Automotive Turbocharger Discs Titanium Vacuum Investment Casting Factory
Introduction to Titanium Turbocharger Disc Casting
Automotive turbocharger discs operate under extreme conditions, demanding lightweight materials with superior strength, thermal stability, and fatigue resistance. Neway AeroTech, a specialized titanium vacuum investment casting factory, produces precision-engineered automotive turbocharger discs using advanced casting processes. Utilizing high-performance alloys such as Ti-6Al-4V (TC4), we deliver turbocharger discs tailored specifically for demanding automotive turbocharging applications.
Our precision casting capabilities position us as a leading factory within the automotive sector.
Core Challenges in Titanium Turbocharger Disc Casting
Precision casting of titanium turbocharger discs presents several challenges:
High Reactivity: Titanium reacts aggressively with oxygen at temperatures above 600°C, requiring specialized vacuum casting environments (<0.1 Pa).
Dimensional Precision: Achieving tight tolerances of ±0.15 mm and intricate blade geometry.
Material Integrity: Ensuring porosity below 0.2% and consistent mechanical properties.
Fatigue Resistance: Turbocharger discs must endure cyclic stresses from rapid temperature fluctuations and rotational speeds over 150,000 RPM.
Titanium Vacuum Investment Casting Process
Wax Pattern Creation
Precision molds produce wax patterns replicating exact turbocharger disc geometry.
Pattern accuracy within ±0.1 mm ensures dimensional consistency.
Shell Building
Ceramic shell layers are formed around the wax pattern, with controlled drying stages to maintain shell integrity.
Shell thickness typically 6–12 mm to withstand molten titanium (~1700°C).
Vacuum Melting and Casting
Vacuum induction melting ensures titanium purity and prevents oxidation (pressure <0.1 Pa).
Controlled pouring under vacuum achieves near-net shapes, minimizing post-machining.
Shell Removal and Finishing
Shell removed mechanically or chemically.
Precise CNC finishing achieves surface roughness of Ra 3.2–6.3 µm and critical dimensions within ±0.15 mm.
Comparison of Turbocharger Disc Manufacturing Methods
Manufacturing Method | Accuracy | Surface Finish | Complexity Handling | Production Efficiency |
|---|---|---|---|---|
Vacuum Investment Casting | ±0.15 mm | Ra 3.2–6.3 µm | High | Moderate–High |
CNC Machining | ±0.005 mm | Ra 0.8–1.6 µm | Moderate–High | Moderate |
Selective Laser Melting (SLM) | ±0.10 mm | Ra 6.3–12.5 µm | High | Moderate |
Forging | ±0.2 mm | Ra 6.3–12.5 µm | Moderate | High |
Manufacturing Process Selection Strategy
Vacuum Investment Casting: Optimal for complex turbocharger disc shapes with good precision (±0.15 mm), cost-effectively produced in medium-to-high volumes.
CNC Machining: Ideal for achieving superior precision (±0.005 mm) and surface finishes, especially for critical tolerance parts.
Selective Laser Melting (SLM): Suitable for rapid prototyping and designs incorporating intricate internal cooling channels.
Titanium Forging: Efficient for high-volume manufacturing where excellent mechanical properties at slightly reduced accuracy (±0.2 mm) are acceptable.
Titanium Alloy Performance Matrix
Alloy | Tensile Strength | Yield Strength | Max Temp | Fatigue Resistance | Automotive Application |
|---|---|---|---|---|---|
950 MPa | 880 MPa | 400°C | Excellent | Turbocharger discs | |
1050 MPa | 960 MPa | 450°C | Superior | High-performance turbocharger discs | |
900 MPa | 830 MPa | 400°C | Excellent | Structural turbocharger components | |
1100 MPa | 1030 MPa | 480°C | Exceptional | High-stress rotating parts | |
1150 MPa | 1050 MPa | 500°C | Outstanding | Premium turbocharger discs | |
980 MPa | 900 MPa | 420°C | Excellent | Corrosion-resistant turbo components |
Material Selection Strategy
Ti-6Al-4V (TC4): Ideal for standard turbocharger discs requiring reliable mechanical properties and lightweight construction.
Ti-6Al-2Sn-4Zr-2Mo: Chosen for discs demanding higher thermal stability (up to 450°C) and superior strength (1050 MPa tensile).
Ti-5Al-2.5Sn: Suitable for cost-effective automotive applications requiring excellent fatigue resistance.
Ti-6Al-6V-2Sn: Optimal for high-performance rotating parts needing outstanding strength (1100 MPa tensile) at elevated temperatures.
Ti-6Al-2Sn-4Zr-6Mo: Selected for premium applications requiring ultimate strength (1150 MPa tensile) and thermal performance (500°C).
Ti-6Al-7Nb: Recommended for turbocharger components in corrosive environments needing robust fatigue resistance.
Key Post-processing Technologies
Heat Treatment: Enhances mechanical properties, improves fatigue resistance.
Hot Isostatic Pressing (HIP): Removes internal porosity, ensuring structural integrity.
CNC Machining Finishing: Achieves precise dimensional tolerances (±0.005 mm) and improved surface finishes (Ra 0.8 µm).
Dynamic Balancing: Minimizes vibrations, essential for high-speed rotation performance.
Industry Case Study: Precision Cast Titanium Turbocharger Discs
Neway AeroTech recently manufactured precision titanium turbocharger discs using vacuum investment casting for a leading automotive turbocharger manufacturer. Leveraging advanced casting technology, rigorous HIP treatment, and precision CNC machining, we achieved exceptional dimensional accuracy (±0.15 mm), lightweight strength, and superior fatigue performance, significantly exceeding customer specifications.
Our advanced capabilities confirm our position as a premier titanium turbocharger disc casting factory.
FAQs
What is your production lead time for vacuum investment cast titanium turbocharger discs?
Can you accommodate prototype or small-volume casting projects?
What industry certifications and quality standards do your titanium turbocharger discs meet?
Do you offer technical support in selecting appropriate titanium alloys?
How do you ensure the quality and reliability of cast turbocharger discs?
