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sel engine. And in the case of gasoline engine it
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the turbine housing, turbine wheel and waste gate valve are usually casting parts made
of heat-resistant cast iron, cast steel and nickel alloy. Among them, the turbine wheel is
generally made by precision casting to meet the high form accuracy, strength and quality
as one of the important parts which dominate the aerodynamic performance of
turbocharger.
Recently, the turbocharger with the flow rate characteristics optimization by variable
nozzle, which is called a variable geometry (VG) turbocharger, has become widely used for
diesel engines.
The VG turbocharger allows an efficient supercharging from a low-speed to a high-speed
of engine, and provides effects of not only the improvement of torque and power but also
the significant reduction of particulate matter (PM) and nitrogen oxide (NOx) by
increasing the exhaust gas recirculation (EGR) rate.
Fig.3 shows the VG turbocharger working principle, and Fig.4 shows a VG turbocharger
construction using a nozzle link mechanism. The nozzle link mechanism, which is a
typical variable mechanism of VG turbocharger, must be operated without lubrication in
a high-temperature exhaust gas environment. For this reason, high accuracy is required
in each part, and the nozzle vane, which effects the aerodynamic performance, is usually
made by precision casting.
Bearing Housing
Lever Plate
Drive Ring
Mount
Support
Ring
Actuator
Crank
Lever
Turbine Housing
Fig.4
VG turbocharger structure
Natural aspirated
EV/HV
Europe
turbo ratio
25
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Diesel
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2010
2011
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2012
2013
2014
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2015
Gasoline
turbo
2016
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Greater China
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2010
2011
2012
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2014
2015
2016
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2010
2011
2012
2013
2014
2015
2016
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North America
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maximum in the case of diesel engine. And in the case of gasoline engine it sometimes
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-speed turbine wheels is 250,000
rpm or higher in such a high-temperature condition. The required boost pressure is in an
uprising trend in accordance with the rising torque and output power. The turbocharger
rotational speed is rising accordingly, and the centrifugal force generated in the turbine
wheel is also increasing. In the case of gasoline engine, the exhaust gas temperature
tends to rise for the fuel consumption reduction in high-speed and high-load operation.
From these points, the operational environment of turbine wheel has been becoming
increasingly severe.
3.2. Point of strength design
The items below must be considered for the strength design of turbine wheel. This
chapter describes the theory of strength design.
(1) Fatigue strength
(2) Creep strength
(3) Resonance
3.2.1 Fatigue strength
The turbocharger rotational speed changes according to the engine speed and load. The
rotational speed of turbocharger in a vehicle changes time to time from starting and
various running conditions in urban area, high-way, hill-climbing and others. The
centrifugal force generated in the turbine wheel changes when the rotational speed
changes. Fig.6 shows an example of turbocharger rotational speed change in urban area
running. The turbocharger rotational speed and centrifugal force deviations are
calculated from the number of load fluctuation cycles. And the fatigue life of turbine
wheel can be attained by the material fatigue strength diagram. The material fatigue
strength diagram of 713C alloy as a representative example of turbine wheel material is
shown in Fig.7. (Aerospace Structural Metals Handbook) In the strength design, the
average level of centrifugal stress which satisfies the required value of fatigue life is
defined as the strength criteria. The shape parameters such as the blade thickness are
decided within the range not to exceed the criteria stress. Fig.8 shows a calculation result
example of stress distribution.
100000
80000
60000
40000
20000
0
0
500
1000
1500
2000
2500
Time [sec]
Fig.6
High
Low
3.2.3. Resonance
The turbine wheel is at the down stream of the turbine scroll, and the turbine blade is
subjected to a pressure fluctuation as the pressure is not uniformly distributed at the
outlet port of the turbine scroll. The pressure fluctuation is especially significant at the
tongue portion of scroll, and the scroll must be designed to provide a pressure distribution
as smooth as possible in the circumferential direction at the outlet port. Fig. 10 shows the
outline of the turbine scroll, and the pressure distribution measured at the scroll outlet
port. When turbine blades pass through the pressure distribution, the turbine is
subjected to multiple number of repeating forces (excitation force) at every rotation.
