1 service training malaga afa i lion dvd chapter: turbochargers turbochargers
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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
AFA ILion DVD
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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AFA ILion DVD
DesignCHAPTER: Turbochargers
12Service Training Malaga
AFA ILion DVD
Design Waste-Gate Turbo
CHAPTER: Turbochargers
13Service Training Malaga
AFA ILion DVD
Design Lubrication System
Lubricating Cooling Cleaning
CHAPTER: Turbochargers
14Service Training Malaga
AFA ILion DVD
Design Lubrication System
Direct lubrication line to Turbo
CHAPTER: Turbochargers
15Service Training Malaga
AFA ILion DVD
Design Lubrication System
CHAPTER: Turbochargers
16Service Training Malaga
AFA ILion DVD
Design Lubrication System
CHAPTER: Turbochargers
17Service Training Malaga
AFA ILion DVD
Design Friction Welding
Hollow thermal barrierCentering Pin
CHAPTER: Turbochargers
18Service Training Malaga
AFA ILion DVD
Design Induction hardened Shaft
CHAPTER: Turbochargers
19Service Training Malaga
AFA ILion DVD
Design Compressor wheel
High Strength Aluminum alloys
CHAPTER: Turbochargers
20Service Training Malaga
AFA ILion DVD
Design Compressor wheel
Balancing Notches
CHAPTER: Turbochargers
21Service Training Malaga
AFA ILion DVD
Design Compressor wheel
Radial milling
CHAPTER: Turbochargers
22Service Training Malaga
AFA ILion DVD
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
26Service Training Malaga
AFA ILion DVD
Design Housing
Cast aluminum alloyCast IronCast ductile iron or nickel alloy
CHAPTER: Turbochargers
27Service Training Malaga
AFA ILion DVD
Design Heat Shield
Protects center housing from high exhaust temperatures
CHAPTER: Turbochargers
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AFA ILion DVD
Operation Start-up
CHAPTER: Turbochargers
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AFA ILion DVD
Operation Turbos are matched
CHAPTER: Turbochargers
30Service Training Malaga
AFA ILion DVD
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
AFA ILion DVD
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
AFA ILion DVD
Normal Wear Bearings
More wear on hot side
CHAPTER: Turbochargers
35Service Training Malaga
AFA ILion DVD
Normal Wear Thrust Bearing
Fine abrasive wear
CHAPTER: Turbochargers
36Service Training Malaga
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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
38Service Training Malaga
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
39Service Training Malaga
AFA ILion DVD
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
41Service Training Malaga
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Lack of Lubrication High Temperature CHAPTER: Turbochargers
42Service Training Malaga
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Lack of Lubrication High Temperature CHAPTER: Turbochargers
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AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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AFA ILion DVD
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
AFA ILion DVD
Turbine wheel separation
Lack of Lubrication High Temperature CHAPTER: Turbochargers
50Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
51Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Adhesive wear and Thermal cracking
CHAPTER: Turbochargers
52Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Discoloration
CHAPTER: Turbochargers
53Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Ductile FractureDiscoloration
CHAPTER: Turbochargers
54Service Training Malaga
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
56Service Training Malaga
AFA ILion DVD
Abrasive in the Oil Extended Oilchange Intervals
Excessive shaft motion
CHAPTER: Turbochargers
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AFA ILion DVD
Abrasive in the OilCHAPTER: Turbochargers
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AFA ILion DVD
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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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
64Service Training Malaga
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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AFA ILion DVD
High Exhaust Temp. CHAPTER: Turbochargers
67Service Training Malaga
AFA ILion DVD
Foreign Object Road-signs
• Wheel Blade Damage
• Bent Center Shaft
• Normal Bearing Wear
• Wheel Separation
CHAPTER: Turbochargers
68Service Training Malaga
AFA ILion DVD
Foreign Object Wheel Blade Damage
CHAPTER: Turbochargers
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Foreign Object Wheel Blade Damage
Uniform Bending
CHAPTER: Turbochargers
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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
74Service Training Malaga
AFA ILion DVD
Wheel BurstCHAPTER: Turbochargers
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AFA ILion DVD
Wheel BurstCHAPTER: Turbochargers
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Wheel BurstCHAPTER: Turbochargers
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AFA ILion DVD
Wheel BurstCHAPTER: Turbochargers
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AFA ILion DVD
Blade FatigueCHAPTER: Turbochargers
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AFA ILion DVD
Blade FatigueCHAPTER: Turbochargers
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AFA ILion DVD CHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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AFA ILion DVD
Casting InclusionCHAPTER: Turbochargers
84Service Training Malaga
AFA ILion DVD
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
AFA ILion DVD
Weak Inertial/Friction WeldCHAPTER: Turbochargers
87Service Training Malaga
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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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AFA ILion DVD
Bent ShaftCHAPTER: Turbochargers
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Misdrilled Oil HolesCHAPTER: Turbochargers
92Service Training Malaga
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Misdrilled Oil HolesCHAPTER: Turbochargers
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Missed Oil HolesCHAPTER: Turbochargers
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