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Exhaust manifold with integrated turbocharger loader
There is no doubt that technical advantages result from integrating the turbine housing of a turbo loader into the exhaust manifold. However, at the same time, the casting becomes more complex, as does the follow-up machining, which has now to guarantee the exact position between flange and turbine housing. In the interaction of blank production and CNC machining, important precautions to prevent possible problems in manufacturing may be taken in the design itself. The risks they may result from divided responsibilities and communication problems are also avoidable, since the ACTech GmbH manufactures the parts in-house.
Further levels of development were implemented in prototypes and tested to optimize the turbo loader's performance later on, as well as for the further optimization of the installation space inside the vehicle. Costs and waiting time for the modeling equipment are rendered unnecessary through direct milling of the molding material for the outer mold segments and laser-sintering for Direct Croning® cores. Even one-of-a-kind part production can be managed within a short time and at low cost. The prototypes have characteristics identical to those of the series parts; thus, they allow conclusions without the need to invest in modeling equipment.
Even in the early stages of development, prototypes may shed light on problems that could appear in series production or cost-intensive implementations for higher part quantities. For this reason, an investment in prototypes is always less expensive than solving the problem after starting series production. ACTech GmbH is willing to cooperate with the subsequent series foundry as well.
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