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    E

    h

    ngineeringSociety

    or dvancing Mobility

    andSea ir and Space 400 COMMONWEALTH DRIVE WARRENDALE PA 15096

    ap

    e h n i ~

    m

    r rl S

    88 56

    Improvement of Turbocharger l i fe for

    Diesel and Gasoline Engines

    Takaaki Koike Takashi Kobayashi

    and

    Kideaki Matsuoka

    Ishikawajima Harima

    Heavy Industries Co.

    l td

    Fusayoshi Nakamura

    Warner Ish Corp.

    International Congress and

    Exposition

    Detroit Michigan

    February 29March

    988

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    opyrightClearance Center. lnc., Operat ions Center, P.O. Box 765. Schenectady,

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    S

    Npetr

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    mde ed

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    O Ob, I.lO ,, ,J) O r . l l l . l ~

    SAE GLOBAL MOBILITY DATABASE

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    ISSN0148 7191

    Copyright

    1988 Society of Automotive Engineers,lnc.

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    880563

    Improvement of Turbocharger l ife

    fo

    Diesel and Gasoline Engines

    Takaaki Koike Takashi Kobayashi and Kideaki Matsuok

    lshikawajima Harima

    Heavy Industries Co Lt

    Fusayoshi Nakamur

    Warner lshi Cor

    ABSTRACT

    Turbochargers

    fo r vehicle use have b een

    uti l ized for

    passenger

    cars and trucks to

    a ch ie ve h ig h pOtver, high

    torque to fuel

    consumption

    and

    as a

    countermeasure

    for lotv

    emission

    of

    CO,

    He,

    NO

    etc

    x

    Turbochargers ar e e xp ec te d to

    pl y

    major role in future to improve t he per fo rm -

    ance of automobiles.

    Horeover l i f e o f t ur bo ch ar ge rs ha s been

    increased

    steadily

    in

    spite

    of

    severe

    heat

    and

    stress condition

    due t o r equi rement from

    engine manufactures.

    In case of truck use turbochargers great

    ef for ts ha ve be en made to

    increase

    turbocharger

    l i fe

    from 500 000 kms to 1 000 000

    kms

    though

    the

    stress of

    the

    wheels ha s been raised due to

    increased

    boost pressure.

    Also

    l i fe of

    pas-

    senger car us e

    turbocharger ha s been increased

    in

    spite

    of higher exhaust

    ga s temperature.

    This

    paper

    describes ou r e xp er ie nc e o f

    durabil i ty problems and ou r solut ion.

    SPECIFICATION AND

    DESIGN

    CONSTRUCTION OF

    IHI TURBOCHARGERS

    Fig. 1 shows general view of the

    typical

    model ou r turbochargers used

    for passenger

    car .

    This

    is IHl RHB52 model turbocharger applied to

    passenger

    cars

    of 1.5

    L -

    2.0

    L

    class

    which

    is

    most

    popula r passenger

    cars

    in Ja pan . The

    turbine wheel

    diameter of

    this

    model is approx.

    50

    mm.

    Table 1 shows other models of IHI turbo-

    chargers.

    Fig. 2 is the

    sect ional view

    of

    RHB52

    turbocharger.

    This

    is th e typical basic construction of

    th e vehicle use

    turbocharger.

    The turbocharger

    is normally installed on an engine by a

    gas

    inle

    flange of a turbine

    housing.

    Oi l cooling

    chamber or

    water

    cooling chambe

    is designed in the bearing

    housing

    in case

    of

    high

    exhaust gas

    t emperature usage.

    Table 1

    Specification of lH I

    Turbocharger

    Application

    Turbocharger

    Turbine

    wheel

    Compressor

    Hax. allowable Hax.

    allowable

    Hodel

    dia. mm

    impeller

    dia.

    speed

    rpm

    gas

    temp.

