CHAPTER: Turbochargers

1Service Training Malaga

AFA ILion DVD CHAPTER: Turbochargers

Turbochargers

2Service Training Malaga

AFA ILion DVD CHAPTER: Turbochargers

3Service Training Malaga

AFA ILion DVD

In This Presentation

• Function

• Design

• Operation

• Normal wear

• Why Turbos Fail

CHAPTER: Turbochargers

4Service Training Malaga

AFA ILion DVD

Function CHAPTER: Turbochargers

5Service Training Malaga

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Function CHAPTER: Turbochargers

6Service Training Malaga

AFA ILion DVD

Turbocharger Functions

• Normalize Air Supply

• Boost Air Supply

CHAPTER: Turbochargers

7Service Training Malaga

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

CHAPTER: Turbochargers

8Service Training Malaga

AFA ILion DVD

NormalizingFirst commercial use 1940’s in Airplane

CHAPTER: Turbochargers

9Service Training Malaga

AFA ILion DVD

Boosting

• More Oxygen / Increased Fuel Setting

• Higher Power

• Better Combustion

- Better Fuel Economy

- Cleaner Emissions

•Quieter

CHAPTER: Turbochargers

10Service Training Malaga

AFA ILion DVD

BoostingCHAPTER: Turbochargers

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DesignCHAPTER: Turbochargers

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Design Waste-Gate Turbo

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Design Lubrication System

Lubricating Cooling Cleaning

CHAPTER: Turbochargers

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Design Lubrication System

Direct lubrication line to Turbo

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Design Lubrication System

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Design Lubrication System

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Design Friction Welding

Hollow thermal barrierCentering Pin

CHAPTER: Turbochargers

18Service Training Malaga

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Design Induction hardened Shaft

CHAPTER: Turbochargers

19Service Training Malaga

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Design Compressor wheel

High Strength Aluminum alloys

CHAPTER: Turbochargers

20Service Training Malaga

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Design Compressor wheel

Balancing Notches

CHAPTER: Turbochargers

21Service Training Malaga

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Design Compressor wheel

Radial milling

CHAPTER: Turbochargers

22Service Training Malaga

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Design Free-floating journal bearings

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

CHAPTER: Turbochargers

23Service Training Malaga

AFA ILion DVD

Design Snap rings

Rounded edge towards the bearing

CHAPTER: Turbochargers

24Service Training Malaga

AFA ILion DVD

Copper/tin/lead alloy or from aluminium

Design Thrust Bearing

Bearing stationaryWasher full shaft RPM

CHAPTER: Turbochargers

25Service Training Malaga

AFA ILion DVD

Design Seal Rings

High temperature resistant chrome alloyCold side cast iron

End gap

CHAPTER: Turbochargers

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Design Housing

Cast aluminum alloyCast IronCast ductile iron or nickel alloy

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Design Heat Shield

Protects center housing from high exhaust temperatures

CHAPTER: Turbochargers

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Operation Start-up

CHAPTER: Turbochargers

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Operation Turbos are matched

CHAPTER: Turbochargers

30Service Training Malaga

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Operation Air Restriction

Turbo spin 80 000 RpmSurface speed 30m/second

Energy stored in rotating component can equal the engine HP

CHAPTER: Turbochargers

31Service Training Malaga

AFA ILion DVD

Normal WearIncreased clearance

CHAPTER: Turbochargers

32Service Training Malaga

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Normal Wear Hot side

Little leak past the seal ring

CHAPTER: Turbochargers

33Service Training Malaga

AFA ILion DVD

Normal Wear Turbine Wheel

No discoloration Seal ring with gap separation

CHAPTER: Turbochargers

34Service Training Malaga

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Normal Wear Bearings

More wear on hot side

CHAPTER: Turbochargers

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AFA ILion DVD

Normal Wear Thrust Bearing

Fine abrasive wear

CHAPTER: Turbochargers

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Normal Wear Thrust washers

CHAPTER: Turbochargers

37Service Training Malaga

AFA ILion DVD

• Lack of Lubrication

• Abrasive in the Oil

• High Exhaust Temperature

• Foreign Objects

• Turbo Problems

Why Turbos FailCHAPTER: Turbochargers

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AFA ILion DVD

• Temper Colors/ Cooked Oil

• Adhesive Wear

• Weakened Metal

• Wheel Contact with Housing

• Wheel separation from Shaft

Lack of Lube Road-signs

CHAPTER: Turbochargers

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Lack of Lubrication Housing Contact CHAPTER: Turbochargers

40Service Training Malaga

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Temper colors and cooked oil residue

Lack of Lubrication Housing Contact CHAPTER: Turbochargers

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Lack of Lubrication High Temperature CHAPTER: Turbochargers

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Lack of Lubrication High Temperature CHAPTER: Turbochargers

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Lack of Lubrication High Temperature CHAPTER: Turbochargers

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Lack of Lubrication High Temperature CHAPTER: Turbochargers

