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Titanium Aluminide Turbochargers – Improved Fuel Economy, Reduced Emissions (TIALCHARGER)
Start date: Feb 1, 2013, End date: Jun 30, 2015 PROJECT  FINISHED 

The TiAlCharger project aims to create a cost-effective, mass producible, low inertia titanium aluminide turbocharger assembly providing:• Weight savings of 60%• A reduction on mass moment of inertia of 36% (compared to Nickel super alloys that are the current state of the art)• Operation at temperatures >950°C• Increased fuel to air ratios thereby improving vehicle efficiency by an additional 5% and reducing CO2 emissions reduced by 8%.The technologies behind this innovation are Electron Beam Melting (EBM) and Electron Beam Welding (EBW). The EBM process has the potential to fabricate a turbine wheel from successive layers of powder allowing a hollow, lightweight, low-inertia rotor-wheel to be formed. The TiAl wheel will be joined to the steel shaft using the EBW process, the challenge being to create a weld between dissimilar materials that is robust enough to withstand the vibrations, high temperatures and rotational speeds present in a turbocharger. This fabrication method provides the possibility to manufacture turbocharger wheels from TiAl, which (if of the required quality) retains its strength at high temperatures, expanding the usage of turbochargers to a broad range of engine types.The project will enable our SME consortium to:• Create a new IP protectable product giving us greater security from ever decreasing margins• Direct increased sales and revenues worth an estimated €58 million, creating/safeguarding ~176 new jobs p.a, by year 5 post-project (EU market)• Supply into a market technology that is expected to expand from 20% of US cars to over 85%, representing the potential to increase European exports by over >€200m by 2020.
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