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AFA I
CHAPTER: Turbochargers
Turbochargers
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AFA I
CHAPTER: Turbochargers
Lion DVD
AFA I
CHAPTER: Turbochargers
In This Presentation
Function Design Operation Normal wear Why Turbos Fail
Lion DVD
AFA I
CHAPTER: Turbochargers
Function
Lion DVD
AFA I
CHAPTER: Turbochargers
Function
Lion DVD
AFA I
CHAPTER: Turbochargers
Turbocharger Functions
Lion DVD
AFA I
CHAPTER: Turbochargers
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
Lion DVD
AFA I
CHAPTER: Turbochargers
Normalizing
First commercial use 1940s in Airplane
Lion DVD
AFA I
CHAPTER: Turbochargers
Boosting
More Oxygen / Increased Fuel Setting Higher Power Better Combustion - Better Fuel Economy - Cleaner Emissions Quieter
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AFA I
CHAPTER: Turbochargers
Boosting
10
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AFA I
CHAPTER: Turbochargers
Design
11
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AFA I
CHAPTER: Turbochargers
Design
Waste-Gate Turbo
12
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AFA I
CHAPTER: Turbochargers
Design
Lubricating Cooling Cleaning
Lubrication System
13
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AFA I
CHAPTER: Turbochargers
Design
Direct lubrication line to Turbo
Lubrication System
14
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AFA I
CHAPTER: Turbochargers
Design
Lubrication System
15
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AFA I
CHAPTER: Turbochargers
Design
Lubrication System
16
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AFA I
CHAPTER: Turbochargers
Design
Friction Welding
17
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AFA I
CHAPTER: Turbochargers
Design
18
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AFA I
CHAPTER: Turbochargers
Design
High Strength Aluminum alloys
Compressor wheel
19
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AFA I
CHAPTER: Turbochargers
Design
Balancing Notches
Compressor wheel
20
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AFA I
CHAPTER: Turbochargers
Design
Compressor wheel
Radial milling
21
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AFA I
CHAPTER: Turbochargers
Design
22
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AFA I
CHAPTER: Turbochargers
Design
Rounded edge towards the bearing
Snap rings
23
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CHAPTER: Turbochargers
Design
Copper/tin/lead alloy or from aluminium
Thrust Bearing
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AFA I
CHAPTER: Turbochargers
Design
High temperature resistant chrome alloy Cold side cast iron
Seal Rings
End gap
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AFA I
CHAPTER: Turbochargers
Design
Housing
Cast aluminum alloy Cast Iron Cast ductile iron or nickel alloy
26
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AFA I
CHAPTER: Turbochargers
Design
Protects center housing from high exhaust temperatures
Heat Shield
27
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CHAPTER: Turbochargers
Operation
Start-up
28
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AFA I
CHAPTER: Turbochargers
Operation
29
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AFA I
CHAPTER: Turbochargers
Operation
Air Restriction Energy stored in rotating component can equal the engine HP
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AFA I
CHAPTER: Turbochargers
Normal Wear
Increased clearance
31
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CHAPTER: Turbochargers
Normal Wear
Hot side
32
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CHAPTER: Turbochargers
Normal Wear
No discoloration Seal ring with gap separation
Turbine Wheel
33
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AFA I
CHAPTER: Turbochargers
Normal Wear
More wear on hot side
Bearings
34
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CHAPTER: Turbochargers
Normal Wear
Fine abrasive wear
Thrust Bearing
35
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AFA I
CHAPTER: Turbochargers
Normal Wear
Thrust washers
36
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AFA I
CHAPTER: Turbochargers
Abrasive in the Oil High Exhaust Temperature Foreign Objects Turbo Problems
37
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CHAPTER: Turbochargers
Lack of Lube
Temper Colors/ Cooked Oil
Road-signs
Adhesive Wear Weakened Metal Wheel Contact with Housing Wheel separation from Shaft
38
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Housing Contact
39
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Housing Contact
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
41
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
42
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
43
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
44
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Rapid Shutdown
High Temperature
45
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Cooked oil residual
High Temperature
46
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Quench dots/rings
High Temperature
47
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Bushing stuck to shaft
High Temperature
48
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
Turbine wheel separation
High Temperature
49
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
50
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
51
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
Discoloration
52
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AFA I
CHAPTER: Turbochargers
Lack of Lubrication
High Temperature
53
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CHAPTER: Turbochargers
Lack of Lubrication
WHY
Service Training Malaga 54
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AFA I
CHAPTER: Turbochargers
Road-signs
55
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CHAPTER: Turbochargers
56
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CHAPTER: Turbochargers
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CHAPTER: Turbochargers
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CHAPTER: Turbochargers
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CHAPTER: Turbochargers
Road-signs
64
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CHAPTER: Turbochargers
65
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CHAPTER: Turbochargers
66
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CHAPTER: Turbochargers
Foreign Object
Wheel Blade Damage
Road-signs
67
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CHAPTER: Turbochargers
Foreign Object
68
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CHAPTER: Turbochargers
Foreign Object
Uniform Bending
69
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CHAPTER: Turbochargers
Foreign Object
Fresh Damage
70
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CHAPTER: Turbochargers
Foreign Object
Old Damage
71
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CHAPTER: Turbochargers
Turbocharger Problems
Design/Materials
Manufacturing
72
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CHAPTER: Turbochargers
Design/Materials
Wheel Burst
73
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CHAPTER: Turbochargers
Wheel Burst
74
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CHAPTER: Turbochargers
Wheel Burst
75
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CHAPTER: Turbochargers
Wheel Burst
76
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CHAPTER: Turbochargers
Wheel Burst
77
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CHAPTER: Turbochargers
Blade Fatigue
78
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CHAPTER: Turbochargers
Blade Fatigue
79
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CHAPTER: Turbochargers
80
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CHAPTER: Turbochargers
Casting Inclusion
81
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CHAPTER: Turbochargers
Casting Inclusion
82
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CHAPTER: Turbochargers
Casting Inclusion
83
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CHAPTER: Turbochargers
Casting Inclusion
84
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CHAPTER: Turbochargers
Manufacturing
Weak Inertial/Friction Weld
85
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CHAPTER: Turbochargers
86
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CHAPTER: Turbochargers
87
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CHAPTER: Turbochargers
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CHAPTER: Turbochargers
Bent Shaft
Use T bar when tightening Compressor nut
89
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CHAPTER: Turbochargers
Bent Shaft
90
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CHAPTER: Turbochargers
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