Qci 9310 024.Z

NUMBER REVISION
DOCUMENT TITLE PAGE AND REVISION RECORD QCI-9310-024 Z

DOCUMENT TYPE PAGE 1 OF 53
QUALITY CONTROL INSTRUCTION
TITLE
Control Instructions for Ferrous Turbine & Ferrous Compressor Housings
PREPARED BY APPROVED APPROVED
K. Schloff D. Heinz, Q. C. L. Muller, Prod. Engineering

LAST REVISED BY APPROVED APPROVED
Tomas Fedra, HCOE W. Wahl, Mftg. Engineering R. M. Mendelson

PROPRIETARY NOTICE
This Document contains proprietary information and such information may not be disclosed to others for any purpose or used for
manufacturing without written permission from Garrett Motion, Inc.
REVISION RECORD
REV. ITEM
LTR. ECR NO. DATE DESCRIPTION CHECKED APPROVED
Placed on current template and updated
V ECR-18-00099 1 03/08/18 DC SM
formatting
Added new Sections 8.11.1, 8.11.2, 8.11.3, &
2
8.11.4, renumbered following sections
Updated company name and logo
W ECR-19-01177 1 06/14/19 DC PP
Revised in its entirety
2
Section 6.15 & 6.16.6: Added WG and VNT
Y ECR-19-01598 1 07/11/19 DC PP
applicability
Section 6.16.2: Corrected section references in
2
the table, added Note for Proto to the table
Section 7.3: Revised table – changed “Non-
Z ECR-19-02701 1 01/08/20 DC PP
sealing surfaces” to “Mating Surfaces”, added
row for “Other Surfaces”
Section 7.5: Revised critical areas
2
Revised Figure 54
3
DISTRIBUTION: per CDI-0004

GAR_DOC (R. 10/18) The user must verify that this is the current revision prior to use and if not, remove it from use.
NUMBER QCI-9310-024 REVISION Z
BY DATE Page 2
Tomas Fedra 01/08/20 of 53
TITLE QUALITY CONTROL INSTRUCTION

1.0 Introduction
This Quality Control Instruction contains the procedures and criteria for acceptance of all ferrous turbine
& compressor housing castings and turbine & compressor housing machined parts. Acceptance criteria
different than stated in this QCI, whether or not customer imposed, must be clearly stated on the
applicable casting or machined housing drawings or in other documents specified on the drawing.
2.0 Scope
This QCI applies to all purchased ferrous turbine housing castings, ferrous compressor housing castings,
machined turbine housings, and machined compressor housings. It is effective upon issue and when
called out on the Engineering drawing.
Acceptance criteria different than stated in this QCI, whether or not customer imposed, must be clearly
stated on the applicable casting or machined housing drawings or in other documents specified on the
drawing.
This QCI should be referenced by the supplier in all quotations and purchase order acknowledgments.
3.0 Definitions, Abbreviations, and Symbols

AE Application Engineer
APQP Advanced Product Quality Planning
CT Computer Tomography
EDM Electrical Discharge Machining
EPCP Early Production Containment Plan
FEA Finite Element Analysis
GT30 Garrett Turbo size 30 (specified on the model tab of the drawing)
IDM Industrial Division Material specification (a Garrett document)
IFP Industrial Finish/Plating specification (a Garrett document)
IWBS Industrial Welding, Brazing, Soldering specification (a Garrett document)
ODT Off Definitive Tooling
PDP Purchasing Department Instruction (a Garrett document)
PI Process Instruction (a Garrett document)
PPAP Production Part Approval Process
QCI Quality Control Instruction (a Garrett document)
SOP Start Of Production
SQ&D Supplier Quality & Development
VNT Variable Nozzle Turbine
WG Wastegate
GAR_DOC (R. 10/18) The user must verify that this is the current revision prior to use and if not, remove it from use. Garrett Proprietary & Confidential
BY DATE Page 3

4.0 List of Related Documents

ASTM E446-10 Standard Reference Radiographs for Steel Castings up to 2 in. (50.8 mm) in Thickness
IATF 16949 Quality Management in Automotive Industry
IFP-001 Corrosion Protection of Cast Iron and Steel Component Parts
IWBS-005 Repair of Casting Imperfections by Welding
IWBS-008 Foundry Weld Repair of Stainless Steel Turbine Housings
PDP-0627 Supplier Production Part Approval Process (PPAP)
PI-5780 Identification of Castings and Injection Molded Plastic Parts
PI-5865 Automatic Pressure Decay Leak Testing
PI-6009 Definition of the Locations to Analyse for Turbine Housings or Manifold
Microstructure Characterization
PI-6111 Definition of the Locations to Analyse for Compressor Housings Material Soundness
and Microstructure Characterization
QCI-9310-020 Deburring Requirements
QCI-9310-122 Product Cleanliness
QCI-9310-190 Process Control and Capability Requirements to Meet Engineering Specifications
VDA 6.3 Process Audit
BY DATE Page 4

