Abstract: An exemplary method of depositing a layer of a material on an interior substrate surface of a complex geometry component includes the steps of providing the complex geometry component having an aperture defining an edge of the interior substrate surface of the complex geometry component, at least a portion of the interior substrate surface defining a first area not visible from the aperture, providing a heating element adjacent to the first area of the complex geometry component, energizing the heating element to raise a surface temperature of the first area and establish a thermal gradient between the first area and an adjacent area, and providing a vapor deposition apparatus configured to deposit the layer of material on the interior substrate surface corresponding to the first area of the complex geometry component.

Abstract: An articulating joint includes a linkage and a pin. The linkage includes a surface defining an opening. The pin extends along a pivot axis, and is disposed, at least in-part, in the hole. The pin has a core component made of a first material, and an outer component that at least partially circumferentially surrounds the core component and is made of a wear resistant material. The outer component includes a gradated sub-surface depth extending in a radial direction.

Abstract: A turbine wheel for a turbocharger of a vehicle propulsion system includes a central hub and a plurality of blades extending outwardly from the central hub. Each of the blades defining an inducer section and an exducer section, and each of the blades including a first surface portion and a second surface portion. The first surface portion including a thermal barrier coating and the second surface portion free from the thermal barrier coating.

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, an alloy includes aluminum in a first amount, iron in a second amount, silicon in a third amount, and an additive in a fourth amount. The additive is selected from the group consisting of a non-metal additive, a transition-metal additive, a rare-metal additive, and combinations thereof. The first amount, the second amount, the third amount, and the fourth amount produce an alloy with a stoichiometric formula (Al1-xAx)3Fe2Si where A is the additive.

Abstract: A turbine wheel for a turbocharger of a vehicle propulsion system includes a central hub and a plurality of blades extending outwardly from the central hub. Each of the blades defining an inducer section and an exducer section, and each of the blades including a first surface portion and a second surface portion. The first surface portion including a thermal barrier coating and the second surface portion free from the thermal barrier coating.

Abstract: An exemplary method of depositing a layer of a material on an interior substrate surface of a complex geometry component includes the steps of providing the complex geometry component having an aperture defining an edge of the interior substrate surface of the complex geometry component, at least a portion of the interior substrate surface defining a first area not visible from the aperture, providing a heating element adjacent to the first area of the complex geometry component, energizing the heating element to raise a surface temperature of the first area and establish a thermal gradient between the first area and an adjacent area, and providing a vapor deposition apparatus configured to deposit the layer of material on the interior substrate surface corresponding to the first area of the complex geometry component.

Abstract: An articulating joint includes a linkage and a pin. The linkage includes a surface defining an opening. The pin extends along a pivot axis, and is disposed, at least in-part, in the hole. The pin has a core component made of a first material, and an outer component that at least partially circumferentially surrounds the core component and is made of a wear resistant material. The outer component includes a gradated sub-surface depth extending in a radial direction.

Abstract: A method of joining parts of the wastegate assembly, and a wastegate assembly includes an arm defining a hole. The wastegate assembly also includes a shaft. The shaft includes a first end disposed inside the hole of the arm. The shaft includes an outer surface defining a groove disposed inside the hole of the arm. The arm and the first end of the shaft are welded together to form a joint having a joint root region disposed adjacent to the groove. A turbocharger includes a compressor, a turbine and a rotating assembly driven by exhaust gas. The rotating assembly has a turbine wheel disposed inside the turbine and a compressor wheel disposed inside the compressor. The turbocharger further includes the wastegate assembly described above, and the wastegate assembly defines an opening configured to selectively redirect at least a portion of the exhaust gas to bypass the turbine wheel.

Abstract: A wastegate actuator assembly includes a regulating rod, an arm, and a shaft. The regulating rod includes a proximate end region and a distal end region wherein the proximate end region of the regulating rod may be connected to an actuator. The arm includes a first end region and a second end region. The first end region is pivotally coupled to the distal end region of the regulating rod via a crank pin, a first cup spring, and a second cup spring wherein the first and second cup springs retain a solid lubricant substantially around the crank pin. The regulating rod may move in a linear fashion causing the arm and the shaft to rotate so as to move a wastegate cover connected to the shaft from a closed wastegate duct position (toward the wastegate duct) to an open wastegate duct position (away from the wastegate duct).

