Inconel 738LC Superalloy Equiaxed Crystal Casting Turbocharger Components Manufacturer
Introduction
Turbochargers in aerospace, automotive, and industrial gas turbines face continuous exposure to high-temperature exhaust gases, extreme thermal gradients, and severe mechanical loading. Their hot-section components—including turbine wheels, vanes, and diffusers—must combine creep resistance, fatigue strength, and oxidation durability. Inconel 738LC, a low-carbon modification of Inconel 738, is a nickel-based superalloy specifically designed for high-temperature cast components with improved weldability and reduced cracking risk.
Neway AeroTech is a leading manufacturer of turbocharger components using equiaxed crystal casting. Our vacuum investment casting process for Inconel 738LC ensures stable microstructure, reliable dimensional accuracy, and superior mechanical properties. We serve customers in aerospace, automotive, and power generation sectors worldwide.
Core Technology of Equiaxed Casting for Inconel 738LC Turbo Components
Wax Pattern Production High-precision wax patterns replicate complex blade, wheel, and housing geometries with ±0.05 mm accuracy.
Shell Mold Construction 6–8 mm thick ceramic shells are built layer-by-layer to support high thermal loads and metal flow consistency.
Vacuum Induction Melting Inconel 738LC alloy is melted at ~1450°C under vacuum (≤10⁻³ Pa) for chemical stability and inclusion control.
Equiaxed Crystal Solidification Molten alloy fills the preheated mold and solidifies under controlled cooling, producing uniform, isotropic grain structures (ASTM 5–7).
Shell Removal and Cleaning Shells are removed by mechanical blasting and chemical leaching, preserving cooling features and fine contours.
Post-Casting Heat Treatment Solution and aging treatment promotes γ′ phase stabilization and reduces residual stress.
CNC Machining and EDM Final features—such as seal faces, root attachments, and oil passageways—are machined using CNC and EDM.
Inspection and Quality Control Dimensional and internal integrity are verified using CMM, X-ray, and ultrasonic testing.
Inconel 738LC Material Properties for Turbocharger Components
Max Operating Temperature: 1050°C
Tensile Strength: ≥1000 MPa
Creep Rupture Strength: ≥200 MPa at 850°C (1000 hrs)
Yield Strength: ≥850 MPa
Oxidation Resistance: Excellent under continuous exhaust gas exposure
Weldability: Improved due to reduced carbon content
Grain Size Control: ASTM 5–7 under equiaxed casting
Case Study: Inconel 738LC Turbine Wheels for Aerospace Turbochargers
Project Background
A global aerospace OEM required Inconel 738LC turbine wheels and diffuser segments for a high-performance turbocharger operating at 1000°C under cyclic thermal load. The client’s priorities included crack resistance, dimensional consistency, and ISO-compliant traceability across full production batches.
Applications
Aerospace Auxiliary Turbochargers require long-term fatigue strength and oxidation resistance under altitude cycling and rapid starts.
Automotive Performance Turbos, Turbine wheels and housings are exposed to extreme exhaust temperatures and boost cycles.
Industrial Generator Turbo Systems Integrated diffusers and vanes operating at elevated pressure ratios with minimal cooling flow.
Manufacturing Workflow for Inconel 738LC Turbo Components
CFD-Assisted Gating Design CFD analysis optimizes mold fill and cooling behavior to prevent hot spots and segregation.
Vacuum Equiaxed Casting Execution Casting is performed under vacuum using shell molds and tightly controlled solidification to form equiaxed grains.
Heat Treatment Process Heat treatment improves phase stability and mechanical strength.
Finishing and Tolerance Control Precision finishing is carried out using CNC machining and EDM to meet tolerances as tight as ±0.02 mm.
Final Inspection Dimensional validation is performed using CMM, with defect screening via X-ray and ultrasonic methods.
Key Manufacturing Challenges
Maintaining dimensional stability during heat treatment cycles
Preventing hot tears and grain coarsening in complex hub geometries
Ensuring microstructural consistency across thin and thick sections
Achieving weldability and field-repair compatibility
Results and Verification
ASTM 6 grain size achieved consistently across all batch components
Creep rupture strength >200 MPa confirmed via tensile coupon testing
Final part tolerances within ±0.03 mm for rotating assemblies
100% pass rate for NDT across multiple production batches
Dimensional and metallurgical conformance documented per AS9100 and NADCAP standards
FAQs
Why is Inconel 738LC preferred for turbocharger components?
How does equiaxed casting improve performance in hot-section parts?
Can Inconel 738LC castings be welded or repaired in the field?
What quality standards are followed in turbo component production?
What is the typical lead time for Inconel 738LC turbo parts?
