Turbo Charger

Lion DVD
AFA I
CHAPTER: Turbochargers
Turbochargers
Service Training Malaga
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AFA I
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AFA I
In This Presentation
Function
Design
Operation
Normal wear
Why Turbos Fail
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AFA I
Function
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AFA I
Function
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AFA I
Turbocharger Functions
Normalize Air Supply

Boost Air Supply
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AFA I
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
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AFA I
Normalizing
First commercial use 1940s in Airplane
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AFA I
Boosting
More Oxygen / Increased Fuel Setting
Higher Power
Better Combustion
- Better Fuel Economy
- Cleaner Emissions
Quieter
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AFA I
Boosting
10
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AFA I
Design
11
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Design
AFA I
Waste-Gate Turbo
12
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Design
AFA I
Lubrication System
Lubricating
Cooling
Cleaning
13
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AFA I
Design
Lubrication System
Direct lubrication line to Turbo
14
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Design
AFA I
Lubrication System
15
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Design
AFA I
Lubrication System
16
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Design
AFA I
Friction Welding
Hollow thermal barrier

Centering Pin
17
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Design
AFA I
Induction hardened Shaft
18
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AFA I
Design
Compressor wheel
High Strength Aluminum alloys
19
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Design
AFA I
Compressor wheel
Balancing Notches
20
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Design
AFA I
Compressor wheel
Radial milling
21
Lion DVD
Design
AFA I
Free-floating journal bearings
Copper/tin/lead alloy or from aluminium

Lube holes or groove
22
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AFA I
Design
Snap rings
Rounded edge towards the bearing
23
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AFA I
Design
Thrust Bearing
Copper/tin/lead alloy or from aluminium
Bearing stationary
Washer full shaft RPM
24
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AFA I
Design
Seal Rings
High temperature resistant chrome alloy

Cold side cast iron
End gap
25
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Design
AFA I
Housing
Cast aluminum alloy

Cast Iron
Cast ductile iron or nickel alloy
26
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AFA I
Design
Heat Shield
Protects center housing from high

exhaust temperatures
27
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Operation
AFA I
Start-up
28
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Operation
AFA I
Turbos are matched
29
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Operation
AFA I
Air Restriction
Energy stored in rotating
component can equal the
engine HP
Turbo spin 80 000 Rpm

Surface speed 30m/second
30
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AFA I
Normal Wear
Increased clearance
31
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Normal Wear
AFA I
Hot side
Little leak past the seal ring
32
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AFA I
Normal Wear
Turbine Wheel
No discoloration
Seal ring with gap separation
33
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Normal Wear
AFA I
Bearings
More wear on hot side
34
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Normal Wear
AFA I
Thrust Bearing
Fine abrasive wear
35
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Normal Wear
AFA I
Thrust washers
36
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AFA I
Why Turbos Fail

Lack of Lubrication
Abrasive in the Oil
High Exhaust Temperature
Foreign Objects
Turbo Problems
37
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AFA I
Lack of Lube
Road-signs
Temper Colors/ Cooked Oil

Adhesive Wear
Weakened Metal
Wheel Contact with Housing
Wheel separation from Shaft
38
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AFA I
Lack of Lubrication
Housing Contact
39
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AFA I
Lack of Lubrication
Housing Contact
Temper colors and cooked oil residue

40
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AFA I
Lack of Lubrication
High Temperature
41
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AFA I
Lack of Lubrication
High Temperature
42
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AFA I
Lack of Lubrication
High Temperature
43
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AFA I
Lack of Lubrication
High Temperature
44
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AFA I
Lack of Lubrication
High Temperature
Rapid Shutdown
45
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AFA I
Lack of Lubrication
High Temperature
Cooked oil residual
46
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AFA I
Lack of Lubrication
High Temperature
Quench dots/rings
47
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AFA I
Lack of Lubrication
High Temperature
Bushing stuck to shaft
48
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AFA I
Lack of Lubrication
High Temperature
Turbine wheel separation
49
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AFA I
Lack of Lubrication
High Temperature
50
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AFA I
Lack of Lubrication
High Temperature
Adhesive wear and