    OC

    mm

    Nicro

    passenger car

    RHB3

    35.5 35.5

    250 000

    950

    RHB4 46.0

    46.0

    200 000

    950

    Passenger

    car

    RHB5

    52.5 52.5

    180 000 950

    RHC6

    62.0 65.0

    140 000 750

    or

    950

    Truck

    RHC7

    74.0 76.0

    132 000

    750

    RHC9

    90.0

    90.0

    9

    ODD 750

    0148 7191/88/0229 0563 02.50

    Copyright1988 Society

    of

    Automotive Engineers lnc

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    2 880

    Fig. 1

    General

    view

    of RHBS

    The follmving problems

    are

    major ones

    ol

    have experienced to correspond to th e

    require

    ment fo r high performance and long

    l i fe

    Problems re la t ing to passenger

    car

    use

    turbochargers;

    a

    Capability dotm

    of

    journal bearing y

    coking

    problem

    b Capability dO\VTI of seal at th e

    turbine

    side

    c

    Stabi l i ty

    dotvn of th e

    bearing

    system by

    severe

    running

    condition and also poor

    lubricat ing condition

    Problems relating to truck

    use

    turbo

    chargers;

    OIL COOLING

    W TER OOLING

    a

    Creep s trength

    and

    low cycle

    fatigue

    strength by increased stress of a

    compressor impeller

    b

    Oxidation and

    crack

    of a turbine housin

    by h ig h ex ha us t

    ga s

    temperature and

    increased

    heat

    load

    f luctuat ion,

    especial ly

    center wall

    of

    t he twin- fl ow

    scrol l

    IHPROVEHENT

    OF THE TURBOCH RGERS

    The

    major problems

    mentioned

    above

    have

    been resolved

    and

    turbochargers improvement is

    explained

    belOtv

    Fig. 2 Cross section of RHB

    Fig. 3 shows typical problems

    of

    vehicle

    use turbochargers.

    ~ n

    users claim

    Large all consumption

    White smoke

    Abnormal noise

    Poor acceleration

    Power down

    Rough running

    After burning

    I

    r

    in turboch rger trouble

    Oil leakage (Turbine

    Camp.)

    Bearing damage

    Housing rub

    Blade damage

    Carbon bridge

    Air or exhaust gas leakage

    Bol t loose or drop

    Housing cr ck

    Failure of waslegale

    IHPROVE}ffiNT

    OF JOURN L BE RING N BE RING

    SYSTEH

    Ful l - f loa t ing

    journal bearings

    are

    used in most of modern turbochargers due to

    bet ter

    dumping

    charac ter is t ics

    against

    se l f -

    exci ti ng v ibra t ion and cr i t ica l speed as

    well

    as bet ter stabi l i ty a t

    high

    speed

    range.

    Stabi l i ty

    of

    th e bearing

    sys tem has

    becom

    more important

    year

    by

    year because of

    increas

    of running

    speed

    of turbocharge rs at th e opera

    tion range

    and

    also poor

    lubricat ing condition

    such

    as

    low o il pressure or

    high

    temperature o

    lubricating oi l

    Also,

    there will occur such problems as

    bearing

    fa i lure

    or

    noisy

    turbochargers.

    In

    order to p revent th es e p robl ems, d imension o f

    th e bearing i t se l f bearing clearance, bearing

    form, bearing span,

    dimension

    of shaft

    diamete

    and bal an ci ng o f a turbine

    rotor

    assembly have

    been

    improved.

    The following items are

    important.

    Fig.

    3 Typical problems

    a J

    Selecting th e

    b est s ha ft

    diameter

    and

    journal bearing

    span

    in order no t to

    include harmful cr i t ica l

    speed

    in th e

    operating range

    b

    Decision of

    th e

    best

    dimension

    of journ

    bearings

    t o p revent

    self

    exciting vibra

    tion

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    880563

    Copper

    Sulfur

    Fig.

    6 Bearing damaged by coking

    Close

    examination

    by electron microsco

    and E .D.X. i ndica te s a t tack to the

    bearing

    surface by sulfur

    which

    seems to

    be

    include

    in

    lubricating

    oi l Fig.

    7 shmvs sulfur

    attack to th e bearing surface.

    Fig.

    7 Sulfur

    attack to the bearing

    surface

    Sn by

    melting

    away due to their low melting

    point . Of course

    this

    means reduction of

    bear

    ing

    l i fe As

    to Cu Pb Sn

    alloy

    \vhich is

    also

    very

    popular as bearing material , there is a

    possib i l i ty of

    the

    bearing coking problem. That

    is : shortening

    of

    bearing l i fe becaus e o f grow-

    ing

    of black

    layer

    on

    th e

    bearing surface and

    fla kin g o ff of this portion.

    The

    surface

    of the

    bearing

    damaged by

    coking

    becomes completely

    corroded

    and i ts color

    changes

    to

    black as shown in Fig. 6. Part

    of

    the

    bea ring sur fa ce

    is damaged by

    scratched

    and

    flaked off .

