SupremEX For Turbocharger Impellers (Compressor Wheels)

BACKGROUND Turbocharger components have mainly been manufactured from die cast aluminum alloys for many years for conventional systems. The need for higher performance turbocharger components has demanded the use of higher performing materials, such as Machined From Solid (MFS) 2618 series aluminum alloy for the impeller. As turbochargers get more efficient, spin faster and increase compression ratio, the need for improved material properties has become a reality for many high performance applications. SupremEX is an optimal solution and can provide the highest material performance above industry standard aluminum alloys. WHAT IS SUPREMEX? SupremEX is a family of high performance Metal Matrix Composites (MMC) made up principally of aluminum alloys and nano to micron sized ceramic reinforcements. The ratio of the metal and reinforcement can be varied to alter the physical and mechanical properties, along with manufacturability. The MMC products are manufactured by high energy mixing, to create a very fine grained, homogenous powder which can be consolidated with several methods. AMC 225 Xfine- contains 75 vol% Aluminum 2124 and 25 vol% silicon carbide. AMC 217 Xfine- contains 83 vol% Aluminum 2124 and 17 vol% silicon carbide. SupremEX is also manufactured in many other reinforcement percentages and aluminum alloy forms. The material is commonly consolidated by Hot Isostatic Pressing (HIP) to a fully dense product and can be forged or extruded to additional shapes and to increase mechanical properties and to provide cost effective shapes. SUPREMEX MATERIAL COMPARISON TO AL 2618-T61: 37% Increase in Room Temperature Tensile Strength 150% Increase in Fatigue Strength 34% Increase in Youngs Modulus (Stiffness) 20% Reduction in Coefficient of Thermal Expansion (CTE) Superior abrasion and erosion resistance Nearly identical Thermal Conductivity and Density SUPREMEX ADVANTAGES: Smaller core for higher compression ratios Thinner blades for faster rotational speeds Less vane erosion and wear Higher efficiency from less material growth (CTE) Weight reduction for optimized designs o Also longer bearing life from reduced loads on bearings Double the product life or Mean Time Between Failure (MTBF)

United Kingdom Materion Aerospace Metal Composites 1 RAE Road Farnborough, Hampshire, GU1 6XE Tel: +44(0) 1252 375001 Email: amc@materion.com

United States Materion Brush Beryllium and Composites 14710 W. Portage River South Rd. Elmore, OH 43416 Tel: +1 (419) 862-4283 Email: Jason.clune@materion.com

Industry Partner Miltera Machining Research Corp. 120 Otonabee Drive Kitchener, ON, N2C 1L6, Canada Tel: +1 (519) 725-2554 Email: info@miltera.com

COMMON FAILURE MECHANISMS FOR TURBOCHARGER IMPELLERS 1. 2. 3. Fatigue failure due to cyclic bending of vanes a. a. a. 4. Catastrophic failure of impeller Impeller does not have enough strength at high temperatures (greater than 200C) and fails. Vanes have permanent deformation over time resulting in contact with housing, either wearing surfaces and or complete failure. Common erosion of vanes and loss of efficiency High Temperature Failure Elevated temperature creep of vanes and bore

Particle impact erosion a.

Mechanical and Physical Properties Al 355-T6

Ultimate Tensile Strength - ksi Yield Strength - ksi Elongation % Fatigue Strength - ksi Youngs Modulus -Msi Shear Modulus - Msi CTE @ 25oC ppm/oC Thermal Conductivity - W/mK Density -Lbs/in3 Specific Strength Breaking Length Specific Stiffness 37 26.8 1.5% 12 10.2 3.8 22.3 142 .0979 378 978 104

Al 354-T61 48 37 3% 21 10.6 4 20.9 136 .0979 490 1269 108

Al 2618 T61 64 54 4% 22 10.8 3.92 22.3 146 .0997 642 1661 108

AMC217Xfine AMC225Xfine 84 61 6% 55 14.5 5.58 16.8 155 .10 840 2174 145 88 64 4% 54 16.7 6.42 15.5 150 .104 846 2190 161

Information is for comparative purposes only and information provided is based on general industry information and material properties can be different based on minimum, typical or maximum properties along with specific heat treatment conditions.

MaterialPerformanceComparison
SpecificStiffness(MSI/lbs/inch^3)
180 160 140 120 100 80 60 40 20 0 0 200 400 600 800 SpecificStrength(ksi/lbs/in^3) 1000 Al354T61 Al2618T61 AMC217Xfine AMC225Xfine