Thermal cracking
51
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AFA I
Lack of Lubrication
High Temperature
Discoloration
52
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AFA I
Lack of Lubrication
High Temperature
Ductile Fracture
Discoloration
53
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AFA I
Lack of Lubrication
WHY
54
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AFA I
Abrasive in the Oil
Road-signs
Scratches, Cuts, Grooves

Little Heat Damage
Rapid Wear
Embedded Debris
55
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AFA I
Abrasive in the Oil
Extended Oilchange Intervals
Excessive shaft motion
56
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AFA I
Abrasive in the Oil
57
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AFA I
Abrasive in the Oil
Missing Hot side Seal
Exhaust carbon cause fine abrasive cutting
58
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AFA I
Abrasive in the Oil
59
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AFA I
Abrasive in the Oil
60
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AFA I
Abrasive in the Oil
61
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AFA I
Abrasive in the Oil

New turbo failed after 3 weeks of service
62
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AFA I
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
63
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AFA I
High Exhaust Temp.
Road-signs
Much Heat Damage

- Cooked Oil
- Oxidation
- Temper Colors
Much Bearing Wear
64
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AFA I
High Exhaust Temp.

Open Turbo and look inside
65
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AFA I
High Exhaust Temp.
66
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AFA I
Foreign Object
Road-signs
Wheel Blade Damage

Bent Center Shaft
Normal Bearing Wear
Wheel Separation
67
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Foreign Object
AFA I
Wheel Blade Damage
68
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Foreign Object
AFA I
Wheel Blade Damage
Uniform Bending
69
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Foreign Object
AFA I
Wheel Blade Damage
Fresh Damage
70
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Foreign Object
AFA I
Wheel Blade Damage
Old Damage
71
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AFA I
Turbocharger Problems
Design/Materials
Manufacturing
72
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AFA I
Design/Materials
Wheel Burst
Blade Fatigue
Casting Inclusion
Weak Wheel
73
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AFA I
Wheel Burst
74
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AFA I
Wheel Burst
75
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AFA I
Wheel Burst
76
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AFA I
Wheel Burst
77
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AFA I
Blade Fatigue
78
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AFA I
Blade Fatigue
79
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AFA I
80
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AFA I
Casting Inclusion
81
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AFA I
Casting Inclusion
82
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AFA I
Casting Inclusion
83
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AFA I
Casting Inclusion
84
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AFA I
Manufacturing
Weak Inertial/Friction Weld
Bent Shafts
Rough Bores
Misdrilled Oil Holes
Balancing Errors
85
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AFA I
86
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AFA I
87
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AFA I
88
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AFA I
Bent Shaft
Use T bar when tightening Compressor nut
89
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AFA I
Bent Shaft
90
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AFA I
91
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AFA I
92
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AFA I
Missed Oil Holes
93

Turbo Charger

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Turbo Charger

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Lion DVD

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Normalize Air Supply

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Direct lubrication line to Turbo

Service Training Malaga

Service Training Malaga

Service Training Malaga

Hollow thermal barrier

Service Training Malaga

Service Training Malaga

Induction hardened Shaft

High Strength Aluminum alloys

Service Training Malaga

Service Training Malaga

Service Training Malaga

Free-floating journal bearings

Copper/tin/lead alloy or from aluminium

Service Training Malaga

Rounded edge towards the bearing

Service Training Malaga

Copper/tin/lead alloy or from aluminium

High temperature resistant chrome alloy

Cast aluminum alloy

Service Training Malaga

Protects center housing from high

Service Training Malaga

Service Training Malaga

Service Training Malaga

Turbos are matched

Turbo spin 80 000 Rpm

Service Training Malaga

Little leak past the seal ring

Service Training Malaga

Service Training Malaga

More wear on hot side

Service Training Malaga

Fine abrasive wear

Service Training Malaga

Service Training Malaga

Why Turbos Fail

Service Training Malaga

Temper Colors/ Cooked Oil

Service Training Malaga

Service Training Malaga

Temper colors and cooked oil residue

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Cooked oil residual

Service Training Malaga

Service Training Malaga