Abstract: A turbine housing assembly is disclosed, the assembly including a turbine housing defining a rotational axis for a turbine wheel. The assembly further includes a cartridge that is receivable by the turbine housing, the cartridge including spacer posts and a plate component that includes spacer post openings. The spacer posts may be laser beam welded into the spacer post openings to form laser beam welds as well as define an axial vane clearance between the plate component and a surface of the turbine housing. The turbine housing is further contacted by ends of the spacer posts. Each of the laser beam welds includes a power ramp-up area, an intermediate area and a power ramp-down area, where the power ramp-down area curves away from the power ramp-up area to reduce weld defects.

Abstract: A bushing includes a first wall section disposed about a channel. The first wall section is formed of a first sintered powdered metal alloy having a first mean sintering temperature in powdered form. A second wall section is disposed adjacent and affixed to the first wall section about the channel. The second wall section is formed of a second sintered powdered metal alloy having a second mean sintering temperature in powdered form that is different than the first mean sintering temperature. The difference between the first and second mean sintering temperatures is about 150° C. or less.

Abstract: A turbine housing assembly can include a turbine housing that defines a rotational axis for a turbine wheel; and a cartridge receivable by the turbine housing, where the cartridge includes spacer posts and a plate component that includes spacer post openings, where the spacer posts are laser beam welded into the spacer post openings to form laser beam welds to define an axial vane clearance between the plate component and a surface of the turbine housing contacted by ends of the spacer posts, and where each of the laser beam welds includes a power ramp-up area, an intermediate area and a power ramp-down area, where the power ramp-down area curves away from the power ramp-up area to reduce weld defects.

Abstract: A motor case for an electric motor of an e-boosting device is configured to be received within an outer housing to cooperatively define a coolant jacket. The motor case includes a shell member that at least partly defines a motor cavity for receiving the electric motor. The motor case also includes a dam member that is fixed to the shell member. The dam member projects from the shell member in an outboard direction from an outer surface of the shell member. The shell member and the dam member are configured to be received within the outer housing to define the coolant jacket and with the dam member partitioning the coolant jacket. The dam member is made of a different material from the shell member.

Abstract: Turbine housing assemblies and related fabrication methods are provided. A turbine housing assembly includes a bearing flange, a tongue member, a first sheet metal structure providing an inner contour of an inlet passage and joined to the tongue member, and a second sheet metal structure including an inlet portion providing an outer contour of the inlet and a volute portion providing an outer contour of a volute in fluid communication with the inlet. The volute portion is joined to the tongue member to define the volute, and the inlet portion of the second sheet metal structure is joined to the first sheet metal structure to define the inlet passage.

Abstract: A motor assembly for an e-boosting device is disclosed. The motor assembly includes a motor case and a motor cavity within the motor case. The motor case is configured to receive an electric motor that is configured to drivingly rotate a rotor about an axis of rotation. The motor assembly also includes a through-hole defined by the motor case. The motor case configured to be received in an outer housing to cooperatively define a coolant jacket with the outer housing. The coolant jacket includes a fluid flow path defined partly by the through-hole. Methods of manufacturing the motor assembly are also disclosed.

Abstract: A bi-metal variable geometry turbocharger (VGT) vane includes a structural, airfoil-shaped flag portion, and a functional, cylindrically-shaped shaft portion connected to the flag portion. The flag portion and the shaft portion are formed of a first metal alloy, and the shaft portion further includes a surface area formed of a second metal alloy different from the first metal alloy.

Abstract: A method of manufacturing a motor case for an electric motor of an e-boosting device in which the motor case is received within an outer housing to cooperatively define a coolant jacket. The method includes forming a shell member. The method also includes overmolding a dam member to the shell member. The dam member projects from an outer surface of the shell member. The overmolding of the dam member includes forming a molded through-hole through the dam member. The dam member and the outer surface are configured to define a fluid boundary for a coolant of the coolant jacket when the motor case is received in the outer housing. The through-hole defines a passage for the coolant in the coolant jacket.

Abstract: A bi-metal variable geometry turbocharger (VGT) vane includes a structural, airfoil-shaped flag portion, and a functional, cylindrically-shaped shaft portion connected to the flag portion. The flag portion and the shaft portion are formed of a first metal alloy, and the shaft portion further includes a surface area formed of a second metal alloy different from the first metal alloy.

Abstract: Turbine housing assemblies and related fabrication methods are provided. A turbine housing assembly includes a bearing flange, a tongue member, a first sheet metal structure providing an inner contour of an inlet passage and joined to the tongue member, and a second sheet metal structure including an inlet portion providing an outer contour of the inlet and a volute portion providing an outer contour of a volute in fluid communication with the inlet. The volute portion is joined to the tongue member to define the volute, and the inlet portion of the second sheet metal structure is joined to the first sheet metal structure to define the inlet passage.

Abstract: A method of manufacturing a motor case for an electric motor of an e-boosting device in which the motor case is received within an outer housing to cooperatively define a coolant jacket. The method includes forming a shell member. The method also includes overmolding a dam member to the shell member. The dam member projects from an outer surface of the shell member. The overmolding of the dam member includes forming a molded through-hole through the dam member. The dam member and the outer surface are configured to define a fluid boundary for a coolant of the coolant jacket when the motor case is received in the outer housing. The through-hole defines a passage for the coolant in the coolant jacket.

Abstract: A motor case for an electric motor of an e-boosting device is configured to be received within an outer housing to cooperatively define a coolant jacket. The motor case includes a shell member that at least partly defines a motor cavity for receiving the electric motor. The motor case also includes a dam member that is fixed to the shell member. The dam member projects from the shell member in an outboard direction from an outer surface of the shell member. The shell member and the dam member are configured to be received within the outer housing to define the coolant jacket and with the dam member partitioning the coolant jacket. The dam member is made of a different material from the shell member.

Abstract: A motor assembly for an e-boosting device is disclosed. The motor assembly includes a motor case and a motor cavity within the motor case. The motor case is configured to receive an electric motor that is configured to drivingly rotate a rotor about an axis of rotation. The motor assembly also includes a through-hole defined by the motor case. The motor case configured to be received in an outer housing to cooperatively define a coolant jacket with the outer housing. The coolant jacket includes a fluid flow path defined partly by the through-hole. Methods of manufacturing the motor assembly are also disclosed.