Turbocharger

Lion DVD AFA I CHAPTER: Turbochargers
Turbochargers
Service Training Malaga 1


In This Presentation
• Function
• Design
• Operation
• Normal wear
• Why Turbos Fail

Function

Function

Turbocharger Functions
• Normalize Air Supply
• Boost Air Supply

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

Normalizing
First commercial use 1940’s in Airplane

Boosting
• More Oxygen / Increased Fuel Setting
• Higher Power
• Better Combustion
- Better Fuel Economy
- Cleaner Emissions
•Quieter

Boosting

Design

Design Waste-Gate Turbo

Design Lubrication System
Lubricating
Cooling
Cleaning

Direct lubrication line to Turbo



Design Friction Welding
Hollow thermal barrier

Centering Pin

Design Induction hardened Shaft

Design Compressor wheel
High Strength Aluminum alloys

Balancing Notches

Radial milling

Design Free-floating journal bearings
Copper/tin/lead alloy or from aluminium

Lube holes or groove

Design Snap rings
Rounded edge towards the bearing

Design Thrust Bearing
Copper/tin/lead alloy or from aluminium
Bearing stationary
Washer full shaft RPM
Design Seal Rings
High temperature resistant chrome alloy

Cold side cast iron
End gap
Design Housing
Cast aluminum alloy

Cast Iron
Cast ductile iron or nickel alloy

Design Heat Shield
Protects center housing from high

exhaust temperatures

Operation Start-up

Operation Turbos are matched

Operation Air Restriction
Energy stored in rotating

component can equal the
engine HP
Turbo spin 80 000 Rpm

Surface speed 30m/second

Normal Wear
Increased clearance

Normal Wear Hot side
Little leak past the seal ring

Normal Wear Turbine Wheel
No discoloration
Seal ring with gap separation

Normal Wear Bearings
More wear on hot side

Normal Wear Thrust Bearing
Fine abrasive wear

Normal Wear Thrust washers

Why Turbos Fail

• Lack of Lubrication
• Abrasive in the Oil
• High Exhaust Temperature
• Foreign Objects
• Turbo Problems

Lack of Lube Road-signs
• Temper Colors/ Cooked Oil

• Adhesive Wear
• Weakened Metal
• Wheel Contact with Housing
• Wheel separation from Shaft

Lack of Lubrication Housing Contact

Lack of Lubrication Housing Contact
Temper colors and cooked oil residue

Lack of Lubrication High Temperature




Rapid Shutdown

Cooked oil residual

Quench dots/rings

Bushing stuck to shaft

Turbine wheel separation


Adhesive wear and

Thermal cracking

Discoloration

Ductile Fracture
Discoloration

Lack of Lubrication
WHY
Abrasive in the Oil Road-signs
• Scratches, Cuts, Grooves

• Little Heat Damage
• Rapid Wear
• Embedded Debris

Abrasive in the Oil Extended Oilchange Intervals
Excessive shaft motion

Abrasive in the Oil

Abrasive in the Oil Missing Hot side Seal
Exhaust carbon cause fine abrasive cutting

Abrasive in the Oil

Abrasive in the Oil

Abrasive in the Oil

Abrasive in the Oil

New turbo failed after 3 weeks of service

Abrasive in the Oil

1. Debris size = pin head
2. Debris shape = spherical
3. Debris uniformity = same size
4. Debris color = black, blue, grey, silver.
5. Magnetic = yes

High Exhaust Temp. Road-signs
• Much Heat Damage

- Cooked Oil
- Oxidation
- Temper Colors
• Much Bearing Wear

High Exhaust Temp.

Open Turbo and look inside

High Exhaust Temp.

Foreign Object Road-signs
• Wheel Blade Damage

• Bent Center Shaft
• Normal Bearing Wear
• Wheel Separation

Foreign Object Wheel Blade Damage

Uniform Bending

“Fresh Damage”

Old Damage

Turbocharger Problems
• Design/Materials
• Manufacturing

Design/Materials
• Wheel Burst
• Blade Fatigue
•Casting Inclusion
•Weak Wheel

Wheel Burst

Wheel Burst

Wheel Burst

Wheel Burst

Blade Fatigue

Blade Fatigue


Casting Inclusion

Casting Inclusion

Casting Inclusion

Casting Inclusion

Manufacturing
• Weak Inertial/Friction Weld
• Bent Shafts
• Rough Bores
• Misdrilled Oil Holes
• Balancing Errors

Weak Inertial/Friction Weld



Bent Shaft
Use T bar when tightening Compressor nut

Bent Shaft

Misdrilled Oil Holes

Misdrilled Oil Holes

Missed Oil Holes

Turbocharger

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Lion DVD AFA I CHAPTER: Turbochargers

Service Training Malaga 1

Service Training Malaga 2

Service Training Malaga 3

Service Training Malaga 4

Service Training Malaga 5

Service Training Malaga 6

Service Training Malaga 7

Service Training Malaga 8

Service Training Malaga 9

Service Training Malaga 10

Service Training Malaga 11

Design Waste-Gate Turbo

Service Training Malaga 12

Design Lubrication System

Service Training Malaga 13

Design Lubrication System

Direct lubrication line to Turbo

Service Training Malaga 14

Design Lubrication System

Service Training Malaga 15

Design Lubrication System

Service Training Malaga 16

Design Friction Welding

Hollow thermal barrier

Service Training Malaga 17

Design Induction hardened Shaft

Service Training Malaga 18

Design Compressor wheel

High Strength Aluminum alloys

Service Training Malaga 19

Design Compressor wheel

Service Training Malaga 20

Design Compressor wheel

Service Training Malaga 21

Design Free-floating journal bearings

Copper/tin/lead alloy or from aluminium

Service Training Malaga 22

Design Snap rings

Rounded edge towards the bearing

Service Training Malaga 23

Design Thrust Bearing

Copper/tin/lead alloy or from aluminium

Design Seal Rings

High temperature resistant chrome alloy

Cast aluminum alloy

Service Training Malaga 26

Design Heat Shield

Protects center housing from high

Service Training Malaga 27

Service Training Malaga 28

Operation Turbos are matched

Service Training Malaga 29

Operation Air Restriction

Energy stored in rotating

Turbo spin 80 000 Rpm

Service Training Malaga 30

Service Training Malaga 31

Normal Wear Hot side

Little leak past the seal ring

Service Training Malaga 32

Normal Wear Turbine Wheel

Service Training Malaga 33