Turbocharging in automotive has been and will continue to be a key component to the new technology that will make a positive difference in the next-generation engines of the year to come. This is due to “Green Zone Policy” to fulfil Legislative requirements to reduce CO2 emissions by 2020, which resulted in significant effort by car manufacturers to explore various method of pollution abatement. One of the most effective ways is by downsizing (reduce weight and increase indicated power) the engine and shortening the cylinder stroke. This new engine needs to boost (turbocharged) to increase indicated power and new materials for engine component have to be introduced to reduce the weight.

One of the component in the turbocharging which can improved is on the turbocharger turbine, by changing the existing material tungsten (melting point 3370oC) which is much heavier and expensive to a ceramic coated nickel (melting point 1455oC) which is lighter and less expensive. This work is to design and fabricate new material for turbocharger turbine and to be tested to internal combustion engine car.

The performance test on the right sizing and matching will also have to be carried out. The ceramic coated will act as thermal barrier which increase thermal efficiency of turbocharger turbine and will protect material of surrounding component such as cables, rubber and piping/ using ceramic, it is expected noise level of the engine will be reduced.

Objective
• 1. To design a novel turbine volute casing with high heat resistance for automotive turbocharger.
• 2. To fabricate ceramic coated turbocharger turbine volute for high temperature application up to 1200°C.