1 service training malaga afa i lion dvd chapter: turbochargers turbochargers

1Service Training Malaga

AFA ILion DVD CHAPTER: Turbochargers

Turbochargers


AFA ILion DVD

In This Presentation

• Function

• Design

• Operation

• Normal wear

• Why Turbos Fail

CHAPTER: Turbochargers


AFA ILion DVD

Function CHAPTER: Turbochargers


AFA ILion DVD

Turbocharger Functions

• Normalize Air Supply

• Boost Air Supply



AFA ILion DVD

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



AFA ILion DVD

NormalizingFirst commercial use 1940’s in Airplane



AFA ILion DVD

Boosting

• More Oxygen / Increased Fuel Setting

• Higher Power

• Better Combustion

- Better Fuel Economy

- Cleaner Emissions

•Quieter



AFA ILion DVD

BoostingCHAPTER: Turbochargers


AFA ILion DVD

DesignCHAPTER: Turbochargers


AFA ILion DVD

Design Waste-Gate Turbo



AFA ILion DVD

Design Lubrication System

Lubricating Cooling Cleaning



AFA ILion DVD


Direct lubrication line to Turbo



AFA ILion DVD




AFA ILion DVD

Design Friction Welding

Hollow thermal barrierCentering Pin



AFA ILion DVD

Design Induction hardened Shaft



AFA ILion DVD

Design Compressor wheel

High Strength Aluminum alloys



AFA ILion DVD


Balancing Notches



AFA ILion DVD


Radial milling



AFA ILion DVD

Design Free-floating journal bearings

Copper/tin/lead alloy or from aluminium Lube holes or groove



AFA ILion DVD

Design Snap rings

Rounded edge towards the bearing



AFA ILion DVD

Copper/tin/lead alloy or from aluminium

Design Thrust Bearing

Bearing stationaryWasher full shaft RPM



AFA ILion DVD

Design Seal Rings

High temperature resistant chrome alloyCold side cast iron

End gap



AFA ILion DVD

Design Housing

Cast aluminum alloyCast IronCast ductile iron or nickel alloy



AFA ILion DVD

Design Heat Shield

Protects center housing from high exhaust temperatures



AFA ILion DVD

Operation Start-up



AFA ILion DVD

Operation Turbos are matched



AFA ILion DVD

Operation Air Restriction

Turbo spin 80 000 RpmSurface speed 30m/second

Energy stored in rotating component can equal the engine HP



AFA ILion DVD

Normal WearIncreased clearance



AFA ILion DVD

Normal Wear Hot side

Little leak past the seal ring



AFA ILion DVD

Normal Wear Turbine Wheel

No discoloration Seal ring with gap separation



AFA ILion DVD

Normal Wear Bearings

More wear on hot side



AFA ILion DVD

Normal Wear Thrust Bearing

Fine abrasive wear



AFA ILion DVD

Normal Wear Thrust washers



AFA ILion DVD

• Lack of Lubrication

• Abrasive in the Oil

• High Exhaust Temperature

• Foreign Objects

• Turbo Problems

Why Turbos FailCHAPTER: Turbochargers


AFA ILion DVD

• Temper Colors/ Cooked Oil

• Adhesive Wear

• Weakened Metal

• Wheel Contact with Housing

• Wheel separation from Shaft

Lack of Lube Road-signs



AFA ILion DVD

Lack of Lubrication Housing Contact CHAPTER: Turbochargers


AFA ILion DVD

Temper colors and cooked oil residue

Lack of Lubrication Housing Contact CHAPTER: Turbochargers


AFA ILion DVD

Lack of Lubrication High Temperature CHAPTER: Turbochargers


AFA ILion DVD



AFA ILion DVD

Rapid Shutdown



AFA ILion DVD

Cooked oil residual



AFA ILion DVD

Quench dots/rings



AFA ILion DVD

Bushing stuck to shaft



AFA ILion DVD

Turbine wheel separation



AFA ILion DVD



AFA ILion DVD

Lack of Lubrication High Temperature Adhesive wear and Thermal cracking



AFA ILion DVD

Lack of Lubrication High Temperature Discoloration



AFA ILion DVD

Lack of Lubrication High Temperature Ductile FractureDiscoloration



AFA ILion DVD

Lack of Lubrication

WHY



AFA ILion DVD

Abrasive in the Oil Road-signs

• Scratches, Cuts, Grooves

• Little Heat Damage

• Rapid Wear

• Embedded Debris



AFA ILion DVD

Abrasive in the Oil Extended Oilchange Intervals

Excessive shaft motion



AFA ILion DVD

Abrasive in the OilCHAPTER: Turbochargers


AFA ILion DVD

Abrasive in the Oil Exhaust carbon cause fine abrasive cutting

Missing Hot side Seal



AFA ILion DVD

Abrasive in the Oil CHAPTER: Turbochargers


AFA ILion DVD



AFA ILion DVD

Abrasive in the Oil New turbo failed after 3 weeks of service



AFA ILion DVD

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



AFA ILion DVD

High Exhaust Temp. Road-signs

• Much Heat Damage

- Cooked Oil

- Oxidation

- Temper Colors

• Much Bearing Wear



AFA ILion DVD

High Exhaust Temp. Open Turbo and look inside



AFA ILion DVD

High Exhaust Temp. CHAPTER: Turbochargers


AFA ILion DVD

Foreign Object Road-signs

• Wheel Blade Damage

• Bent Center Shaft

• Normal Bearing Wear

• Wheel Separation



AFA ILion DVD

Foreign Object Wheel Blade Damage



AFA ILion DVD


Uniform Bending



AFA ILion DVD


“Fresh Damage”



AFA ILion DVD


Old Damage



AFA ILion DVD

Turbocharger Problems

• Design/Materials

• Manufacturing



AFA ILion DVD

Design/Materials

• Wheel Burst

• Blade Fatigue

•Casting Inclusion

•Weak Wheel



AFA ILion DVD

Wheel BurstCHAPTER: Turbochargers


AFA ILion DVD



AFA ILion DVD

Blade FatigueCHAPTER: Turbochargers


AFA ILion DVD

Casting InclusionCHAPTER: Turbochargers


AFA ILion DVD



AFA ILion DVD

Manufacturing

• Weak Inertial/Friction Weld

• Bent Shafts

• Rough Bores

• Misdrilled Oil Holes

• Balancing Errors



AFA ILion DVD

Weak Inertial/Friction WeldCHAPTER: Turbochargers


AFA ILion DVD



AFA ILion DVD

Bent ShaftUse T bar when tightening Compressor nut



AFA ILion DVD

Bent ShaftCHAPTER: Turbochargers


AFA ILion DVD

Misdrilled Oil HolesCHAPTER: Turbochargers


AFA ILion DVD

Missed Oil HolesCHAPTER: Turbochargers

1 service training malaga afa i lion dvd chapter: turbochargers turbochargers

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