Dynamic turbine wheel on TiAl

SWSTech AG takes pride in solving ingenious technological challenges in the production of components. The example presented here is a new turbine wheel in titanium aluminide (TiAl) produced by the company.

Free of chlorine and heavy metals, the Ortho NF-X oil guarantees a perfect treatment of highly alloyed steels or implants steels but also non-ferrous metals and aluminum. It is an entirely new phenomenon in modern manufacturing techniques. This universal usage has also been verified during machining of the titanium aluminide turbine wheel and constituted a factor of success of this project.
Free of chlorine and heavy metals, the Ortho NF-X oil guarantees a perfect treatment of highly alloyed steels or implants steels but also non-ferrous metals and aluminum. It is an entirely new phenomenon in modern manufacturing techniques. This universal usage has also been verified during machining of the titanium aluminide turbine wheel and constituted a factor of success of this project.

If most thermally exposed exhaust gas turbochargers’ turbine wheels were, until today, cast and finished by machining, they are nowadays more and more often realized by CNC milling in new lighter materials.

Innovative  project
In the automotive, industry and more particularly in motorsports, the relatively high density of turbine wheels (8.5 g/cm³) and the resulting rather passive behaviour of the turbochargers have always been a source of annoyance. Dynamic researchers have succeeded in developing a new titanium alloy that is close to nickel based alloys in regard to resistance to high temperatures but whose density is much lower (3.8 g/cm³).

SWSTech AG equipment enables the manufacture of prototypes of milled turbine wheels that are usually cast in nickel-based alloys, a tedious operation. In the current project, the wheel is milled in a single operation from titanium aluminide, a high-tech material difficult to machine. The rotor without central bore is firmly tight on a Hermle 5 axis machining center by an automatic process. All operations can be machined within an optimal cycle time thanks to the excellent accessibility to the part.

Multifunction cutting oil
During the various milling operations, the Swisscut Ortho NF-X 10 universal high performance cutting oil of Motorex has fulfilled several functions that played a decisive role in the outcome of machining: hard chip evacuation, cooling of the tool and the machined part, development of a lubricant film between the blade of the tool and the workpiece and surface protection of the part.

Turbochargers of series engines reach speeds of 300,000 rpm and are subject to extremely high thermal stresses: "Turbo shaft" of the Mitsubishi Lancer Evo 10 (Japan version). Photo credit: Mitsubishi Motors.
Turbochargers of series engines reach speeds of 300,000 rpm and are subject to extremely high thermal stresses: “Turbo shaft” of the Mitsubishi Lancer Evo 10 (Japan version). Photo credit: Mitsubishi Motors.
The rotor wheel was carried out on a Hermle 5 axis C 22 U dynamic machining centre.
The rotor wheel was carried out on a Hermle 5 axis C 22 U dynamic machining centre.

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Motorex AG Langenthal
Technischer Kundendienst (technical Customer Service)
POSTFACH
CH-4901 Langenthal
Tel. + 41 (0) 62 919 74 74
Fax + 41 (0) 62 919 76 96
www.motorex.com
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SWSTech AG
Langfeldstrasse 90
CH-8500 Frauenfeld
Tel. + 41 (0) 52 723 49 00
Fax + 41 (0) 52 723 49 01
www.swstech.com

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Midest 2013

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