    1I4N,

    1 2N

    1I2Nl

    i N

    o ld d es ig n

    - N

    o

    IOO

    3kg/cm

    Convenllonill

    L ub o il lulnP

    Lub.

    oil

    press

    Improvement

    Lub

    lemp

    IOQe

    Lub oil pless

    3kg/cm:

    f ~ ~ )

    /

    e

    x

    g

    g

    g

    Fig. 4 Shaft end vibration of

    Fig. 4 and Fig. 5 shoH

    comparison

    of shaft

    end vibration of

    new design

    and o ld d es ign

    turbochargers. An

    improved

    design

    turbocharger

    shows bet ter st bi l i ty t the to ta l operating

    range.

    (c )

    Reduction

    of

    r emaining unbalance so

    as

    to

    l imit amplitude

    of

    shaft

    vibrat ion

    ~ c b 1 S

    8

    N, Turbochmger speed X10 ,pm)

    ~ : : : : Q : : : : : : : : : : = -

    D : : : C : : ~ \ lISN,

    t )

    o c---..........----- , - - ~ -

    5 1 15 18

    N, TUlboctl lIgl. f speed (XIO rpml

    Fig. 5

    Shaft

    end vibration of new design

    IHPROVEHENT

    FOR

    HEAT

    DANAGE

    Coking

    of

    journal bearing Generally vehicle

    use

    engines are

    frequently

    stopped.

    Sometimes

    they

    ar e stopped

    suddenly from high

    engine

    load.

    The temperature around

    th e

    t ur bi ne s id e journal

    bearing

    increases to the ver y h igh

    level

    because

    there

    is

    no

    cooling func tion fo r

    th e

    turbine

    side bearing

    by

    engine

    lubricating

    o il

    when

    an

    engine

    stops.

    Host o f turbucharge rs use Cu Pb Sn al loy or

    AI-Sn a llo y fo r their bearings, so that bearing

    failure

    of the

    t ur bi ne s id e journal bearing

    is

    ap t

    to

    happen due

    to this

    high tempera ture which

    is

    normally

    called

    heat soak back . The peak

    temperature

    during

    heat soak back exceeds 2 DoC

    Under

    such

    a

    high tempera ture

    AI-Sn alloy,

    which

    usually

    used fo r

    the

    journal

    bearing,

    looses

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    4

    88

    o

    o

    20

    Soak

    time; 10 HRS

    Mela ; PBS

    1.5.0

    Sulfur content Oio

    05

    100

    1

    50

    E

    3

    m

    20

    u

    :

    10

    j

    I

    1

    u

    rn

    0

    Cu?S is created because copper is diffused

    to the

    5earing sur face

    due to sulfur ion. This

    black

    color

    layer

    is so-called coking layer .

    t became clear by oil soaking test using

    var ious

    kinds

    of

    lubr icat ing o i l t i th a

    combina

    tion of the bearing mat er ia l t ha t

    there

    ar e

    several inf luent ia l

    factors such

    as lubricat ing

    oil temperature,

    sulfur

    content of

    lubricating

    oil and

    copper

    content

    of

    bearing

    material .

    Typical

    resul ts of oil soaking test ar e shotvn

    in

    Fig.

    8. The black layer becomes thicker as

    the

    temperature goes higher.

    Flaking

    of

    th e

    bearing surface star ts

    over

    300

    o

    e. t is

    recognized that there is

    difference

    in

    the

    level of

    su lf u r a tt ac k

    according to th e bearing

    rna rer ia 1.

    Oil-soaking test

    Fig.

    8 o il soaking test

    200

    Fig. 10 Influence of

    sulfur

    content

    Carbon bridge Lubricating oil becomes

    carbonized

    and

    accumulated

    around

    piston

    ring

    seal and oil drain

    passage

    at

    the

    t ur bi ne s id e

    due

    to high

    temperature by heat soak

    back,

    whi

    is explained before. We

    cal l

    such a phenomeno

    as carbon

    bridge.

    This c arbon

    bridge

    is

    mainly affected by

    th e following

    three factors.