5.0 Types of Housings & Housing Terminology

5.1 Types of Turbine Housings
Figure 1: Undivided volute (mono scroll)
Figure 2: Divided volute (twin scroll)
Figure 3: Sector divided
BY DATE Page 5

Figure 4: Integrated manifold
Figure 5: Water cooled
Figure 6: Dual inlet
BY DATE Page 6

Figure 7: VNT
Figure 8: Wastegate
Figure 9: Free Float
BY DATE Page 7

5.2 Types of Compressor Housings
Figure 10: Compressor housing without ported shroud
Figure 11: Compressor housing with ported shroud
BY DATE Page 8

5.3 Turbine Housing Terminology
Figure 12: External view
Figure 13: Cut section
BY DATE Page 9

5.4 Compressor Housing Terminology
Figure 14: External view
Figure 15: Cut section
BY DATE Page 10

6.0 Requirements for Castings

6.1 Casting Process Development
6.1.1 Foundry Simulation results are required at the start of APQP and any issues highlighted
by it will be added to the APQP issue log submitted to the AE.
6.1.2 Supplier shall submit a final Foundry Process Simulation report showing mold filling
and solidification to be approved by SQ&D before start of tooling build. Whenever
possible all flash, gate pads, and feeders should be placed on surfaces to be machined.
6.2 Supplier Production Performance Approval
The supplier must produce sample castings, validate their conformity and submit the results for
approval. Such approval must be obtained before processing of any production castings, if any of
the following apply:
• A new pattern or core box has been constructed.
• A correction has been made because of inspection of a previous sample.
• An engineering change affecting the pattern or material has been made.
• Any pattern or core box has been relocated to a new foundry source.
• Any changes to gating or feeder system from previously submitted casting simulation.
In general, the supplier (foundry) will be required to pass sample inspection layout report duly
reviewed and approved by Supplier Quality & Development (SQ&D), Manufacturing, and
Product Engineering before proceeding with production. Samples must be inspected by qualified
personnel.
Approval shall be conducted per PDP-0627.
6.3 General Inspection
All casting batches will be processed through an audit inspection (process control plan) to ensure
compliance to drawing specifications (machining stock is generally excluded from these
considerations). Inspection shall include, but not be limited to the following items.
6.3.1 Identification
Casting identification shall be per PI-5780 or as specified on the drawing.
6.3.2 Casting Soundness
The Supplier shall produce evidence of foundry control by non-destructive testing
methods and/or product sectioning per PI-6111 for compressor housings or PI-6009 for
turbine housings to ensure internal casting soundness.
Except where specifically included in the rejection criteria (e.g. shrinkage criteria),
porosity defects of less than 0,5mm in depth or diameter shall not be considered.
6.3.3 Dimensional Characteristics
All characteristics must be inspected per QCI-9310-190.
BY DATE Page 11

6.3.4 Visual Inspection

6.3.4.1 No cracks, hot tears, through porosity (gas passage to outer surfaces) or
cold laps are permitted.
6.3.4.2 All internal and external surfaces must be free from rust. Discoloration
other than surface oxidation is generally not an issue but should be
submitted to Garrett representative for approval.
6.3.4.3 Shot blasting finish is optional. However, all surfaces must be free of
loose material (sand, scale, burrs, …) or cleaning media. Presence of
corrosion protection media is allowable within the limits of IFP-001.
6.3.5 Positive / Negative Surface Imperfections
6.3.5.1 Positive surface imperfections may be blended with adjacent surfaces
provided the drawing tolerance and minimum wall thickness tolerances are
maintained.
6.3.5.2 Negative imperfections on non-machined surfaces cannot violate minimum
wall thickness callout per drawing / 3D model. Bottom must be rounded
and clearly visible.
6.3.5.3 Unless otherwise stated in the acceptance criteria, there shall be no more
than 1 negative imperfection per 1cm2.
6.4 Casting Rework
6.4.1 Weld Repair
Welding is permitted to repair turbine housing castings. However, weld repair is
generally uneconomic on cast ferrous castings. Stainless steel castings and heat
resistant castings of Ni-resist may be economically repaired by welding. The extent of
welding permitted is specified in the material specification (IDM), which will reference
IWBS-005 for ferrous castings and IWBS-008 for stainless steels.
6.4.2 Peening
Peening is not acceptable as it is used to cover casting defects of unknown severity.
6.4.3 Grinding
Grinding at external or internal surfaces in order to remove excessive flash is
acceptable provided it does not cause a thin wall or violates drawing tolerances.
BY DATE Page 12

