TC4 Titanium Impeller 5-Axis CNC Milling with 0.01mm Blade Profile Tolerance for Turbocharger Compressor Wheel
TC4 Titanium Impeller 5-Axis Milling
,Twisted Blade 0.01mm Profile Control
,Non-Standard Impeller Under NDA
- Blade profile tolerance: ±0.01 mm, verified on CMM and blue-light scan before shipment.
- Material: TC4 (Ti-6Al-4V) forged billet, 100% mill certificate traceable to heat number.
- Order size: 1 piece prototype to 10,000 pieces per year, no tooling charge.
- Confidentiality: NDA signed before drawings are opened; cameras and phones stay out of the cell.
A turbocharger compressor impeller has to do three things at once: move air efficiently, survive 150,000 rpm, and stay in balance after thousands of heat cycles. Cast aluminium wheels do this cheaply; titanium wheels do it when the duty cycle is brutal, the boost target is high, or the housing has no room for a bigger wheel. We machine those titanium wheels from solid forged billet on simultaneous 5-axis machining centres, holding blade profile to ±0.01 mm and blade wall thickness to ±0.02 mm.
The parts on this page are made to your drawing, your 3D model, or a sample you courier to us. We are a machining job shop, not a catalogue seller: hub diameter, blade count, splitter arrangement, tip clearance geometry, bore and keyway, and backface contour are all set by your design file, and nothing is outsourced to a third party once the file is in our hands.
Every titanium impeller follows the same controlled route. Deviations are written into the job traveller before the first chip is cut, so the second batch behaves like the first.
| Step | What Happens |
|---|---|
| 1. DFM review | We check the model for tool reach, undercut blades, minimum wall, and datum strategy, then send a written DFM note with any risk flagged before quoting. |
| 2. Billet & stress relief | TC4 forged billet is cut oversize, stress-relieved, and faced so the hub bore and backface can be used as the primary datum for every later operation. |
| 3. Roughing | High-feed roughing removes bulk stock with controlled heat input; titanium is cut at low surface speed to protect the subsurface layer. |
| 4. 5-axis blade milling | Blades, splitters, fillets and hub are finished in a single simultaneous 5-axis setup with a swarf-and-tip toolpath, so there is no re-datum between blade surfaces. |
| 5. Bore, keyway, backface | Bore, keyway or spline, backface and nose features are machined after blade finishing; runout is checked against the blade tip circle. |
| 6. Deburr & surface | Hand and abrasive-flow deburring at blade leading edges, then polishing, bead blast, or as-machined finish to your spec. |
| 7. Balance & inspect | Dynamic balance to G2.5 on request, full dimensional report, material certificate and first article report packed with the parts. |
| Feature | Tolerance | Checked With |
|---|---|---|
| Blade profile vs CAD | ±0.01 mm | Blue-light scanner, section comparison |
| Blade wall thickness | ±0.02 mm | Ultrasonic thickness gauge, CMM |
| Blade index / angular pitch | ±0.05° | CMM rotary scan |
| Hub bore diameter | ±0.005 mm | Air gauge / bore micrometer |
| Tip-to-bore runout | 0.01 mm | CMM, mandrel on granite plate |
| Blade surface roughness | Ra 0.4 µm (Ra 0.2 polished) | Portable roughness tester |
| Balance grade | G6.3 standard, G2.5 on request | Two-plane balancing machine |
| General dimensions | ±0.05 mm | CMM per GB/T 1804-2000 |
Tolerance callouts are the shop-floor default. If your drawing is tighter on one feature and loose on another, we quote against your drawing rather than forcing the whole part into our standard band — that keeps cost where it belongs.
Most impeller enquiries we receive do not match any catalogue part number, which is exactly the work we are set up for.
- Input formats: STEP, IGES, X_T, STL, native SolidWorks or UG files, 2D PDF drawings, a physical sample, or a hand sketch plus key dimensions. If you only have the original cast wheel, we reverse-engineer it on the blue-light scanner and send the model back for your approval.
- Geometry freedom: 6 to 20 blades, full blades with splitter pairs, backward-curved, radial or mixed-flow profiles, open or closed (shrouded) wheels, trimmed inducer, variable hub contour.
- Materials: TC4 / Ti-6Al-4V as standard; Ti-6242 and 15-5PH or 17-4PH stainless available when temperature or strength demands it.
- Size range: 25 mm to 320 mm tip diameter, single parts or matched sets.
- Interfaces: plain bore, keyway, spline, threaded nose, nut thread, dowel hole, or your proprietary locking feature.
- Marking: laser serial numbers, heat-lot codes and customer part numbers, so batch traceability survives shipping.
One-off prototype and 5,000-piece release run use the same fixture family and the same inspection plan, which is why a production release after a prototype approval rarely needs a second round of dimensional negotiation.
