Traditionally, compressor wheels are produced from aluminium because of its low density weighing only one third of the weight of steel. It is also a relatively simple and inexpensive process to cast compressor wheels, but a major disadvantage is that cast aluminium is inherently not as strong as other manufacturing techniques. To create a stronger wheel post-production processes are required, which include heat and solution treatments.

A high proportion of new turbochargers are spinning faster than ever before, with higher pressures, and as a result are subjected too much higher stresses which are beyond the limits of cast aluminium. Consequently, alternative materials and manufacturing processes are used.

If the compressor wheel material is not as strong as it should be it will eventually show signs of fatigue, because the blades are exposed to a continuous cycle of positive and negative stress caused by the wheel spinning fast and then slow.

Variations in Design
In response to the ever changing operating conditions there have been significant developments in compressor wheel design over the years.

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