Abstract: A wastegate actuator assembly includes a regulating rod, an arm, and a shaft. The regulating rod includes a proximate end region and a distal end region wherein the proximate end region of the regulating rod may be connected to an actuator. The arm includes a first end region and a second end region. The first end region is pivotally coupled to the distal end region of the regulating rod via a crank pin, a first cup spring, and a second cup spring wherein the first and second cup springs retain a solid lubricant substantially around the crank pin. The regulating rod may move in a linear fashion causing the arm and the shaft to rotate so as to move a wastegate cover connected to the shaft from a closed wastegate duct position (toward the wastegate duct) to an open wastegate duct position (away from the wastegate duct).

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, an alloy includes aluminum in a first amount, iron in a second amount, silicon in a third amount, and an additive in a fourth amount. The additive is selected from the group consisting of a non-metal additive, a transition-metal additive, a rare-metal additive, and combinations thereof. The first amount, the second amount, the third amount, and the fourth amount produce an alloy with a stoichiometric formula (Al1-xAx)3Fe2Si where A is the additive.

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, mechanical properties are optimized using mechanical-optimizing additives such as a combination of boron, zirconium, chromium and molybdenum. In some aspects, corrosion-inhibiting properties are optimized using corrosion-inhibiting additives such as chromium, molybdenum, and tungsten. In some aspects, ductility is optimized by the inclusion of twinning additives such as any of zinc, copper, vanadium, and molybdenum.

Abstract: A method of joining parts of the wastegate assembly, and a wastegate assembly includes an arm defining a hole. The wastegate assembly also includes a shaft. The shaft includes a first end disposed inside the hole of the arm. The shaft includes an outer surface defining a groove disposed inside the hole of the arm. The arm and the first end of the shaft are welded together to form a joint having a joint root region disposed adjacent to the groove. A turbocharger includes a compressor, a turbine and a rotating assembly driven by exhaust gas. The rotating assembly has a turbine wheel disposed inside the turbine and a compressor wheel disposed inside the compressor. The turbocharger further includes the wastegate assembly described above, and the wastegate assembly defines an opening configured to selectively redirect at least a portion of the exhaust gas to bypass the turbine wheel.

Abstract: Provided herein are thermal barrier coatings (TBC) and turbocharger heat shields comprising the same. The turbocharger heat shield can be metallic and include a front face having an aperture capable of accepting a turbocharger shaft. The TBC can include a bond coat applied to the turbocharger heat shield, an interfacial layer contacting the bond coat, and a ceramic top coat contacting the interfacial layer. The bond coat of the TBC can comprise nickel, at least about 4% aluminum, up to about 36% chromium. One or more of the one or more of the interfacial layer and the ceramic top coat can comprise aluminum oxide, titanium oxide, spinel, yttria-stabilized zirconia, gadolinium zirconate, and combinations thereof. One or more of the interfacial layer and the ceramic top coat can be free from yttria-stabilized zirconia and gadolinium zirconate. The TBC can have a total thickness of at least about 100 ?m.

Abstract: A turbocharger for an internal combustion engine includes a rotating assembly having a turbine wheel disposed inside a turbine housing and a compressor wheel disposed inside a compressor cover. The turbocharger also includes a waste-gate assembly configured to selectively redirect at least a portion of the engine's post-combustion gases away from the turbine wheel. The waste-gate assembly includes a valve, a rotatable shaft connected to the valve, and a bushing fixed relative to the turbine housing and disposed concentrically around the shaft such that the shaft rotates inside the bushing for opening and closing the valve. The bushing is defined by a length, an outer surface in contact with the turbine housing, and an inner surface in contact with the shaft. The inner surface includes a plurality of longitudinal grooves configured to counteract friction between the bushing and the shaft and avoid seizure of the shaft relative to the bushing.

Abstract: A turbocharger for an internal combustion engine includes a rotating assembly having a turbine wheel disposed inside a turbine housing and a compressor wheel disposed inside a compressor cover. The turbocharger also includes a waste-gate assembly configured to selectively redirect at least a portion of the engine's post-combustion gases away from the turbine wheel. The waste-gate assembly includes a valve, a rotatable shaft connected to the valve, and a bushing fixed relative to the turbine housing and disposed concentrically around the shaft such that the shaft rotates inside the bushing for opening and closing the valve. The bushing is defined by a length, an outer surface in contact with the turbine housing, and an inner surface in contact with the shaft. The inner surface includes a plurality of longitudinal grooves configured to counteract friction between the bushing and the shaft and avoid seizure of the shaft relative to the bushing.