AUTOMOTIVE INDUSTRY HOSES

AUTOMOTIVE INDUSTRY HOSES

When you open the bonnet of a car, at first glance you may be struck by the complexity of the engine. But behind this complexity, there are countless auxiliary parts that work like an invisible orchestra. Here is one of the quietest but most critical of these parts: automotive hoses.

For our vehicles to function properly, liquids, gases and compressed air must be transported safely and efficiently. From coolant to fuel, brake hydraulic fluid to air intake, many systems depend on the correct hose selection and application. These hoses ensure that the engine stays cool, the vehicle stops on time and the ride is comfortable and safe.

Automotive hoses are such parts that their presence is often forgotten, but their absence is keenly felt in the event of a breakdown. The wrong hose material, a loose connection or a crack not noticed in time can cause the vehicle to overheat, leak fuel or disable the brake system. So a small hose can have big consequences.

IN AUTOMOTIVE BASIC HOSE TYPES AND FUNCTIONS

The hoses that run inside your car are like veins. Each one carries a different liquid or gas, each one serving a different function. If the wrong hose is used in the wrong place, not only will performance suffer, sometimes you will even be stranded. Let's get to know these hoses one by one:

1. Cooling System Hoses

These are the heroes that prevent the engine from overheating. They provide the hot-cold cycle between the radiator and the engine.

• Radiator hoses (top and bottom): It carries hot water from the engine to the radiator and cooled water back to the engine.
• Heater (heater) hoses: It delivers engine hot water to the interior and allows us to blow warm air from the heater in winter.

2. Fuel System Hoses

Fuel hoses transport gasoline or diesel from the tank into the engine. They are usually made of special materials resistant to high pressure and the chemical composition of the fuel.

• Low pressure fuel hoses: Common in older systems with carburetors.
• High pressure hoses: Used in modern engines with injection, reinforced with special materials such as fluoroelastomer.

3. Brake System Hoses

It is no exaggeration to say that hoses are life-saving. They transmit the hydraulic pressure generated when you press the brake pedal to the brake pads.

• Braided steel hoses: Provides sharper braking with less flexing, generally preferred in performance vehicles.
• Rubber brake hoses: It adapts to suspension movements with its flexible structure.

4. Vacuum and Suction Hoses

Used in the engine air intake system, sensors and brake vacuum boosters. They are usually black in color.

5. Turbo and Intercooler Hoses

In turbocharged vehicles, they are involved in the transmission of compressed air into the engine. They are usually silicone-based and firmly fixed with a clamp system.

HOSE CLASSIFICATION ACCORDING TO MATERIALS

Not all hoses are created equal, friends. Inside the car, each hose is exposed to different conditions: some have to withstand the heat, some have to deal with fuel, some have to withstand high pressure. That's why the material used is so important. Let's see which hose is made of which material and why:

1. Rubber Hoses (EPDM, NBR, HNBR)

One of the most widely used types of hose.

It is especially common in cooling and fuel hoses.

Advantages: Flexible, cost-effective, ozone and heat resistant (EPDM especially up to 130-150°C).

Disadvantage: May harden over time, chemical resistance may be limited.

2. Silicone Hoses

The favorite of performance vehicles!

Exceptional resistance to high temperature (-60°C to +260°C).

Used in heat resistant areas such as turbo, intercooler, radiator.

Advantages: Resistant to aging, ozone and abrasion, long lasting.

Disadvantage: It does not get along well with fuel and oil-based liquids; it cannot be used there.

3. Thermoplastic Hoses (Nylon, Polyurethane)

It is mainly used in fuel, brake and vacuum systems.

Advantages: Lightweight, flexible, high chemical resistance.

Disadvantage: It is not as resistant to extreme temperatures as silicone.

4. Metal Hoses (Stainless Steel, Aluminum)

It is often used in specialized systems that require high pressure and temperature (e.g. exhaust gas conversion systems).

Advantages: The most resistant hose type against mechanical damage and temperature.

Disadvantage: They are less flexible, laborious to install and costly.

5. Composite Hoses

Hybrid hoses that combine the strength of two different materials.

For example: PTFE, Polyester, Spiral Wire reinforced hoses. 

Advantages: It offers both flexibility and durability, especially preferred in industrial applications.

Fabric reinforced high temperature resistant hoses fall into this category.

PERFORMANCE AND DURABILITY CRITERIA

Every hose needs to work well within a certain temperature range. For example, EPDM rubber hoses generally perform between -40°C and +135°C, while silicone hoses are far superior and can be used between -60°C and +260°C. High temperature resistance is especially important for hoses used in turbo systems and around the engine block.

Hoses in different systems are exposed to different pressures. While low pressure hoses can operate between 1 and 3 bar, hydraulic system hoses must withstand pressures of 200 bar and above. This is why hoses have reinforcing layers in their internal structure, such as wire braid, fabric or spiral backing.

Chemical resistance is also a critical factor in hose performance. The hose must be chemically compatible with the fluid it carries. Otherwise, problems such as swelling, cracking or dissolution of the inner coating may occur. Fuel hoses are usually made resistant to fuel types such as gasoline, diesel, ethanol by using NBR inner coating. Cooling hoses, on the other hand, must be resistant to substances such as water, antifreeze and lime.

Automotive hoses must also be resistant to the harsh outdoor environment under the engine hood. Sunlight (UV), ozone, oil vapor and exhaust gases can wear the hose material over time. Quality hoses are manufactured to maintain their form and strength for a long time against these external influences.