    Judging

    from

    th e

    test

    explained above,

    IH

    selected

    the

    material

    which

    belongs

    t o c oppe r

    zinc alloy as a bearing

    material

    since i t ha s

    very

    good

    bearing characteristics

    and ant i

    corrosion character is t ics . We

    apply

    this

    material

    to ou r

    small

    model turbochargers for

    passenger car us e after

    th e

    various tests done

    at ou r company_

    400

    00

    Oil

    ~ / S F \ O W 3 0

    Test pieces

    cj

    Oil

    temp.

    re}

    I

    Soak

    time: 10

    HAS

    100

    100

    E

    3

    m

    u

    50

    :

    }

    u

    r

    The influence of

    copper

    content of th e

    bearing

    material on

    coking

    is shown in Fig. 9.

    Large r coppe r

    content

    is disadvantageous as

    a bearing

    material . Fig.

    10 shows

    influence of

    sulfur

    content of

    lubricating

    oil

    on

    coking.

    t

    is nec es sa ry t o choose low

    sulfur

    content

    oil

    a

    b)

    Operat ing temperature around a turbine

    side

    seal and a turbine shaft at

    th e

    turbine

    side

    under

    working condition

    Naximum

    temperature and tota l

    time

    of

    the heat

    soak

    back

    Fig. 9 Influence of copper content

    c) Additives and

    deterioration

    of lubr i

    cat ing o il

    These factors

    play an important

    role

    to

    shorten

    turbocharger l i fe

    Carbon

    bridge

    caus

    oil leakage

    to

    a turbine

    housing

    by sacrif icin

    smooth

    return

    of

    lubricating

    oil

    to th e

    oil

    drain

    tank of

    an

    engine.

    The following countermeasure

    is

    effective

    Worsllcvcl

    0

    o c

    00

    i

    0

    -/:,._____ -

    ----/Y-

    eo

    d ; . ~ /

    _x

    :

    I

    60

    0

    ,

    ,

    /

    ,

    ,

    g

    ,

    O ~ 0 /

    40

    ,

    OUsonklng tost

    , ,

    /

    0

    ,

    ,

    /

    x-

    0

    x --

    60

    60 90

    Copper conlent

    of

    bcaring malCl;al { l

    100

    a

    b)

    To reduce

    th e

    maximum

    temperature

    around

    seal at

    th e

    curbine

    side

    To reduce the tota l heat soak

    back

    time

    This

    means to

    increase

    cooling rate

    of

    heat soak

    back

    c) To

    increase

    th e space

    around piston

    seal rin g

    and

    oil

    f linger

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    880563

    d)

    To

    use

    bet ter

    qual i ty oil

    and

    timely

    exchange of lubricat ing

    oil so that

    original

    characteristics of the oil

    may be maintained.

    The

    similar

    resul ts were obtained

    at

    th e

    engine

    durabil i ty

    test and

    correlat ion with

    the

    panel

    coking tes t was proved. The resu l ts are

    shotoJU

    in

    Fig. 12 .

    The

    bearing

    housi ng has

    been improved

    to

    overcome such unsui table condi t ions as increase

    of th e

    temperature

    around

    a tu rb in e s id e sea l ,

    increase

    o f th e temperature

    of

    lubricating

    oi l ,

    dec re as e o f cooling rate of t he turbocharge r

    caused by

    ins ta l l ing

    a

    protection

    cover

    for

    engine

    parts , and deterioration of

    lubricating

    oil due to improper oil

    maintenance.

    A

    water -cooled bear ing

    housing by cooling

    water of an eng in e h as become most popular for

    passenger car

    engines a t

    present though i t is

    ol d

    technology

    originally developed for marine

    use turbochargers.

    The space

    around

    o il

    fl inger

    of the

    turbine shaft

    i s occupied by carbon a t the

    re la t ively high

    rate

    with standard

    oil-cooled

    bearing housing , and i t s

    rate

    will

    change

    depending

    on brands of

    lubricating oil .

    So

    we

    establish

    th e

    method

    of

    panel

    coking

    tes t

    to

    simulate

    process of carbon bridge. Fig. 11

    shm.,s

    one

    example of

    t es t r es ul ts .

    I t t.,as

    found by this

    tes t

    that rate of carbon accumu

    la t ion

    is

    affected

    by th e

    brand

    of

    lubricating

    o i l

    and

    the

    difference between new oil and used

    oi 1.

    at e rcooling type

    300

    e:

    I

    E

    2

    Go-stop

    test

    Go-slOp cycles

    Fig. 12 Results of lICo-Stop

    tes t

    1 0 0 1 - = = F = ~ - + - : = : : j : : : : : : : : : : ~ +

    On

    the other

    hand temperature measurement

    tes t

    was

    conducted

    to know

    t he t empera tu re

    of

    the area

    where

    carbon

    bridge

    occurs.