When the force cycle coincides with the blade natural frequency, the blade resonates and
breaks in a short period. When the blade resonates with N-time excitation force in one
rotation, it is called an Nth harmonics resonance. Fig.11 shows the measured results of
resonance stress on the Campbell diagram.
=
1), the excessive fuel supply to lower the combustion temperature has been a common
practice to protect engine parts in a raised combustion temperature at full-load and
high-speed operational ranges. In recent years, however, the excessive fuel supply is not
allowed to attain a better fuel consumption ratio, and the exhaust temperature tends to
be raised. For this reason, a material with higher creep strength is required. Generally
speaking, the 713C alloy is usually used as a turbine wheel material, the MarM alloy
having better high-temperature strength has become frequently used to cope with the
raised exhaust temperature. Fig.12 shows the comparison of 713C and MarM alloy creep
strength.
Although the MarM alloy has higher creep strength than 713C alloy, its lower castability
(fluidity) tends to cause the micro shrinkage. Fig.13 shows the micro shrinkage of MarM
alloy. The Hot Isostatic Pressing (HIP) treatment is sometimes applied to the MarM alloy
to remove casting defects.
Creep strain
= (creep elongation) / (initial exit blade height)
Cut Section
4.2. Defects
Although the product without any defect is ideal, the defect exists even in the precision
molding. Minute defects can be ignored, but a relatively large defect or aggregated defects
are not allowed. The consideration is made to avoid an excessive quality by specifying
standards according to the positions of turbine wheel. And casting appearance limit
samples for relatively easy judgments are made for the control.
4.3. Structure
The microscopic structure changes according to the casting condition, and the
optimization of structure is required for the turbocharger characteristic. The fatigue
strength and creep strength are conflicting characteristics, and a tuning is sometimes
required for some applications. The grain size miniaturization is effective for an
application that requires a long fatigue life. Contrarily, the grain size adjustment is
sometimes required to maintain the creep strength for gasoline engines in which the
exhaust gas temperature is rising.
4.4. Balance
The balance of machining stock of turbine wheel used in a turbocharger is required for a
high-speed rotation. The turbocharger unbalancing noise for a high-power vehicle was
allowed as a proof of high-performance in 1980s. However the noise indicating the
presence of turbocharger is no more allowed these days. The reduction of imbalance in the
machining stock contributes to a better yield and noise reduction. The counter measures
for deviation of each blade, hub bulge, mould mismatch and others are required according
to the necessity. The machining stock imbalance can be measured these days, and the
further quality improvement is expected.
5. Failure examples
5.1. Cause of breakage
Refer to the FTA diagram in Fig.16 for the cause of turbocharger breakage.
T/W breakage
foreign objectdamage
excess centrifugal stress
over revolution
high centrifugal stress design
creep
1st natural frequency
2nd natural frequency
high pressure fluctuation
resonance
material problem
casting defect
macro structure problem
stress concentration
Fig.16 Turbine Scroll Static Pressure Distribution
Fig.23
Resonance
Fig.24
Resonance
Fig.22
Fig.25
Interfere
with
W/G Valve
Other Parts
7. Conclusion
The precision casting, which can mass-produce a high-quality product of sophisticated
form at a moderate price, is an essential technology for the turbocharger which is
subjected to demanding quality, accuracy and cost. As well as for diesel engines, the
turbocharger is becoming an indispensable device for gasoline engines in the trend of less
fuel consumption of passenger cars. The quality of investment casting parts are
considered to be relatively in a high level compared to other casting methods. However,
many problems are still remaining. The turbocharger is in an increasing demand.
Accordingly the requirements of supply and quality stabilization of precision casting
parts such as the turbine wheel are thought to increase. We would like to proceed with
the development and supply of products, which can fulfill the demand of performance,
quality and cost from automobile companies in cooperative engineering works with
casting part manufactures.
Reference
(1) S.Ibaraki, D.Watanabe, T.Yokoyama, T.Arai, M.Ebisu, M.Tojo : 13th Supercharging
Conference 2008, Dresden, 7 (2008)