6.5 Surface Roughness Requirements

6.5.1 Initial measurement of surface roughness for demonstration of process capability at
PPAP stage or after a modification to the core manufacturing process, should be
completed using a contact type instrument which is drawn across the location to be
measured.
Measurement must be done on a flat line, using a stylus head with a tip radius of 5µm
and an angle of 60°.
Measurement must be conducted wherever the casting process could negatively impact
the final result.
Using a visual comparison standard for surface roughness evaluation is an acceptable
alternative, provided the supplier has demonstrated adequate correlation to a contact
type measurement system.
6.5.2 Measurement of surface roughness on a repetitive production basis may be
accomplished with any recognized industry-wide visual comparison standard.
6.5.3 The internal surface roughness values stated on the drawing or in this document apply
only to gas passage surfaces, i.e., those surfaces formed by the internal core. Internal
surface roughness allowance, unless otherwise specified on the drawing, is Ra 6.4 µm
on at least 80% of total area and Ra 12.5 µm on remaining areas.
6.5.4 External cast surface roughness allowance, unless otherwise specified on the drawing,
is Ra 25.4 μm.
6.6 Tongue Area Acceptance Criteria
No defect allowed within +20° and -10° of the tip of the tongue (see Figure 16). Positive
projections may be removed without changing the intended shape and location of the tongue. The
minimum radii of the grinding tool shall be 0.6 mm so as to avoid creating a sharp edge.
Figure 16: Excess material in tongue area
BY DATE Page 13

6.7 Divider Tip Acceptance Criteria

Allowed Defects
Max Height Max Length Max
Exceptions / Comments
(mm) (mm) Quantity
Negative defect -
1,0 15,0 2
lack of fill → Valid for defects located on
Positive defect - divider tip (cores glue line)
1,0 1,0 3
flash
Figure 17: Defect criteria on divider tip
6.8 Positive Projections

• Parting line – generated by the connection of upper and lower halves of the mold or core-to-
mold intersection.
• Glue line – generated by the connection of two separate cores (sand casting) or patterns (lost
foam).
• Flash – sharp, thin projections generated by improper mold closure or core assembly.
• Rigid projections - caused by phenomena such as core or mold erosion/damage.
BY DATE Page 14

6.8.1 Sand Casting

Location of positive projections can be anywhere except in the clamping area for the
first machining operation. External positive projections may be ground to blend with
existing cast surfaces.
Note: Positive projections must not present a hazard when being handled (no sharp
edges).
Allowed Defects
Max Height Max Width
Max Quantity Exceptions / Comments
(mm) (mm)
→ Parting line no smaller at
base than at peak
Parting and glue → No parting line allowed on
1,5 3,0 N/A
lines cast bolt seating areas
→ Except tongue area and
divider tip, see 6.6 and 6.7
→ Rigid projections no smaller
Rigid at base than at peak
projections – Allowable if contained within surface profile tolerance → No rigid projections
external surfaces allowed on cast bolt seating
areas
GT30 and smaller: → Rigid projections no smaller
Rigid
4 in volute, 6 elsewhere at base than at peak
projections – 1,5 3,0
GT32 and larger: → Except tongue area and
internal surfaces
5 in volute, 8 elsewhere divider tip, see 6.6 and 6.7
Flash No defect allowed
Figure 18: Sand casting positive defect criteria

BY DATE Page 15

Flash projection Rigid projection
Figure 19: Flash and rigid projection
Figure 20: Cast bolt seating area

6.8.2 Lost Foam
Grinding of excessive material is allowed if wall thickness is maintained. Glue line has
to be a continuous shape (not wavy).
Figure 21: Glue line acceptance/rejection
BY DATE Page 16

Allowed Defects
Max Height Max Width Max Depth
(mm) (mm) (mm)
→ No glue line allowed on cast bolt
External surfaces 2,0 5,0 0
seating areas
Internal surfaces –
1,0 3,0 0
volute
Internal surfaces –
2,0 5,0 0
other than volute
Figure 22: External and internal glue lines – OK parts
Figure 23: External and internal glue lines – NOK parts
BY DATE Page 17

6.9 Ingates & Feeders

Ingates and feeders are result of casting simulation study and need to be presented and agreed to
by SQ&D and AE. Remaining ingates and necks should be added to 3D model.
Note: If Foundry needs to exceed the recommended maximum height for ingate or feeder necks
SQ&D and AE need to be contacted for approval.
Allowed Defects
Max Height Max Width Max Length
(mm) (mm) (mm)
→ Must not interfere with machine
pick-up
On surfaces to be
N/A → Should be kept to minimum height
machined
to optimize cycle time and cutter
life
→ No sharp edges allowed
→ Must not interfere with machine
To be validated through pick-up or the function of the
On unmachined
1,5 casting simulation and finished part
surfaces
approved by SQ&D/AE → Grinding of gates and feeders
cannot affect wall thickness per 3D
model
Figure 24: Ingates and feeders
BY DATE Page 18

6.10 Impact Damage (Gouges, Dents, & Nicks)

Gouges, dents and nicks from handling are acceptable if they do not interfere with either machine
pickup, assembly, or bolt installation and maintain minimum wall thickness. Impact damage with
no significant depth (e.g.: less than 0.15mm in depth or cannot be felt by the fingernail) or raised
edges and that are within surface finish standards shall not be considered as defects or included in
counts.
In order to protect important functional surfaces, a supplier can add a wear bar on a casting based
on production experience. If its size exceeds 1mm, SQ&D and AE need to be contacted for
approval. Damage to the wear bar is a “normal” phenomenon.
Note: This chapter affects machined surfaces only in case of damage to corners. For other areas
only casting surfaces are being considered.
Allowed Defects
Max Depth Max Width Max Length
(mm) (mm) (mm)
Corners to
No defect allowed
sealing surfaces
→ Dimensions are valid for machined
Corners to parts
non-sealing → Defect must not impact requirements
2,0 2,0 90° or 5,0
surfaces (flanges, for machined holes, see section 7.5
bosses, pads…) → Defect must not impact requirements
for sealing surface 7.4.1
Wear bar Unlimited
→ Minimum wall thickness has to be
Other areas 1,5 ∅ 20,0 kept
→ No cracks accepted
Figure 25: Impact damage – corners – defect size
BY DATE Page 19

