” was added to the standard model nomenclature to help distinguish this unique motorsport component from the standard commercial product assembled at the same BorgWarner location.
The AirWerks S400SX is a serviceable twin hydrodynamic journal bearing turbocharger with a high-pressure ratio compressor stage utilizing extended-tip technology and a high-efficiency turbine stage. This specialized turbocharger configuration provides ultra-fast response and more than 70 PSI of boost.
Setting Records
By the end of the 2005 race season, the S400SX had begun to create a presence in the sport compact arena. The GM Racing Cobalt was the first and only FWD four-cylinder to surpass 200 mph in the quarter mile. The Cobalt also ran the fastest FWD pass ever in 7.292 seconds at 201.61 mph. The very same year, Brent Rau pushed his Mitsubishi Eclipse to a new elapsed time (ET) record of 6.976 seconds and established a new Pro Outlaw RWD (rear-wheel drive) record of 198.29 mph.
Continuing the Legacy
Today, AirWerks S400SX turbochargers are built for high-performance applications and offer numerous unique turbine housing flow characteristics.
This same technology is also available in other sizes, including:
Faster spool-up at lower engine speeds. Powerful boost for top-end performance.
Available on a variety of AirWerks Series turbochargers, “S” generation compressor wheels boost performance. The innovative extended-tip technology delivers the increased airflow of a larger compressor wheel with the lower mass of a smaller, low-inertia wheel.
The S200 series provides ample boost to support 200-500 horsepower engines. By comparison, a single S500 series turbocharger can supply enough boost for well over 1,600 horsepower.
The chart below displays the rated peak horsepower capability for each AirWerks turbocharger (click to enlarge).
The compressor and turbine wheel designs have the greatest influence on the turbocharger’s operational and performance characteristics. BorgWarner engineers perform finite element analysis (FEA) and computational fluid dynamics (CFD) to optimize wheel durability and performance based on the application needs. After several CFD iterations, performance is confirmed on a gas stand and tested per SAE standards.
Despite today's advanced computer technology and detailed calculation programs, it is testing which finally decides on the quality of the new aerodynamic components. The fine adjustment and checking of results is carried out on turbocharger test stands.
Click on a model below to see each turbocharger’s dimensions and its compressor map
BW AirWerks Turbochargers