45Service Training Malaga

AFA ILion DVD

Rapid Shutdown

Lack of Lubrication High Temperature CHAPTER: Turbochargers

46Service Training Malaga

AFA ILion DVD

Cooked oil residual

Lack of Lubrication High Temperature CHAPTER: Turbochargers

47Service Training Malaga

AFA ILion DVD

Quench dots/rings

Lack of Lubrication High Temperature CHAPTER: Turbochargers

48Service Training Malaga

AFA ILion DVD

Bushing stuck to shaft

Lack of Lubrication High Temperature CHAPTER: Turbochargers

49Service Training Malaga

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Turbine wheel separation

Lack of Lubrication High Temperature CHAPTER: Turbochargers

50Service Training Malaga

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Lack of Lubrication High Temperature CHAPTER: Turbochargers

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Lack of Lubrication High Temperature Adhesive wear and Thermal cracking

CHAPTER: Turbochargers

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Lack of Lubrication High Temperature Discoloration

CHAPTER: Turbochargers

53Service Training Malaga

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Lack of Lubrication High Temperature Ductile FractureDiscoloration

CHAPTER: Turbochargers

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AFA ILion DVD

Lack of Lubrication

WHY

CHAPTER: Turbochargers

55Service Training Malaga

AFA ILion DVD

Abrasive in the Oil Road-signs

• Scratches, Cuts, Grooves

• Little Heat Damage

• Rapid Wear

• Embedded Debris

CHAPTER: Turbochargers

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AFA ILion DVD

Abrasive in the Oil Extended Oilchange Intervals

Excessive shaft motion

CHAPTER: Turbochargers

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Abrasive in the OilCHAPTER: Turbochargers

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Abrasive in the Oil Exhaust carbon cause fine abrasive cutting

Missing Hot side Seal

CHAPTER: Turbochargers

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Abrasive in the Oil CHAPTER: Turbochargers

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Abrasive in the Oil CHAPTER: Turbochargers

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Abrasive in the Oil CHAPTER: Turbochargers

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AFA ILion DVD

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

CHAPTER: Turbochargers

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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  

CHAPTER: Turbochargers

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AFA ILion DVD

High Exhaust Temp. Road-signs

• Much Heat Damage

- Cooked Oil

- Oxidation

- Temper Colors

• Much Bearing Wear

CHAPTER: Turbochargers

65Service Training Malaga

AFA ILion DVD

High Exhaust Temp. Open Turbo and look inside

CHAPTER: Turbochargers

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High Exhaust Temp. CHAPTER: Turbochargers

67Service Training Malaga

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Foreign Object Road-signs

• Wheel Blade Damage

• Bent Center Shaft

• Normal Bearing Wear

• Wheel Separation

CHAPTER: Turbochargers

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AFA ILion DVD

Foreign Object Wheel Blade Damage

CHAPTER: Turbochargers

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AFA ILion DVD

Foreign Object Wheel Blade Damage

Uniform Bending

CHAPTER: Turbochargers

70Service Training Malaga

AFA ILion DVD

Foreign Object Wheel Blade Damage

“Fresh Damage”

CHAPTER: Turbochargers

71Service Training Malaga

AFA ILion DVD

Foreign Object Wheel Blade Damage

Old Damage

CHAPTER: Turbochargers

72Service Training Malaga

AFA ILion DVD

Turbocharger Problems

• Design/Materials

• Manufacturing

CHAPTER: Turbochargers

73Service Training Malaga

AFA ILion DVD

Design/Materials

• Wheel Burst

• Blade Fatigue

•Casting Inclusion

•Weak Wheel

CHAPTER: Turbochargers

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AFA ILion DVD

Wheel BurstCHAPTER: Turbochargers

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Wheel BurstCHAPTER: Turbochargers

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Wheel BurstCHAPTER: Turbochargers

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Wheel BurstCHAPTER: Turbochargers

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Blade FatigueCHAPTER: Turbochargers

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Blade FatigueCHAPTER: Turbochargers

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Casting InclusionCHAPTER: Turbochargers

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Casting InclusionCHAPTER: Turbochargers

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Casting InclusionCHAPTER: Turbochargers

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Casting InclusionCHAPTER: Turbochargers

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AFA ILion DVD

Manufacturing

• Weak Inertial/Friction Weld

• Bent Shafts

• Rough Bores

• Misdrilled Oil Holes

• Balancing Errors

CHAPTER: Turbochargers

86Service Training Malaga

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Weak Inertial/Friction WeldCHAPTER: Turbochargers

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Weak Inertial/Friction WeldCHAPTER: Turbochargers

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Weak Inertial/Friction WeldCHAPTER: Turbochargers

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Bent ShaftUse T bar when tightening Compressor nut

CHAPTER: Turbochargers

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Bent ShaftCHAPTER: Turbochargers

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Misdrilled Oil HolesCHAPTER: Turbochargers

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Misdrilled Oil HolesCHAPTER: Turbochargers

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Missed Oil HolesCHAPTER: Turbochargers