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Casting of Aluminum Supercharger / Turbocharger Components

At Epcor Foundry, a division of Seilkop Industries, Inc. we provide precision aluminum casting solutions to customers with difficult-to-cast parts. We were approached by a tier one supercharger manufacturer who was having trouble with porosity issues in their cast components. The customer’s design required that heavy cast sections, fed by thin sections, and created areas for massive shrink porosity. We developed an in-core chill technology that eliminated the porosity problem. The tooling was designed to cast a chill into the rotor core, which allowed the heavy section to solidify without the associated shrink porosity, thus preventing the leaking problem.

These castings featured dimensions of 22” x 18” x 6” and were produced from A356 T6 aluminum, cast on our DISA Match 130 and Roberts Sinto FBO #3 20x24” high speed mold machines which allowed us to meet tolerances of ±.010”. After the parts were cast and de-cored they are trimmed in an automated trim cell, before being shot blasting, plated, and powder coating. We manufactured up to 50,000 of these components for this customer in the South, with 10 week lead times. These can be factory or aftermarket parts to increase the performance of cars by increasing the flow of air into the engine.

Sand Casting has been around for centuries, but new technology continues to refine our process and allow us to cast shapes and geometries that would have been previously impossible. Our expert staff works with our customers to provide solutions to the most difficult casting problems. For more information about this cast aluminum supercharger project, see the table below, or contact us directly.

Epcor Foundry

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Highlights of this Cast Aluminum Supercharger Project

Product Name
Supercharger/Turbocharger
Product Description
These are factory or aftermarket parts to increase the performance of cars by forcing air into the engine.
Aluminum Casting Capabilities Applied/Processes
Primary:
Casting
De-Coring
Automated Trim Cell
Secondary:
Shot Blasting
Plating
Powder Coating
Equipment Used to Manufacture Part
DISA Match 130 & Roberts Sinto FBO #3 20x24" High speed mold machines
Overall Part Dimensions
22"x18"x6"
Tightest Tolerances
±0.010"
Material Used
Aluminum A356 T6
Material Finish
Color: Plated, Powder Coated
In Process Testing/Inspection Performed
Dimensional Inspection, Ball Checking, Flow Checking, Leak Testing
Industry for Use
Automotive Industry
Volume
75,000
Delivery/Turnaround Time
10 Weeks
Delivery Location
South
Standards Met
Customer Specifications, 2D CAD Drawing

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