Figure 26: Impact damage – corners - locations
Figure 27: Impact damage – other areas
Figure 28: Impact damage - wear bar
BY DATE Page 20

6.11 Core Parting Line

Flash on sand cores must be removed prior to core assembly. Visual imperfections are acceptable
within following limits:
Allowed Defects
Max Height Max Width Max Length
(mm) (mm) (mm)
→ None allowed in tongue area
Core parting line 0,5 0,5 unlimited
→ No sharp edges allowed
Figure 29: Core parting line size
Figure 30: Core parting line acceptance/rejection
BY DATE Page 21

6.12 Lack of Fusion

• Cold Laps - result from two streams of metal meeting and not fusing together due to low
temperature.
• Localized discontinuities – can occur close to a metallic insert like a chaplet (their use is
permitted if they are completely fused with surrounding casting).
Allowed Defects
Max Depth Max ∅ Max
(mm) (mm) Quantity
→ Not acceptable under any
Lack of fusion No defect allowed
circumstances
Figure 31: Example of a cold lap
BY DATE Page 22

6.13 Gas Entrapment

Gas entrapment is generated when there is insufficient mold permeability to permit gas to escape
as metal enters. The trapped gas may form localized negative imperfection on casting surfaces
which need to be evaluated against the criteria below.
Note: trapped gas can be drawn below the surface by the metal stream and form internal
porosities in which case acceptance criteria from section 6.16 will apply.
Allowed Defects
Max Depth Max Width Max Length
(mm) (mm) (mm)
→ Cannot be located on containment
band
6 x wall → Only on one side of a wall
Gas laps 1,0 2,0
thickness → Minimum wall thickness cannot be
affected
→ Except tongue area, see 6.6
Figure 32: Gas entrapment
BY DATE Page 23

6.14 Ported Shroud Cavity Including Ribs

6.14.1 Negative Imperfections
Allowed Defects
(mm) (mm) Quantity
→ No grouping of defects (distance
All areas 1,0 2,0 multiple
< 10 mm) allowed
6.14.2 Positive Imperfections

Allowed Defects
Max Height
(mm) Max ∅ (mm) Max Quantity Exceptions / Comments
Between → Burs at machined slot permissible per

No defect allowed
slot and rib QCI-9310-020
→ No detachable material allowed
Other areas May not go beyond PS slot multiple
(rework acceptable)
Figure 33: Positive imperfections on ported shroud
BY DATE Page 24

6.15 Surface Porosity & Inclusions

• Sand inclusion – caused by loose grains of sand from mold or cores.
• Slag inclusion – caused by contaminated, poorly filtered metal entering the mold.
• External shrinkage – caused by insufficient metal feed during the solidification stage.
• Pinholes – generated by chemical reaction of the melt (or gas entrapment - see section 6.13).
The following areas are considered critical on a housing (WG or VNT as applicable):
Figure 34: Tongue area, Wastegate seat area, Bushing boss

6.15.1 GT32 & Larger
Allowed Defects
(mm) (mm) Quantity
→ Only 1 defect per individual area
Critical areas 1,0 2,0 2
→ No defect allowed on the tongue
→ Min 10mm between each inclusion
→ Minimum wall thickness of the
1,5 3,0 10
containment band must be guaranteed
Radial passage
→ Except divider tip, see 6.7
Multiple → No grouping of clusters (distance
1,0 1,0
within 20 cm2 < 25mm) allowed
2,0 4,0 10 → Min 10mm between each inclusion
Other areas
1,0 1,0
BY DATE Page 25

Figure 35: Surface porosity and inclusions - GT32 and larger

6.15.2 GT30 & Smaller
Allowed Defects
(mm) (mm) Quantity
→ Only 1 defect per individual area
→ No defect allowed on the tongue
→ Min 10mm between each inclusion
1,0 1,5 3 → Minimum wall thickness of the
Radial passage containment band must be guaranteed
1,0 1,0
1,0 3,0 10 → Min 10mm between each inclusion
Other areas
1,0 1,0
Figure 36: Surface porosity and inclusions – GT30 and smaller
BY DATE Page 26

Bottom visible
Bottom not visible
Figure 37: Surface porosity and inclusions acceptance/rejection
6.16 Subsurface Porosities

