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Turbochargers are widely used to boost internal combustion engines for both on and off high way applications to meet emission and performance requirements. Due to the high operating temperature, turbochargers are subjected to hostile environment. Low vibration level is one of the key requirements while designing turbo for every application. An engine bracket is employed to support turbine housing to reduce total vibration level. Turbine housing in the turbocharger is commonly equipped with boss to accommodate the engine bracket supporting which eventually includes additional constraints in the turbocharger system. Additional constraints in the turbine housing can lead to adverse impact in the Thermo-Mechanical Fatigue (TMF) life of the housing component. Boss generally has critical influence to thermal stress distribution of the turbine housing.

Turbocharger is widely used to boost engine due to emissions, fuel and cost reasons. As one of the hot components, it is subjected to severe temperature and thermal load history. Under these conditions, the material suffers hostile thermal mechanical fatigue (TMF) damage especially for the turbine housing side which absorbs hot exhaust gas directly to drive the turbine wheel. The cracking of turbine housing occurs frequently in the inlet flange location due to its very complex geometry and consequently complicated temperature and stress distribution, seriously affecting the normal operation of the engine. In the electric power industry, one of the most challenging tasks is to ensure the guaranteed lifetime. This paper proposes a novel turbine housing inlet flange design to control this type of failure effectively and improve the component lifetime and reliability. The novel design extends the inlet flange and includes the heat dissipation function as well.