Waste Gate Flap
Overview
Focus:
In-House AssemblyIndustry:
AutomotiveDimensions (mm):
65 x 55 x 30Weight (g):
176.6500,000+
Inco 2.4671
Delivered
16-Year
Vacuum Cast
Electron Beam Welded
Texmo Blank has produced over 500,000 waste gate flaps for turbochargers over an ongoing 16 year relationship with our automotive client. These parts regulate boost pressure, control turbo speed, and improve safety and performance in turbocharges. The parts are produced across 2 of our global locations: Germany for high quality casting, and Romania for specialised machining.
Material Selection
The part is made of a nickel-based superalloy – Inco 2.4671 (Inco713 C). This material has a high tensile strength, can withstand extreme temperatures – of around 1000°C – and has excellent creep resistance making it ideal for constant friction environments.
Vacuum Casting
Vacuum casting is a specialised process that our facility in Germany offers. Inco 2.4671 can react with oxygen and nitrogen in its molten state, which creates flaws in the part if cast in a typical casting environment.
In order to take full advantage of the highly heat and wear resistant properties that Inco 2.4671 has, tightly controlled vacuum casting was utilised.
Machining & Welding
Our team at our Romanian facility are experts on highly technical machining and assembly. The waste gap flap required specialised machining equipment and cutting materials because of the high wear resistance of Inco 2.4671.
A special production line was created to facilitate efficient electron beam welding (which is also done in a vacuum due to the material reaction with elements that occurs in welding). Functional integration of the part followed by in-house assembly means procurement and management of one part instead of two.
Testing & Control Measures
Alongside a comprehensive failure mode and effects analysis, and across different stages of the production process, the part was tested for quality, process stability and weaknesses. We have our own internal certification process, which checks for risks and ensures process stability for all parts casted in the foundry.
In addition to standard production part approval process (PPAP), Texmo Blank has developed a defect-image reference sheet – covering all steps of the production process. This ensured 100% quality – from start to finish – first time.
Sustainable Delivery
Special plastic inlays were produced for safe transport – every week based on an agreed forecast-plan – to avoid damage to the completed parts.
We have established a system for the reuse of these inlays to prevent these materials from ending up as waste. After use, the plastic inlays are returned, inspected for damage, and reused, reducing the need for new packaging materials.
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.