6.16.1 Porosity Inspection Methods
All ferrous or steel based turbine and compressor housings shall be produced under
control of subsurface porosity through X-Ray (alternative checking method by CT is
possible) and die penetrant testing. So as not to miss any potential defects due to the
complex shapes of the housings, and to increase the sensitivity of the X-Ray and die
penetrant testing, the supplier shall make part of these tests on wire EDM slices/cuts of
the part.
After slicing or cutting, the pieces need to be tested with die penetrant and checked
with X-Ray individually. If these tests reveal the presence of subsurface porosity, then
additional slices/cuts need to be performed through those areas. The porosity area
needs to be polished and examined under microscope manually or based on evaluation
software.
BY DATE Page 27

6.16.2 Checking Frequency

Depending on the purpose and sample submission size (prototype, ODT/PPAP), or on
which period of the product life cycle the part is in, the inspection frequency and the
inspection position shall vary. Unless otherwise specified and agreed with the Quality
and Engineering representatives of the Customer in the quotation period, the requested
frequency and inspection position can be found in the summary table below. One
production batch equals one melting furnace material.
Porosity Inspection Requirements
Inspection Method Reports
Production Inspection
Sample Inspection Position Cutting & Submission
batch size Frequency X-ray Penetration Acceptance
polishing to Customer
slicing
1 pcs per production per Per Section
Entire part every per slice Y
batch slice 6.16
≤10 pcs 10mm
Rest of the part in Per Section
Entire part N/A 100% N/A Y
the batch 6.16
Proto* 1 pcs/cavity from Per Section
slicing
first & last mold of per 6.16
each production slice
>10 pcs 10mm
batch
the batch 6.16
slicing Per Section
1 part per production per
Entire part every per slice 6.16 Y
batch slice
≤10 pcs 10mm
the batch 6.16
ODT /
PPAP 1 pcs/cavity from Per Section
slicing
first & last mold of per 6.16
each production slice
>10 pcs 10mm
batch
the batch 6.16
1 pcs/cavity from Locations specified in Section Per Section
first mold of first 6.16.3 and critical areas per 6.16
ladle & last mold of pouring simulations, or per cut per cut Per cut
last ladle of the previous X-Ray results, or
EPCP N/A
production day engine tests, or FEA results
1 pcs/cavity from Per Section
first & last mold of Entire part N/A 100% N/A 6.16
document
each ladle
and archive
Locations specified in Section Per Section
1 pc / week or 1 pc / 6.16.3 and critical areas per 6.16
2000 pcs, whatever pouring simulations, or per cut per cut per cut
Mass
N/A comes earlier previous X-Ray results, or
Production
engine tests, or FEA results
10 pcs / each Per Section
Entire part N/A 100% N/A
production day 6.16
*Prototype suppliers delivering parts for purposes other than reliability testing are excluded from this requirement.
In mass production status, statistical data on findings can be reviewed by SQ&D and
the supplier after SOP+1 year. A reduction in checking frequency is permitted if the
stability of production quality is demonstrated:
a) No porosity outside the acceptance criteria in any samples.
b) No rejection due to porosity from Customer.
BY DATE Page 28

6.16.3 Cutting Examples

• Entire part slicing
• Critical area slicing
6.16.4 Documentation Requirements

Inspection result report preparation, submission to customer and or retention and
archiving need to follow the same rules as other quality inspection results reporting,
submission, retention and archiving.
6.16.5 Definition of Porosity Size
a) The size of a porosity is equal to the diameter Dp of the smallest circle covering it
entirely.
b) A porosity is made up of a single pore or a cluster of connected pores.
c) Pores are considered to be connected, if they are closer than the diameter of the
smaller pore.
d) A porosity is considered to be connected with the surface, if it is closer than its
diameter.
The distance d between two pores is equivalent to the distance between their two
closest points.
The following images illustrate the diameter Dp of the internal porosity in the case of
connected pores:
Surface
Dp = Porosity Dp = Porosity
diameter diameter
BY DATE Page 29

6.16.6 Acceptance Criteria

The locations to be analyzed at minimum in order to evaluate the porosity level of a
specific housing are defined in PI-6009. The following areas are considered critical on
a housing (WG or VNT as applicable):
Figure 38: Containment band, Contour, Tongue area, Wastegate seat area, Bushing boss
In addition, Engineering will define as required, on a case by case basis, additional

critical areas based on:
a) casting simulation results (e.g. MAGMA®) provided by supplier
b) radiographic X-ray results
c) stress regions defined by FEA simulations
d) engine test results
No further actions are required, if the following criteria regarding porosity size are met:
GT30 and smaller
Allowed Defects
Max ∅ (mm) Max Quantity Exceptions / Comments

Critical areas → Analysis to be performed by metallographic
0,5 1%
micro-section with magnification 20:1 or 25:1
Other areas
1,25 5% → Determination of quantity see 6.15.7
GT32 and larger

Allowed Defects
Max ∅ (mm) Exceptions / Comments
Critical areas Level 2 per ASTM E446-10 → Analysis to be performed through X-ray
Other areas Level 3 per ASTM E446-10 radiography
Engineering and Supplier can agree to an extension of these criteria if the part’s
functional durability has been demonstrated through successful engine qualification
testing.
Note: No through porosity is acceptable. Effective wall thickness (excluding porosity)
must be greater than the minimum wall thickness specified on the drawing.
BY DATE Page 30