Finally, mechanical wear and flexing resistance is also an important criterion for hoses. Vehicle vibrations and road impacts cause hoses to move constantly. In the face of this movement, the hose must be both flexible and durable. Some hoses stretch too much over time and their inner diameter narrows. This restricts fluid flow. Especially in the brake system, this can cause a "rubbery" soft feel to the pedal and compromise safety.

ASSEMBLY CLAMP AND EQUIPMENT

• In order for automotive hoses to fulfill their duties properly, not only quality material is not enough; correct assembly is just as important as the material. The hose must be selected in the appropriate diameter, the cut must be made properly, and it must fit snugly to the connection points in the system. Otherwise, leaks, loosening and system failures may occur over time.

• The clamps used at the connection points of the hose secure and seal the hose. With an incorrectly selected or loose clamp, the hose cannot do its job properly. The most commonly used clamps include screw tightened band type clamps, T-bolt and spring clamps.

• Especially T-bolt type heavy duty clamps are preferred for high pressure applications. Thanks to a large contact surface, these clamps apply high clamping force without crushing the hose and increase tightness. Such clamps are widely used in areas such as turbo systems and intercooler connections.

• In tight spaces or with small diameter hoses, mini clamps come into play. These clamps are used, for example, in areas such as vacuum lines and glass water hoses. They offer both practical assembly and a tight grip.

• In addition to clamps, special connection hardware is used for some hose connections. Cam & groove joints, quick-acting sockets or screw fittings make it easier to disassemble and assemble the system. These types of connections are especially preferred in areas where serviceability is required.

• It is also important that the hose is not kinked, overstretched or subjected to friction during hose assembly. If there is vibration on the surfaces on which the hose is fixed, anti-friction sleeves or clamped support pieces should be used.

MAINTENANCE, CONTROL AND CHANGE PROCESSES

• The most effective way to extend the life of automotive hoses is regular visual inspection and periodic maintenance. Checking the engine compartment at regular intervals allows early detection of potential malfunctions. If the surface of the hose shows signs of cracking, bulging, softening or hardening, it is time for replacement.

• Problems such as sediment accumulation or deterioration of antifreeze may occur on the inner surfaces of the hoses of the cooling system over time. Therefore, coolant flushes should be performed at the intervals recommended by the manufacturers. Aging fluid both wears out the hose from the inside and reduces the efficiency of parts such as the radiator and thermostat.

• The biggest risk to be aware of in fuel hoses is leakage. Gasoline or diesel leaks, especially at the hose connection points, are vital not only for performance but also for fire risk. In every maintenance, it must be checked whether the clamps of the hose ends are tight and whether the hose surface is softened by contact with fuel.

• Periodic inspection is a must for brake hoses. Because these hoses are one of the most critical parts that carry hydraulic pressure. If you get a "soft like rubber" feeling when you press the brake pedal, the internal structure of the hose may be stretching. In this case, the hose needs to be replaced. In general, brake hoses should be replaced between 5 and 7 years.

• Clamps at the connection points of hoses can loosen over time. Especially hot-cold cycles, vibrations and engine movements cause this loosening. During maintenance, the tightness of the clamps should be checked and replaced with new ones if necessary.

• Although there is no specific replacement period for hoses, as a general rule, it is recommended that they are checked and renewed within 5 to 8 years. Factors such as the climate where the vehicle is located, the type of use, engine temperature values may affect this period.

FUTURE TRENDS AND INNOVATIVE APPROACHES

As the automotive industry is rapidly moving towards electric and hybrid vehicles, this shift is directly affecting hose technologies. Although they have systems that carry less liquid and gas than conventional internal combustion engines, electric vehicles also require special hose systems for heat management. Especially the thin-diameter, high-temperature resistant hoses used in battery cooling systems come to the fore.

Studies on biobased and recyclable materials as an alternative to traditional hose materials are increasing. Sustainability, reducing carbon footprint and environmentally friendly production approach lead hose manufacturers to develop more environmentally friendly solutions.

Thanks to advances in material technologies, hoses are becoming not only durable but also smart. Thanks to sensor integrations in new generation hoses, pressure, temperature or flow rate can be monitored instantly. In this way, the system can give warnings before possible malfunctions occur.

3D printing technology is already being used in the test phase for the production of special purpose hoses. In the future, it will be possible to produce customized hose designs faster, more efficiently and in a way that reduces waste.

As vehicles become more compact, hose systems need to take up less space. This is why flexible, lightweight, yet high-performance hose designs are gaining importance. This not only makes installation easier, but also reduces vehicle weight and increases fuel efficiency.

SUMMARY

Automotive hoses work like the invisible nervous system of vehicles. These parts, which allow fuel to reach the engine, brake power to reach the wheels and coolant to reach the radiator, may look small, but they play a big role. The right material, proper installation and regular maintenance are the basis for long-lasting and safe operation of hoses.

With advancing technologies, the world of hoses is not standing still. Lightweight hoses suitable for electric vehicles, environmentally friendly materials and smart systems open the door to a whole new era in this field.

But whether it's a classic vehicle or a modern electric model, the basic need remains the same: hoses that are reliable, durable and do their job thoroughly. That's why underestimating automotive hoses, checking them in good time and making quality choices are as essential for driving safety as they are for vehicle performance.