Waste Gate Flap

Overview

Focus:

In-House Assembly

Industry:

Automotive

Dimensions (mm):

65 x 55 x 30

Weight (g):

176.6

500,000+

parts produced

Inco 2.4671

or Nickel-chromium-based superalloy

Delivered

sustainably and weekly

16-Year

client relationship

Vacuum Cast

in German facility

Electron Beam Welded

in Romanian facility

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

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

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

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

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

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.

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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.

Procurement Information
:

United States

+1 574 696 9990

usa@texmoblank.com

:

United Kingdom

+44 114 399 5710

uk@texmoblank.com

:

Germany

+49 7371 1820

germany@texmoblank.com

:

Romania

+40 256 22 7817

romania@texmoblank.com

:

India

+91 425 920 0500

india@texmoblank.com

Hello, Let’s Schedule a Call.

Our introductory calls are perfect for those wanting to know more about Texmo Blank’s capabilities or kick start a new project. You’ll speak with one of our New Relations team, in a timezone and language of your choice. These video calls last around 20 minutes and cover our process, capabilities and your requirements.