Turbine Wheel & Nozzle
Overview
Focus:
Total Cost Of OwnershipIndustry:
AutomotiveDimensions (mm):
122 X 312 (combined)Weight (g):
1698 (combined)150,000
Vacuum Cast
X-Ray Tested
Two-Part Assembly
End-To-End Process
Total Cost of Ownership
The turbine wheel and nozzle we produce is used in the automotive industry, recovers energy from exhaust gases and supports the drive of the crankshaft in order to reduce fuel consumption. We have supplied 150,000 sets since production started.
Manufacturing Processes
The turbine wheels are made using vacuum casting. The chosen superalloy - Inconel 713C - cannot be cast in a normal atmosphere as it will react with elements in the air when it is in its liquid state. After careful preparation, the turbine wheel was electron-beam welded with the shaft to a turbine runner, which is ground within a five micron tolerance. The turbine runner is balanced and the dimensions are automatically measured. The nozzles are cast under normal conditions, and the machining is done using our standard high-end equipment.
The challenge we faced in making these parts is the combination of different operations required to make the final assembly to an acceptable cost. The materials chosen are not simple to machine and welding operations must be very precise as the parts are very hot when operating.
Optimised Production Line
To produce the turbine wheels we installed a robotic-supported two-chamber vacuum casting production line. The nozzle was produced on our fully automated casting line for open-atmosphere casting with two cooperating robots.
For machining and assembly a specific production line was established to handle the unique aspects of this process for these parts. The equipment was installed in the sequence of production to avoid unnecessary internal transport and improve the flow of the production process.
Assembly & Delivery
The material used for the turbine wheel - Inconel 713C - cannot be welded under normal atmospheric conditions due to its aluminium and titanium content. These materials react readily with oxygen and nitrogen if the material is not protected during welding. To allow us to weld the parts effectively during assembly we used a vacuum chamber with an electron beam welder.
The surfaces and tolerances of these parts mean that they are highly sensitive and require special treatment when delivering them to customers. In order to avoid damage during handling and transport we worked with the customer to develop a special protective packaging.
Impact
The complexity and application of the parts means investment casting is the only production process possible. Both the castings and the machining and assembly are challenging and require our full expertise to ensure they are done right.
Previously Texmo Blank only did the castings, and another supplier handled the machining and assembly, however we are now able to bring the whole process under one roof. This is advantageous for the customer as they no longer need to coordinate two different suppliers as part of the production process. Getting the full service from one supplier improves communication at every stage of production as well as reducing total cost of ownership due to reduced transportation and improved efficiency and speed.
Sustainability & Development
By providing the full service to the customer we eliminate the need to use multiple suppliers, reducing the negative environmental impact of the production by reducing the need for travel and transportation. We also improve sustainability by recycling scrapped parts from any production stage.
We continuously work on improving our processes in terms of consumption of energy, reduction of cycle times and honing our processes.
Get In Touch
We take pride in building successful, long-term relationships with our clients, because their reputation is our priority.
If that sounds like an investment castings partner you’d like to work with, you can book an introduction call with our friendly and knowledgeable New Relations Team — in a language and time zone to suit you.