Dongfeng KL intercooler exhaust pipe Clamp 1109034-T38V0

Constructed to withstand the extreme heat of intercooler exhaust gases (temperatures ranging from 150℃ to 400℃ during normal operation), the clamp’s body is made of heat-treated carbon steel (Q345) with a high-temperature resistant ceramic coating (thickness: 20-25μm). This coating not only resists thermal oxidation (no peeling or cracking after 1,000 hours of continuous exposure to 400℃) but also reduces heat transfer to the surrounding chassis components, preventing thermal damage to nearby wiring harnesses or plastic parts. The clamp’s locking bolt is crafted from nickel-chromium alloy (Inconel 600), which maintains tensile strength (≥ 650MPa) even at high temperatures and resists galling—ensuring the bolt remains tight and does not seize due to thermal cycling

To address the critical need for airtightness in intercooler exhaust systems, this clamp features a double-seal structure: an inner layer of heat-resistant silicone rubber ( Shore A hardness: 70±5, temperature resistance: -50℃ to 300℃) and an outer metal compression ring. The silicone rubber forms a tight seal between the clamp and the exhaust pipe’s outer surface, compensating for minor surface irregularities (up to 0.5mm) on the pipe and preventing exhaust gas leakage (leakage rate ≤ 0.1L/min at 300kPa pressure). The metal compression ring, with a semi-circular cross-section, distributes clamping force evenly across the pipe’s circumference (clamping force: 800-1,000N), avoiding localized stress that could damage the pipe’s thin-walled structure (common in intercooler piping)

Dongfeng KL trucks often operate in high-vibration environments (e.g., construction sites, rough rural roads), so this clamp is designed with vibration-damping features to maintain performance over time. The clamp’s body is equipped with two rubber isolators (made of EPDM rubber, vibration absorption rate: ≥ 60% at 10-500Hz) between the metal body and the mounting lugs. These isolators reduce the transfer of engine and road vibrations to the intercooler exhaust pipe, preventing fatigue cracks in the pipe or clamp. Additionally, the clamp’s locking nut features a nylon insert (self-locking design) that resists loosening due to vibration—testing shows no bolt rotation (≤ 1°) after 100 hours of vibration testing at 200Hz, ensuring long-term clamping stability

This intercooler exhaust pipe clamp meets strict automotive and exhaust system standards, including ISO 10434-2 (Automotive exhaust system clamps) and Dongfeng’s internal standard DF/QR 12-2021, ensuring it meets performance requirements for exhaust gas sealing and durability. Each unit undergoes 100% factory testing, including: ① high-temperature cycling tests (1,000 cycles of -40℃ to 400℃); ② pressure leakage tests (at 500kPa); ③ vibration durability tests. Installation is tool-friendly: it uses a standard 10mm wrench for tightening, and the clamp’s open design allows for easy installation over the exhaust pipe without disassembling the entire intercooler system—reducing maintenance time by 40% compared to flange-type connections. The clamp also has a marked torque specification (25±2 N·m) on the body, guiding technicians to achieve optimal clamping force without over-tightening