Which component often experiences thermal stress from high exhaust temperatures?

The turbocharger is a component that is particularly susceptible to thermal stress due to the high temperatures of exhaust gases that it encounters. As a turbocharger is designed to increase the engine's efficiency and power output by forcing more air into the combustion chamber, it is placed in the exhaust stream, where it directly benefits from the energy found in the high-temperature exhaust gases. This exposure to extreme heat can lead to thermal expansion, which might cause cracks or warping if the material quality or design is not adequate to withstand such conditions.

In contrast, the fuel injector primarily deals with fuel inside the engine rather than exhaust gases. The intake manifold is focused on directing air-fuel mixtures into the engine cylinders and typically operates at lower temperatures. Meanwhile, the cooling system works to regulate engine temperatures to prevent overheating, rather than being subjected to high thermal stress itself. Thus, the turbocharger is uniquely positioned within the engine to face the brunt of thermal stress from high exhaust temperatures.