Internal combustion engines with turbochargers can use fuel more efficiently by using direct injection and supercharging system technology: The term “Engine Downsizing” relates to the use of a smaller engine in order to achieve substantial reductions in CO2-emissions. In this case, the turbocharger speeds in excess of 200.000 rpm necessitate the use of sophisticated materials such as titanium aluminide. Manufacturers of turbochargers and their components need suitably adapted machine concepts, geared to the highly dynamic manufacturing processes used to produce large volumes of the complex radial compressors made of high-performance materials which are required. The Fraunhofer IPT systematically develops complex, automated manufacturing process chains which permit high volumes of highest possible quality radial compressors to be manufactured.

Radial compressors

The market is demanding ever more efficient combustion engines for mobility-related applications: Downsizing increases drive efficiency whilst maintaining constant power. Radial compressors in particular, offer enormous potential for savings due to their high compression ratio per stage. The machining technology involves circular trochoidal milling and provides an economically efficient means of processing materials which are difficult to machine. The complex process control involved demands a combination of highly dynamic machine tools and adaptive process design.