Exhaust system for offshore powerboat with inboard engine
2025
Confidential Client
Water-cooled tube-in-tube exhaust system with Inconel 625 LCF inner tube and AISI 304 stainless steel outer tube
The Challenge
A marine engine repair technician from the Rome area asked us to recreate the exhaust manifolds for two racing boats equipped with water-cooled manifolds and exhaust terminals, as the original components had broken and lost their internal-external insulation: water was therefore able to re-enter the engine, causing cylinder corrosion. The main challenge would have been the production costs, as each manifold is different, requiring the design and construction of 8 different templates.
The Solution
We have completely redesigned the manifolds by standardizing the first component and creating custom masks only for the terminals, significantly reducing costs and development time. We utilized Inconel 625 LCF, a material with exceptional mechanical strength, to reduce weight and improve reliability. To ensure insulation between the gas passage and the seawater cooling circuit, we performed leak tests using penetrating fluids and pressure tests with air at 2 atmospheres to detect any potential leaks.
Gallery
Technical Specifications
| Material | Inconel 625 LCF + AISI 304 stainless steel |
| Type | Water-cooled tube-in-tube exhaust |
| Main Diameter | 102 mm |
| Engine | V8 Mercury 8.0L |
| Finish | Hand polishing |
| Technologies Used | 3D scanning, CAD design, cold forming, TIG welding, penetrant testing |