An impeller drawing is the commercial core of a turbo program. We treat it that way:
- A mutual NDA is signed before we open the file. Our standard NDA is available in English and Chinese; yours is welcome.
- Drawings are held in a restricted folder accessible only to the project engineer and the cell supervisor — not to the general shop network.
- The impeller cell is a camera-free zone. No photographs, no video, no social media posts, no sample parts left on display.
- We do not display customer parts, logos or program names on our website, catalogue or trade-show panels without written permission.
- Where a program requires it, blades are machined in a separated time slot with no other customer's parts in the cell.
- Files and inspection data are deleted or returned on request at program close, with written confirmation.
- Subcontracting is not permitted without your written approval — all titanium machining happens in our own plant in Dongguan.
Dongguan Changxinda Precision Technology Co., Ltd has been machining custom metal parts since 2008 — 15+ years, 90 to 100 staff, and 50–60% of output exported to North America and Europe. The plant runs 4-axis and 5-axis CNC machining centres, turn-mill combined lathes, and CNC lathes, with an ISO 9001:2015 certified quality system, and serves medical equipment, robotics, automotive, aerospace, automation, laser, LED, lithium battery and precision instrument customers. Annual turnover sits in the RMB 10–20 million band, more than 200 customers served, and every shipment leaves with a first article report. We are a manufacturer with our own floor, not a trading desk that forwards your drawing elsewhere.
- Prototype: 3–7 working days after drawing approval for single titanium wheels; 15–20 days where a new fixture must be built.
- Small batch (10–100 pcs): 7–14 working days, scheduled into a reserved weekly cell slot.
- Repeat orders: released from stored programs and fixtures, so lead time does not restart from zero.
- Capacity: 10,000 pieces per month across the plant, with titanium work planned against a fixed weekly window.
- Visibility: a dated progress note with photos of the actual part at roughing, finishing and inspection stages.
- Shipping: export cartons with foam cradles, DHL/FedEx/UPS express or air/sea freight per your forwarder, documents prepared for customs.
- Rush: overtime slots are held each week for urgent prototype or line-down situations — tell us the date you must have it and we will confirm before you order.
Turbocharger and supercharger compressor stages, small gas turbine rotors, APU and auxiliary power units, centrifugal and mixed-flow compressors, air-cycle machine rotors, fuel cell air compressors, dental and medical turbine handpieces, dental air turbines, vacuum blowers, HVAC high-speed blowers, and test-bench impeller rigs. Motorsport and off-highway turbo programs, marine turbocharger service, and industrial turbo rebuilders regularly order small titanium batches where a cast wheel will not hold.
A: Yes. STEP or IGES plus the critical interface dimensions (bore, keyway, backface datum, tip clearance target) is usually enough. We build the machining model, send a DFM note listing any feature that cannot be cut as modelled, and confirm before starting. If a 2D drawing exists, we work to it and to the model, and the drawing governs where the two disagree.
A: Titanium keeps strength at exhaust-side temperatures where aluminium softens, tolerates higher tip speed for a given wheel diameter, and resists fatigue from repeated heat cycles and foreign-object nicks. The trade-off is machinability: TC4 cuts at roughly one-third the speed of 6061 and needs rigid tooling and a controlled heat input, which is where the 30–50% longer cycle time comes from. We quote the trade honestly rather than pretending titanium machines like aluminium.
A: The finished wheel is blue-light scanned and the point cloud is aligned to the CAD model; section cuts at hub, mid-span and tip report deviation per blade. Bore, backface and keyway are measured on the CMM against the same datum set used in machining. Deviation charts and the CMM report ship with the parts, and we keep the raw scan data for two years in case a question comes up later.
A: You get the deviation report with the shipment, so you see the actual numbers rather than a pass stamp. If a feature sits outside your drawing, we re-machine or replace at our cost after agreeing the measurement method with you — the usual root cause is a datum interpretation difference, and that gets written into the job traveller so the next batch cannot repeat it.
A: Yes, we sign customer NDAs routinely and can return a countersigned copy before work starts. Inside the plant, only the project engineer, the CAM programmer and the cell supervisor open the file. No photographs leave the cell, and nothing about your program appears in our marketing material.
A: Programs, fixtures, tool lists and inspection plans are archived per part number after the first run. A repeat order reuses all of it, so the schedule covers machining and finishing only — not programming and fixturing. That is why the second order typically ships in a third of the first order's time, and why we can promise a date instead of a range.
A: One piece. There is no tooling charge and no setup fee for standard 5-axis work. Price follows material, wheel diameter, blade count, tolerance band and finish, so send the drawing and quantity and you get a written quotation typically within 24 hours.
Attach your model or drawing, tell us the quantity and the date you need the parts, and we will reply with a quotation, a process route and a delivery date — not a request for more information you have already given. Prototype enquiries are welcome and NDA paperwork can be handled in the same exchange.
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