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Turbochargers: Function, Design, and Operation

Explore the functions, design elements, and operational aspects of turbochargers, including normal wear and reasons behind turbocharger failure. Learn about the importance of lubrication and how to prevent common issues.

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Turbochargers: Function, Design, and Operation

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  1. CHAPTER: Turbochargers Turbochargers

  2. CHAPTER: Turbochargers

  3. CHAPTER: Turbochargers In This Presentation • Function • Design • Operation • Normal wear • Why Turbos Fail

  4. CHAPTER: Turbochargers Function

  5. CHAPTER: Turbochargers Function

  6. CHAPTER: Turbochargers Turbocharger Functions • Normalize Air Supply • Boost Air Supply

  7. CHAPTER: Turbochargers Normalizing • Compensate for thinner Air • Waste gate valve by-pass turbo boost • Normal Power at high Altitudes • Fuel deration at 2 150 m to avoid over speed • Quieter Exhaust, better combustions and emissions

  8. CHAPTER: Turbochargers Normalizing First commercial use 1940’s in Airplane

  9. CHAPTER: Turbochargers Boosting • More Oxygen / Increased Fuel Setting • Higher Power • Better Combustion • - Better Fuel Economy • - Cleaner Emissions • Quieter

  10. CHAPTER: Turbochargers Boosting

  11. CHAPTER: Turbochargers Design

  12. CHAPTER: Turbochargers Design Waste-Gate Turbo

  13. CHAPTER: Turbochargers Design Lubrication System Lubricating Cooling Cleaning

  14. CHAPTER: Turbochargers Design Lubrication System Direct lubrication line to Turbo

  15. CHAPTER: Turbochargers Design Lubrication System

  16. CHAPTER: Turbochargers Design Lubrication System

  17. CHAPTER: Turbochargers Design Friction Welding Hollow thermal barrier Centering Pin

  18. CHAPTER: Turbochargers Design Induction hardened Shaft

  19. CHAPTER: Turbochargers Design Compressor wheel High Strength Aluminum alloys

  20. CHAPTER: Turbochargers Design Compressor wheel Balancing Notches

  21. CHAPTER: Turbochargers Design Compressor wheel Radial milling

  22. CHAPTER: Turbochargers Design Free-floating journal bearings Copper/tin/lead alloy or from aluminium Lube holes or groove

  23. CHAPTER: Turbochargers Design Snap rings Rounded edge towards the bearing

  24. CHAPTER: Turbochargers Design Thrust Bearing Copper/tin/lead alloy or from aluminium Bearing stationary Washer full shaft RPM

  25. CHAPTER: Turbochargers Design Seal Rings High temperature resistant chrome alloy Cold side cast iron End gap

  26. CHAPTER: Turbochargers Design Housing Cast aluminum alloy Cast Iron Cast ductile iron or nickel alloy

  27. CHAPTER: Turbochargers Design Heat Shield Protects center housing from high exhaust temperatures

  28. CHAPTER: Turbochargers Operation Start-up

  29. CHAPTER: Turbochargers Operation Turbos are matched

  30. CHAPTER: Turbochargers Operation Air Restriction Energy stored in rotating component can equal the engine HP Turbo spin 80 000 Rpm Surface speed 30m/second

  31. CHAPTER: Turbochargers Normal Wear Increased clearance

  32. CHAPTER: Turbochargers Normal Wear Hot side Little leak past the seal ring

  33. CHAPTER: Turbochargers Normal Wear Turbine Wheel No discoloration Seal ring with gap separation

  34. CHAPTER: Turbochargers Normal Wear Bearings More wear on hot side

  35. CHAPTER: Turbochargers Normal Wear Thrust Bearing Fine abrasive wear

  36. CHAPTER: Turbochargers Normal Wear Thrust washers

  37. CHAPTER: Turbochargers Why Turbos Fail • Lack of Lubrication • Abrasive in the Oil • High Exhaust Temperature • Foreign Objects • Turbo Problems

  38. CHAPTER: Turbochargers Lack of Lube Road-signs • Temper Colors/ Cooked Oil • Adhesive Wear • Weakened Metal • Wheel Contact with Housing • Wheel separation from Shaft

  39. CHAPTER: Turbochargers Lack of Lubrication Housing Contact

  40. CHAPTER: Turbochargers Lack of Lubrication Housing Contact Temper colors and cooked oil residue

  41. CHAPTER: Turbochargers Lack of Lubrication High Temperature

  42. CHAPTER: Turbochargers Lack of Lubrication High Temperature

  43. CHAPTER: Turbochargers Lack of Lubrication High Temperature

  44. CHAPTER: Turbochargers Lack of Lubrication High Temperature

  45. CHAPTER: Turbochargers Lack of Lubrication High Temperature Rapid Shutdown

  46. CHAPTER: Turbochargers Lack of Lubrication High Temperature Cooked oil residual

  47. CHAPTER: Turbochargers Lack of Lubrication High Temperature Quench dots/rings

  48. CHAPTER: Turbochargers Lack of Lubrication High Temperature Bushing stuck to shaft

  49. CHAPTER: Turbochargers Lack of Lubrication High Temperature Turbine wheel separation

  50. CHAPTER: Turbochargers Lack of Lubrication High Temperature

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