6.16.7 Methodology of Porosity Count

a) The microsection for porosity evaluation must be located in the area of maximum
porosity.
b) The dimension of the area chosen for evaluation shall be the shape of a square,
isosceles triangle or circle, and cover the maximum surface from wall to wall).
c) The total % of porosity shall be determined with appropriate software.

d) Critical and non-critical areas must be inspected separately.
Example 1
Porosity level is determined through manual count.
Example 2
Porosity level is determined by calculating the % of porosities and graphite, then
subtracting the % of graphite taken from a neutral area.
BY DATE Page 31

7.0 Requirements for Machined Housings

7.1 Sample Machined Housing Approval
The supplier must produce sample machined housings, validate their conformity, and submit the
results for approval. Such approval must be obtained before processing of any production
machined parts, if any of the following apply.
• Implementation of new machining equipment.
• Significant modifications to the production process (e.g.: turning replaced by milling...).
• Production has been relocated in another plant (include also the use of subcontractor).
• Change of supplier (new foundry).
• Any other general conditions as described in IATF16949 or VDA6.3 reference manual.
7.2 Inspection
Each machined housing shall be processed through a visual inspection to ensure compliance to
drawing specifications. Inspection shall include, but not be limited to the following in Section 7.3.
7.3 Acceptance Criteria
The following are general rules for acceptance criteria unless otherwise specified on the drawing.
• All sharp edges must be removed.
• 100% leak testing per PI-5865 is mandatory.
• Contamination levels must be kept under control per QCI 9310-122.
• Deburring requirements must be followed per QCI-9310-020.
• All characteristics must be inspected per QCI-9310-190.
• All machined surfaces must be free from rust.
• All machined surfaces must be free of positive projections. Burrs acceptable per QCI-9310-
020, or raised edges within surface finish standards shall not be considered as defects or
included in counts.
• Except where specifically included in the rejection criteria, negative imperfections of less
than 0,2mm in depth or diameter shall not be considered.
• Unless clearly specified otherwise in Sections 7.4 – 7.12, all of the following generic
acceptance criteria for machining surfaces shall always apply:
BY DATE Page 32

Allowed Defects
(mm) (mm) Quantity
→ Negative imperfections only, no
protrusions allowed
→ Rounded, bottom must be visible
Sealing surfaces 0,5 0,5 2 → No grouping of defects (distance < 10 mm)
allowed
→ Isolated pores with diameter less than
0,2 mm are not included in counts
protrusions allowed
Mating surfaces 0,5 1,0 multiple → No grouping of defects (distance < 5 mm)
allowed
protrusions allowed
Other surfaces 1,0 2,0 multiple → No grouping of defects (distance < 5 mm)
allowed
→ Isolated pores with diameter less than 0,2
mm are not included in counts
7.4 Flanges
Sealing surfaces should be specified on the drawing, especially for manifolds. In absence of a
definition, acceptance criteria of sealing and non-sealing surfaces as described in the following
paragraphs shall be used for evaluation of part conformity. Several examples are shown for each
type of flange. In case of different designs, the exact location of the sealing surface needs to be
determined during APQP discussions. The same criteria shall be applied for sealing surfaces and
other surfaces respectively.
7.4.1 Inlet & Outlet Flanges, Bolted
As a standard, surfaces are defined as follows:
• A non-sealing band of 2mm width around inlet or outlet port
• A sealing band of 7mm width around the 2mm non-sealing band note: in case of
wall thickness ≤7mm, the entire surface shall be considered sealing.
• A critical band of 3mm width around all bores (threaded/non-threaded).
BY DATE Page 33

Allowed Defects
(mm) (mm) Quantity
→ GT30 and smaller
No defect allowed 0,2 mm are not included in counts
Sealing surface and → Not applicable around non-threaded
critical areas holes, see chapter 7.5.2
→ GT32 and larger
0,5 0,5 10 → Not applicable around non-threaded
holes, see chapter 7.5.2
→ In case of multiple ports (manifold),
Other areas 0,5 1,0 6
max quantity applies to the entire part
Figure 39: Bolted inlet flange – undivided
Figure 40: Bolted inlet flange – divided Figure 41: Bolted inlet flange - manifold
BY DATE Page 34

Figure 42: Bolted outlet flange

7.4.2 Inlet & Outlet Flanges, V-Band and Marman
Allowed Defects
(mm) (mm) Quantity
No defect allowed → Isolated pores with diameter less than
Sealing surface and
critical areas 0,2 mm are not included in counts
0,5 0,5 10 → GT32 and larger
Figure 43: V-band, Marman
BY DATE Page 35