    The

    tes t

    resul ts on th e turbocharger

    tes t

    bench is shown

    in Fig. 13 . Fig. 14 shows test resul ts on the

    test vehicle.

    The

    temperature

    at

    each position

    has

    been reduced by design modification and

    water cooling.

    3; \ I

    ~ I i l l o

    0 2.1/

    ]10 ~ .

    ~

    ==--

    I

    O il

    UI t:::I::f

    \.1

    ~

    -j:\C---..' ~

    J ~ Q ~ :

    Original type

    Oil cooling type

    4001---+--- , , -+- Turbine inlet gas temp. 70CTC

    LO. Inlet lemp. lQO C

    LO. Pressule:

    2kg/cm

    gage

    N

    Mall. speed

    1100 cycle

    B

    I cycle

    A

    Smin

    ,

    : : 13S0 CI :

    ,

    A h

    :

    ~

    ~

    i

    , : :

    O-K

    Oil flow

    Tempemlule

    of lesl piece

    c

    Healer

    B

    Oil lemp. 140 C

    c-

    '0

    6

    03

    c-

    03

    n

    ,

    :

    0

    I

    I

    ;

    1=

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    6

    880

    Oil cooling bearing housing Water cooling bearing housing

    2

    1

    I

    I

    ~

    I

    Go

    , SlOP

    Time

    I

    Fig. 16

    Mileage

    (x10 km)

    Improvement of

    wear

    of

    turbine

    side

    piston

    ring seal

    for

    truck

    use turbocharger

    Fig. 14 Results on

    th e

    test vehicle

    oLso _--:,X;00C---;; o--;,eor::--c5 O---;; 00C--- Co--;, eoC-

    Seal - Seal

    of

    a

    turbocharger at th e

    both

    sides

    of turbine

    and

    compressor

    is very

    important.

    Such

    seal

    bi l i ty

    is required that can

    withstand

    high vacuum t th e compressor side and

    also

    severe hea t inf luence t th e

    turbine

    side

    because deterioration of lubricat ion is accel

    erated

    by

    blow-by

    gas.

    Smoke

    level

    becomes

    worse by generating

    white smoke

    caused by o i l

    leakage from th e bearing housing a t th e turbine

    side.

    According ly the l i fe of a turbocharger

    will

    be reduced.

    Fig.

    15

    shows new

    de sig n o f

    seals a t th e

    both

    sides of turbine and

    com

    pressor. Fig.

    16 shows

    how

    much

    seal capabili ty

    ha s

    been

    increased by

    th e improvement of tem

    perature distr ibut ion

    around

    a t ur bi ne s id e

    seal.

    Oxidation

    and crack of

    a

    turbine housing

    Oxidation

    and

    crack

    of

    a

    turbine

    housing

    are

    influenced by th e

    exhaust

    ga s temperature

    h ea t cy cle and housing

    shape

    such

    as

    twin-flow

    passage

    type or

    with

    integrated

    wastegate

    valve

    The

    turbine

    housing of

    this

    turbocharger is

    spiral

    form

    so

    i t s shape

    is more

    uneven

    than

    other

    parts .

    Besides

    a

    turbocharger is in

    st l led

    on an engine by th e

    ga s

    in let

    flange

    of a turbine housing so

    that i t

    is

    used

    under

    th e severe stress condi ti on . E sp ec ia ll y

    i t

    is

    severe in case of

    truck

    use turbochargers

    because

    most of

    th e

    turbine

    housings

    ar e

    so

    called

    I t T ~ J i n f l o w

    type

    which

    has

    two

    gas flow

    passages

    divided meridionally. This type turb

    housing

    is bet ter to

    ut i l ize pulse

    energy of

    exhaust ga s

    from an engine but

    i t must

    have a

    center

    wall to separate two

    gas passages.

    Thi

    center wall

    is

    often

    cracked

    because i t is

    heated cyclicly

    from both

    sides of the

    wall wh

    exhaust gases pass t hr ough the passages.

    Besides i t is

    dif f icul t

    to absorb deformation o

    th e

    center

    wall when operating temperature

    changes

    by engine load. The

    center

    wall i s

    apt

    to

    be

    cracked by th e

    heat stress caused

    by this

    temperature

    f luctuat ion and

    unevenness

    of the

    housing.

