EGR cooler with Inconel diffuser

1. An EGR cooler, comprising:

an elongated, stainless steel cooler housing including a first end and a second end opposite the first end, the first end including a stainless steel end plate having a first thickness; and

a diffuser having an inlet end defining a gas inlet and an outlet end welded to the stainless steel end plate, the outlet end including a sidewall having a second thickness that is in the range of 30% to 40% of the first thickness, the diffuser being made from an austenitic nickel-chromium-based alloy including at least 58% nickel, at least 20% chromium, and at least 8% molybdenum.

2. The EGR cooler of claim 1 , wherein the first thickness is in the range of 3 mm to 5 mm.

3. The EGR cooler of claim 2 , wherein the second thickness is in the range of 1 mm to 1.5 mm.

4. The EGR cooler of claim 1 , wherein the stainless steel end plate is made of stainless steel 316 alloy.

5. The EGR cooler of claim 1 , wherein the inlet end has a first diameter and the outlet end has a second diameter that is greater than twice the first diameter.

6. The EGR cooler of claim 1 , wherein the EGR cooler is a shell-and-tube heat exchanger.

7. An engine system, comprising:

an internal combustion engine, having an intake manifold for directing intake air into one or more engine cylinders and an exhaust manifold for routing exhaust from the one or more engine cylinders; and

an exhaust system configured to receive exhaust from the exhaust manifold, the exhaust system including:

an EGR conduit arranged to direct a portion of the exhaust received from the exhaust manifold into the intake manifold; and

an EGR cooler arranged in the EGR conduit for cooling the portion of the exhaust directed into the intake manifold, wherein the EGR cooler includes:

an elongated, stainless steel cooler housing including a first end and a second end opposite the first end, the first end including a stainless steel end plate having a first thickness; and

a diffuser having an inlet end defining a gas inlet and an outlet end welded to the stainless steel end plate, the outlet end including a sidewall having a second thickness that is in the range of 30% to 40% of the first thickness, the diffuser being made from an austenitic nickel-chromium-based alloy including at least 58% nickel, at least 20% chromium, and at least 8% molybdenum.

8. The engine system of claim 7 , wherein the first thickness is in the range of 3 mm to 5 mm.

9. The engine system of claim 8 , wherein the second thickness is in the range of 1 mm to 1.5 mm.

10. The engine system of claim 7 , wherein the stainless steel end plate is made of stainless steel 316 alloy.

11. The engine system of claim 7 , wherein the inlet end has a first diameter and has outlet end has a second diameter that is greater than twice the first diameter.

12. The engine system of claim 7 , wherein the EGR cooler is a shell-and-tube heat exchanger.

13. A method for cooling an exhaust stream being routing via an exhaust conduit from an exhaust manifold on an engine to an intake manifold on the engine, the method comprising:

directing coolant through a housing of a stainless steel heat exchanger;

directing the exhaust stream through a diffuser welded to a stainless steel end plate at a gas inlet end of the housing, the diffuser being made from an austenitic nickel-chromium-based alloy including at least 58% nickel, at least 20% chromium, and at least 8% molybdenum; and

directing the exhaust stream through a plurality of tubes extending through the housing from the gas inlet to a gas outlet,

wherein the stainless steel end plate has a first thickness, and the diffuser has a second thickness that is in the range of 30% to 40% of the first thickness.

14. The method of claim 13 , wherein the stainless steel end plate includes stainless steel 316 alloy.

15. The method of claim 13 , wherein the first thickness is in the range of range of 3 mm to 5 mm.