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High-volume automotive casting projects for global OEMs.

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Automotive turbocharger investment casting case study components

Turbocharger Housings — Tier-1 Supplier

We produce turbine housings for a major European Tier-1 turbocharger supplier. The parts are cast in heat-resistant HK30 alloy and must withstand exhaust gas temperatures exceeding 950°C. Annual volume exceeds 200,000 pieces with automotive-grade PPAP documentation.

  • Material: HK30 (25Cr-20Ni heat-resistant alloy)
  • Part weight: 1.2-3.5 kg
  • Dimensional tolerance: ±0.3 mm on critical features
  • Annual volume: 200,000+ pieces
  • Quality system: IATF 16949 compliant process
  • Defect rate: < 200 PPM
Automotive manufacturing investment cast engine components case study

Exhaust Manifolds — EV Hybrid Platform

Cast exhaust manifold for a hybrid electric vehicle platform. The integrated design combines four exhaust ports into a single outlet, reducing weight and improving exhaust flow compared to fabricated alternatives.

  • Material: SiMo 51 (Ductile Iron)
  • Part weight: 4.8 kg (30% lighter than fabricated)
  • Thermal cycling: 850°C x 5,000 cycles
  • Machining: Flange faces, bolt holes, O2 sensor boss
  • Validation: Thermal shock + vibration testing
  • Status: Series production since 2023
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