7.4.3 Turbine to Center Housing Flange

As a standard, surfaces are defined as follows:
• A primary sealing surface in contact with the sealing element (usually C-ring).
• Mating surfaces that can have a secondary sealing effect, but with relaxed criteria
regarding surface defects.
• Surfaces without contact with Center housing.
Allowed Defects
(mm) (mm) Quantity
Sealing surface and → Quantity 10 allowed for GT32 and
0,5 0,5 5
critical areas larger
Mating and adjacent
0,5 1,0 5
surfaces
Other surface 1,0 2,0 3
Typical sealing configurations by product families:
GT12 VNT STEEL
GT14 WG STEEL
BY DATE Page 36

GT12 VNT IRON
GT14 VNT IRON

GT17B VNT IRON
GT20V VNT IRON
GT22V VNT IRON
GT17A VNT IRON

GT12 VNT IRON
GT17V VNT IRON
GT20D VNT IRON
GT22 VNT IRON
GT22 VNT D5S
GT30 VNT IRON
GT35 VNT IRON
BY DATE Page 37

GT45 VNT IRON – A = ∅ 182.0 mm

GT62 WG IRON – A = ∅ 150.0 mm
GT40 VNT IRON

GT45-55 WG IRON
GT45 VNT IRON

GT45 WG IRON
GT55 WG IRON
GT62 WG IRON
GT70 WG IRON
BY DATE Page 38

GT70 WG IRON
7.4.4 Compressor Housing Inlet & Outlet Flanges

Allowed Defects
(mm) (mm) Quantity
→ No grouping of defects (distance < 5 mm)
Chamfer, radius 0,5 0,5 3
allowed
→ Micro-shrinkage cavity ∅ 5,0mm max, 1
location max
End face and ID 0,5 1 3 → Defects cannot be edge-to-edge of area
allowed
location max
Outer diameter 1,0 2,0 3
allowed
location max
Shoulder 1,0 3,0 5
allowed
BY DATE Page 39

Figure 44: Inlet flange
Figure 47: Outlet with chamfer Figure 46: Outlet with bead Figure 45: Bolted flange
BY DATE Page 40

7.4.5 Compressor to Center Housing Flange

Allowed Defects
(mm) (mm) Quantity
Sealing surface and → Quantity 10 allowed for GT32 and
0,5 0,5 5
critical areas larger
Mating and adjacent
0,5 1,0 5
surfaces
Other surface 1,0 2,0 3
Figure 48: V-band connection with O-ring Figure 49: V-band connection without O-ring
Figure 50: Bolted connection
BY DATE Page 41

7.5 Threaded & Non-Threaded Bolt Holes

Critical areas only apply to threaded holes:
• The first 3 pitches
• Chamfer or counterbore
• A band of 2mm around bore
7.5.1 Bore
Allowed Defects
(mm) (mm) Quantity
Critical area No defect allowed
Other area 1,0 2,0 3
Figure 51: Threaded bolt holes – bore Figure 52: Non-threaded bolt holes – bore
BY DATE Page 42

7.5.2 Face
Allowed Defects
(mm) (mm) Quantity
No defect allowed → Isolated pores with diameter less than
Critical area 0,2 mm are not included in counts
0,5 0,5 2 → GT32 and larger
→ Per individual area
→ Except flange housing-to-housing
Other area 1,0 2,0 2 contact surfaces, see 7.4.1 & 7.4.3 &
7.4.4 & 7.4.5
→ Except VNT spacer holes, see 7.7.2
Figure 53: Threaded bolt hole - face Figure 54: Non-threaded bolt hole - face
BY DATE Page 43

7.6 Turbine Outlet / Compressor Inlet

Allowed Defects
(mm) (mm) Quantity
Contour 0,5 1,0 2
Diffuser 1,0 1,0 3

F diameter 1,0 1,0 5
Inlet/Outlet taper 1,0 2,0 3
Figure 55: Compressor inlet Figure 56: Turbine outlet
BY DATE Page 44

7.7 VNT Criteria

7.7.1 VNT Assembly
Allowed Defects
(mm) (mm) Quantity
Sealing surface No defect allowed
Mating surface 0,5 1,0 5 → More than 15mm between defects
Other surfaces 1,0 2,0 3 → More than 15mm between defects
GT12 STEEL
GT12-22 IRON –
Thermally decoupled
- cartridge assembly
includes contour
BY DATE Page 45

GT20-35 IRON – Normal cartridge

- cartridge assembly does not include contour
GT22-45 IRON – Normal cartridge

- cartridge assembly does not include contour
BY DATE Page 46

7.7.2 VNT Spacer Holes

Allowed Defects
(mm) (mm) Quantity
Critical area No defect allowed
Figure 57: VNT spacer holes – non-threaded Figure 58: VNT spacer holes – threaded
7.8 VNT with Sintered Insert

Bi-material housing design with iron turbine housing cast over stainless steel insert. Sample
reference is 707241. Chip erosion and flash not accepted on functional diameters.
Figure 59: Sintered insert – scheme and NOK example

BY DATE Page 47

7.9 Poppet Valve (TA03)

Linear actuation of the wastegate channel. Examples of TA03 turbine housings are: 409634,
409839, 430738.
Allowed Defects
(mm) (mm) Quantity
Sealing and important → Isolated pores with diameter less than
No defect allowed
surfaces 0,2 mm are not included in counts
Surrounding surface 0,5 1,0 3
Figure 60: Poppet valve for TA03
BY DATE Page 48

