Ford Begins Commercial Production of Hydrogen IC Engine

Ford's trifuel V10 internal combustion engine.
(Photo: Ford Motor Co.) DEARBORN HEIGHTS, MI (July 28, 2006) - At the North American International Auto Show earlier this year, Ford introduced the F250 Superchief, a concept trifuel pickup with a 6.8L V10 internal combustion engine that could be powered by hydrogen, E85 or gasoline. Based on that concept, Ford has now initiated production of a dedicated hydrogen-fueled, internal combustion (IC) V10 engine. It will be deployed in E450 shuttle buses before the end of 2006.  "This engine represents a significant milestone in Ford's research efforts in hydrogen technology," says Dr. Gerhard Schmidt, vice president, Research and Advanced Engineering, Ford Motor Co. "We have learned a great deal about hydrogen-powered internal combustion engines during the development phase of this engine."  Schmidt says that hydrogen IC engine technology represents an important step toward enabling hydrogen to become a viable motor fuel. Advantages include higher efficiency, all-weather capability and near-zero emissions of regulated pollutants and greenhouse gases such as carbon dioxide (CO2). Schmidt says the technology can also be easily hybridized for further gains in fuel efficiency. 

E450 shuttle bus
(Photo: Ford Motor Co.)

While the hydrogen IC engine shuttle buses will provide valuable real-world experience, Ford is also conducting research into next-generation hydrogen internal combustion engines, including features such as direct injection to enhance power and fuel economy. 

"We have only scratched the surface in terms of what can be achieved with hydrogen internal combustion engine technology and are serious about maintaining our edge in this field," says Vance Zanardelli, Ford's chief engineer for Hydrogen Internal Combustion Engines.

Ford's hydrogen IC engine is much more than just a converted production engine. This 6.8L V-10 engine is specially prepared to burn hydrogen as a fuel. Its specialized components include:

Hydrogen IC Engine SpecificationsEngine Type, Configuration6.8L 90-degree SOHC V10, cast iron block and aluminum heads with hardened seatsIntake Manifold AluminumSupercharger3.3L/rev, twin screw compressor Exhaust ManifoldCast stainless steel Crankshaft Forged steelRedline5,000 rpmThrottle BodyTwin 60 mm, electronicValvetrainHydraulic lash adjusters with roller followers, 2 valves per cylinder.Valve Diameter Intake: 42.5 mm. Exhaust: 34.0 mm.PistonsHigh-temperature forged aluminum alloy with low-friction coated skirts, ultra low oil consumption piston rings.Connecting RodsForged steelIgnitionCoil-on-plug, 9.5 AMP, Iridium- tipped spark plugsBore x Stroke3.55 x 4.16 in. ( 90.2 x 105.8mm)Displacement415 cu. in. / 6,751 ccCompression Ratio9.4:1Horsepower 235 @ 4,000 rpmPeak Boost18-20 psiTorque310 lb.-ft. @ 3,000 rpmFuel InjectionSequential multiportOil Capacity6 quarts, with filterRecommended OilBP/Castrol Synthetic, 5W-20(Table source: Ford Motor Co.) * Valves and valve seats manufactured using specially hardened materials, to compensate for hydrogen's reduced lubricating properties compared to gasoline or natural gas. * Iridium-tipped spark plugs, which allow for increased spark plug life. * High-energy coil-on-plug ignition coils to manage unique ignition characteristics. * Fuel injectors designed specifically for hydrogen and high-volume fuel rails. * Crank damper tuned for hydrogen fuel to ensure smooth operation. * High-output pistons, connecting rods and piston rings designed to accommodate the higher pressure of hydrogen combustion. * The head gasket is strengthened to accommodate increased combustion chamber pressures. * A twin screw supercharger and water-to-air intercooler added to improve power output and maximize efficiency. * An all-new intake manifold to accommodate twin screw supercharger and water-to-air intercooler. * Full-synthetic engine oil formulation, optimized for hydrogen combustion properties, developed in partnership with BP/Castrol. Schmidt says that Ford's strategy for alternative fuels is built around multiple technologies, one of which is hydrogen IC engines. Other options in development include hybrids, clean diesels, biodiesels, advanced engine and transmission technologies and E85 ethanol.(Source: Ford)