    Shape

    of the

    housing

    and materia l of the

    housing

    therefore have

    been improved.

    One example of s t ress analysis of the tw in

    flow turbine housing by F.E.M. is shown in Fig.

    17 .

    Also

    Fig. 18 shows th e test

    resul t

    of the

    improved turbine housing against crack

    around

    th e

    tongue

    of the housing by heat cyc le dur a

    bi l i ty test

    Ipeaksoak lemp after st

    Vechicla speed

    jkm/Hl

    ~ r l 5 a n l Sptlcd r u n ; ~ I

    V\lchicle speed

    kmlH

    ooling chamber ~ = : : _ : : = : :

    Fig.

    15 New design of seal

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    8

    HIPROVENENT

    OF STRENGTH OF ROTATING PARTS

    The

    major problem of

    th e r o ta ti ng pa rt s

    increasing l i fe and rotating

    speed

    is r e k d o ~ v n

    of a

    turbine

    Hheel and a

    compressor

    ,heel

    fatigue.

    Espec ia ll y for the

    relat ively large

    size

    turbochargers used on truck use diesel

    engines, th e

    request

    for h ighe r p re ssure

    rat io ,

    , ,, id er f loH range and l a rger flm

    amount

    ivith

    small

    size

    is

    very

    s trong,

    so

    that

    a

    compressor

    heel \Vith large back lvard angle and

    rake

    angle

    ha s a tendency to be used more.

    Both of blade

    s t ress

    and disk st ress

    therefore) ha s

    gradually

    become higher and th e

    evaluation

    of

    low cycle fatigue strength, high

    cycle

    fatigue strength and creep strength

    becomes more important .

    One

    example

    of

    th e

    compressor-wheel damage

    by low cycle

    fat igue

    te s t i s shown

    in

    Fig.

    21 .

    Fig.

    22 shows th e

    comparison of

    th e s t ress

    analysis of

    a new

    design compressor wheel

    and

    o ld d es ign

    one.

    The

    wheel shape

    ha s

    been

    improved

    to reach the t a rget of th e l i fe by

    control l ing

    th e s t ress

    dis t r ibut ion.

    BETTER

    DURABILITY

    N RELIABILITY

    He

    establ ished

    ou r quali ty and durabili ty

    targets

    for

    our

    products depending on usage of

    turbochargers such

    as

    diesel engine use or

    gasoline

    engine

    use. These quali ty

    and dura

    bi l i ty targets

    a re eva lu at ed by

    turbocharger

    880

    Fig. 21 Low cycle

    fat igue

    fa i lure

    Convenlional

    Fig. 22 Compressor impeller stress analysis

    Table

    2

    Reliabil i ty

    Eva luat ion o f Turbocharger

    Evaluation purpose

    Failure

    mode

    Eva Iua t

    ion

    test

    1 n i t ia l

    failure

    Short

    l i fe of

    bearing

    Non lubricat ing

    o il tes t

    Oil leakage

    Foreign p ar ti cl e t es t

    Bo lt lo ose

    or drop

    Oil seal

    tes t

    Abnormal noise Lot

    temp. tes t

    Vibra t

    ion

    test

    2 Hear

    out

    failure Bearing ear Continuous

    running

    tes t

    Seal

    wear

    Go-stop

    tes t

    Hastegate ear Speed

    f luctuat ion test

    V.G. S. parts

    wear

    Oi l

    p re ss . lim it

    test

    Parts wearing

    tes t

    3

    Fatigue

    fa i lure

    T C

    hee1

    fa i lure Heat

    cycle tes t

    Housing

    crack High

    cycle

    fatigue

    tes t

    Hastegate

    diaphragm

    fai lure

    Low cycle

    fatigue

    test

    Stroke

    tes t

    4

    Creep fa i lure T C wheel damage Continuous

    running

    tes t

    Seal ring

    fa i lure

    Go-stop test

    t.Jastegate valve

    fai lure

    Hastegate

    s t u ~ r

    fa i lure

    5 Deteriorat ion

    fa i lure Dirty

    compressor

    Go-stop test

    Dirty

    turbine

    Corrosion

    tes t

    Carbon bridge

    Oxidation tes t

    Oil passage

    clog

    Continuous

    running

    tes t

    Oxidation

    of housing Oi l

    seal

    tes t

    t.Jastegate

    valve

    oxidation

    V.G.S.

    parts oxidation

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    880563

    NONENCLATURE

    REFERENCES

    CONCLUSION

    The vehicle

    use

    turbocharger must

    have

    adequate

    durabil i ty

    under the

    severe

    condition

    of

    abuse by drivers

    with wide

    operating

    range.