7.10 WG Seat
Acceptance criteria are applied regardless of channel shape (mono, D-shape, twin).
7.10.1 3-Piece Arm & Valve
These criteria are applied regardless of channel shape (mono, D-shape, twin).
Allowed Defects
(mm) (mm) Quantity
→ 1 defect allowed inside sealing area,
Non-sealing surface 0,5 0,5 2
→ 1 defect allowed outside sealing area
Figure 61: WG seat – 3-piece arm & valve

7.10.2 Monoblock
Allowed Defects
(mm) (mm) Quantity
Non-sealing surface 0,5 0,5 1
BY DATE Page 49

Figure 62: WG seat - monoblock
Figure 63: Acceptable defect on WG seat
BY DATE Page 50

7.11 Bushing Hole

7.11.1 Bore
Allowed Defects
(mm) (mm) Quantity
Critical areas No defect allowed
→ No more than 1 cluster of pores with
Non-critical area 0,5 0,5 multiple
diameter 3mm max
Figure 64: Bushing bore for 3-piece arm & valve and monoblock
Examples of OK and NOT-OK parts are as follows:
PART OK PART NOT OK

Figure 65: Bushing bore acceptance/rejection
BY DATE Page 51

7.11.2 Bushing Face

Allowed Defects
(mm) (mm) Quantity
Non-critical area 1,0 2,0 2
Figure 66: Bushing face for 3-piece arm & valve and monoblock
BY DATE Page 52

7.12 Plug
Plug design is used for housings where WG seat cannot be machined directly from turbine
housing outlet.
Allowed Defects
(mm) (mm) Quantity
Sealing area No defect allowed
Bottom and upper step
1,0 2,0 2
+ face
Figure 67: Plug

7.13 Machining Tool Mark
No machining tool mark (tool path mark) is accepted other than those specified by the Garrett
drawing. Using stack-up analysis, the design of the housing should plan for such interference and
design the casting in such a way that machining tool-marks are avoided. See examples in the
figures below.
NOK OK
BY DATE Page 53

Figure 68: Machining tool marks

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NUMBER REVISION

DOCUMENT TITLE PAGE AND REVISION RECORD QCI-9310-024 Z

K. Schloff D. Heinz, Q. C. L. Muller, Prod. Engineering

Tomas Fedra, HCOE W. Wahl, Mftg. Engineering R. M. Mendelson

DISTRIBUTION: per CDI-0004

TITLE QUALITY CONTROL INSTRUCTION

3.0 Definitions, Abbreviations, and Symbols

TITLE QUALITY CONTROL INSTRUCTION

4.0 List of Related Documents

TITLE QUALITY CONTROL INSTRUCTION

5.0 Types of Housings & Housing Terminology

Figure 1: Undivided volute (mono scroll)

Figure 2: Divided volute (twin scroll)

Figure 3: Sector divided

TITLE QUALITY CONTROL INSTRUCTION

Figure 4: Integrated manifold

Figure 5: Water cooled

Figure 6: Dual inlet

TITLE QUALITY CONTROL INSTRUCTION

Figure 9: Free Float

TITLE QUALITY CONTROL INSTRUCTION

5.2 Types of Compressor Housings

Figure 10: Compressor housing without ported shroud

Figure 11: Compressor housing with ported shroud

TITLE QUALITY CONTROL INSTRUCTION

5.3 Turbine Housing Terminology

Figure 12: External view

Figure 13: Cut section

TITLE QUALITY CONTROL INSTRUCTION

5.4 Compressor Housing Terminology

Figure 14: External view

Figure 15: Cut section

TITLE QUALITY CONTROL INSTRUCTION

6.0 Requirements for Castings

TITLE QUALITY CONTROL INSTRUCTION

6.3.4 Visual Inspection

TITLE QUALITY CONTROL INSTRUCTION

6.5 Surface Roughness Requirements

Figure 16: Excess material in tongue area

TITLE QUALITY CONTROL INSTRUCTION

6.7 Divider Tip Acceptance Criteria

Figure 17: Defect criteria on divider tip

6.8 Positive Projections

TITLE QUALITY CONTROL INSTRUCTION

6.8.1 Sand Casting

Figure 18: Sand casting positive defect criteria

TITLE QUALITY CONTROL INSTRUCTION

Flash projection Rigid projection

Figure 19: Flash and rigid projection

Figure 20: Cast bolt seating area

Figure 21: Glue line acceptance/rejection

TITLE QUALITY CONTROL INSTRUCTION

Figure 22: External and internal glue lines – OK parts

Figure 23: External and internal glue lines – NOK parts

TITLE QUALITY CONTROL INSTRUCTION

6.9 Ingates & Feeders

Figure 24: Ingates and feeders

TITLE QUALITY CONTROL INSTRUCTION

6.10 Impact Damage (Gouges, Dents, & Nicks)