    In

    addit ion,

    the

    Same

    l i fe as a vehicle is

    expected

    as

    well

    as

    t he r ea sonabl e price

    as

    automobile par ts . As mentioned above,

    i t

    conta in s several

    diff icul t

    problems

    to

    be

    solved.

    However,

    we have

    achieved

    ou r target by

    improving

    t he turbocharge r to meet many various

    customer's

    requests.

    Though we have explained some of ou r

    experience for improvement of our standard

    turbochargers, we would

    like

    to pursue ou r

    development

    work to obtain even higher re l ia-

    bil i ty

    as

    well

    as

    development

    of new high tech

    nology

    turbochargers

    such

    as

    variable

    geometry

    turbine

    scrol l ceramic turbocharger and bal l

    bearing

    turbochargers.

    1

    Hinoru Kurasat Ja Takashi Kobayashi and

    etc : RHB3 Turbocharger for Small Passenger

    Cars,

    IHI

    Engineering

    Review

    Vol.

    16 No.1 1983

    (2) Nasami Shimizu: Automotive Turbo

    charger,

    IHI Engineering Review Vol. 18 No.2

    1985

    (3)

    Kazuya

    Niyashita:

    Thermal

    Problems

    of

    Internal Combustion Engine, The 586th Inst i tute

    of

    JSNE 1984

    (4 )

    Nasaki KitagaHa,

    etc : Fatigue

    Life

    Eva luat ion o f

    t he Turbocharger

    Components,

    Internat ional Conference and Exposition of ASH

    1985

    Tc Temperature

    of constant

    speed

    Tp

    Peak

    temperature

    of heat soak

    back

    L Crack length

    N Crit ical cycle

    n Harking cycle

    Nt Turbocharger

    speed

    N ; Cri tica l cyc le

    n ; Working cyc le

    High way mode

    Slope mode

    City mode

    Damage line

    N

    n

    QUALITY

    TEST

    Vehicle use turbochargers

    are

    different

    from other

    rotating machineries in

    th e

    points

    of

    mV cost

    and mass p roduc ti on Hith

    many kinds. Besides, we cannot

    expect

    adequate

    technical

    knmvledge

    to

    users

    of

    turbochargers,

    so that

    maintenance

    is no t ahlays

    good though

    turbochargers are used everyday.

    Therefore,

    examination

    of

    design

    quality

    of main portion

    l ike bearing,

    seal and

    mechan

    ica l strength is accomplished to keep qual i ty

    of

    turbochargers by using maximum and minimum-

    l imit par ts

    are

    making

    effor ts to improve rel iabi l -

    i ty by conducting

    evaluation

    tes t simulating

    user ' s

    severe

    condition and

    also

    by maintaining

    q ua lity in

    production.

    sale

    running tes ts

    which simulate actual

    running

    pat tern of a vehicle,

    engine

    bench

    tes ts

    and also vehicle tests

    Durability and rel iabi l i ty of each

    element

    of the vehicle use turbocharger

    are

    evaluated

    from th e various stand points by

    the simulation

    tes ts against

    each fai lure

    mode as

    ho\o

    table

    2.

    DURABILITY TEST

    Several examples

    ofevaluation

    tests are

    shmm in the

    former sect ion.

    As

    explained before.

    f luctuat ion of heat

    load

    and

    rotating speed

    is very often and i t

    affects

    oxidation of

    high temperature portion.

    dete

    r iora t ion ,

    \ Jear and strength of

    r ot at ing pa rt s.

    So. the

    durabil i ty

    of a turbocharger is evalu

    ated on th e basis of Niner 's

    theory

    estab

    l ishing

    cyclic

    random load simulating running

    pat tern of vehicles.

    Fig.

    23 shows one example

    of tes t condi ti on for low

    cycle fatigue tes t

    of

    a

    compressor wheel

    and

    carbon bridge.

    E

    1-+-1- -'----.......

    i

    f--I--+---- -- -,

    t

    E I

    Cycles

    Tor

    High

    T

    or

    a

    Low

    Note:

    T

    2

    depends on temperature drop rate

    for carbon bridge test

    Fig. 23 Test

    condition for

    fatigue

    and carbon bridge

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