Turbo Charger

Lion DVD
AFA I
CHAPTER: Turbochargers
Turbochargers
Service Training Malaga
Lion DVD
AFA I
Lion DVD
AFA I
In This Presentation
Function Design Operation Normal wear Why Turbos Fail
Lion DVD
AFA I
Function
Lion DVD
AFA I
Function
Lion DVD
AFA I
Turbocharger Functions
Normalize Air Supply
Boost Air Supply
Lion DVD
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
Lion DVD
AFA I
Normalizing
First commercial use 1940s in Airplane
Lion DVD
AFA I
Boosting
More Oxygen / Increased Fuel Setting Higher Power Better Combustion - Better Fuel Economy - Cleaner Emissions Quieter
Lion DVD
AFA I
Boosting
10
Lion DVD
AFA I
Design
11
Lion DVD
AFA I
Design
Waste-Gate Turbo
12
Lion DVD
AFA I
Design
Lubricating Cooling Cleaning
Lubrication System
13
Lion DVD
AFA I
Design
Direct lubrication line to Turbo
Lubrication System
14
Lion DVD
AFA I
Design
Lubrication System
15
Lion DVD
AFA I
Design
Lubrication System
16
Lion DVD
AFA I
Design
Friction Welding
Hollow thermal barrier Centering Pin
17
Lion DVD
AFA I
Design
Induction hardened Shaft
18
Lion DVD
AFA I
Design
High Strength Aluminum alloys
Compressor wheel
19
Lion DVD
AFA I
Design
Balancing Notches
Compressor wheel
20
Lion DVD
AFA I
Design
Compressor wheel
Radial milling
21
Lion DVD
AFA I
Design
Free-floating journal bearings
Copper/tin/lead alloy or from aluminium Lube holes or groove
22
Lion DVD
AFA I
Design
Rounded edge towards the bearing
Snap rings
23
Lion DVD
AFA I
Design
Copper/tin/lead alloy or from aluminium
Thrust Bearing
Bearing stationary Washer full shaft RPM

Service Training Malaga 24
Lion DVD
AFA I
Design
High temperature resistant chrome alloy Cold side cast iron
Seal Rings
End gap
Lion DVD
AFA I
Design
Housing
Cast aluminum alloy Cast Iron Cast ductile iron or nickel alloy
26
Lion DVD
AFA I
Design
Protects center housing from high exhaust temperatures
Heat Shield
27
Lion DVD
AFA I
Operation
Start-up
28
Lion DVD
AFA I
Operation
Turbos are matched
29
Lion DVD
AFA I
Operation
Air Restriction Energy stored in rotating component can equal the engine HP
Turbo spin 80 000 Rpm Surface speed 30m/second

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

Lack of Lubrication
Abrasive in the Oil High Exhaust Temperature Foreign Objects Turbo Problems
37
Lion DVD
AFA I
Lack of Lube
Temper Colors/ Cooked Oil
Road-signs
Adhesive Wear Weakened Metal Wheel Contact with Housing Wheel separation from Shaft
38
Lion DVD
AFA I
Lack of Lubrication
Housing Contact
39
Lion DVD
AFA I
Lack of Lubrication
Housing Contact
Temper colors and cooked oil residue

Lion DVD
AFA I
Lack of Lubrication
High Temperature
41
Lion DVD
AFA I
Lack of Lubrication
High Temperature
42
Lion DVD
AFA I
Lack of Lubrication
High Temperature
43
Lion DVD
AFA I
Lack of Lubrication
High Temperature
44
Lion DVD
AFA I
Lack of Lubrication
Rapid Shutdown
High Temperature
45
Lion DVD
AFA I
Lack of Lubrication
Cooked oil residual
High Temperature
46
Lion DVD
AFA I
Lack of Lubrication
Quench dots/rings
High Temperature
47
Lion DVD
AFA I
Lack of Lubrication
Bushing stuck to shaft
High Temperature
48
Lion DVD
AFA I
Lack of Lubrication
Turbine wheel separation
High Temperature
49
Lion DVD
AFA I
Lack of Lubrication
High Temperature
50
Lion DVD
AFA I
Lack of Lubrication
High Temperature
Adhesive wear and Thermal cracking
51
Lion DVD
AFA I
Lack of Lubrication
High Temperature
Discoloration
52
Lion DVD
AFA I
Lack of Lubrication
High Temperature
Ductile Fracture Discoloration
53
Lion DVD
AFA I
Lack of Lubrication
WHY
Lion DVD
AFA I
Abrasive in the Oil

Scratches, Cuts, Grooves
Road-signs
Little Heat Damage Rapid Wear Embedded Debris
55
Lion DVD
AFA I
Abrasive in the Oil

Excessive shaft motion
Extended Oilchange Intervals
56
Lion DVD
AFA I
Abrasive in the Oil
57
Lion DVD
AFA I
Abrasive in the Oil
Missing Hot side Seal
Exhaust carbon cause fine abrasive cutting
58
Lion DVD
AFA I
Abrasive in the Oil
59
Lion DVD
AFA I
Abrasive in the Oil
60
Lion DVD
AFA I
Abrasive in the Oil
61
Lion DVD
AFA I
Abrasive in the Oil

New turbo failed after 3 weeks of service
62
Lion DVD
AFA I
Abrasive in the Oil

1. 2. 3. 4. 5. Debris size = pin head Debris shape = spherical Debris uniformity = same size Debris color = black, blue, grey, silver. Magnetic = yes
63
Lion DVD
AFA I
High Exhaust Temp.

Much Heat Damage
Road-signs
- Cooked Oil - Oxidation - Temper Colors Much Bearing Wear
64
Lion DVD
AFA I
High Exhaust Temp.

Open Turbo and look inside
65
Lion DVD
AFA I
High Exhaust Temp.
66
Lion DVD
AFA I
Foreign Object
Wheel Blade Damage
Road-signs
Bent Center Shaft Normal Bearing Wear Wheel Separation
67
Lion DVD
AFA I
Foreign Object
Wheel Blade Damage
68
Lion DVD
AFA I
Foreign Object
Uniform Bending
Wheel Blade Damage
69
Lion DVD
AFA I
Foreign Object
Fresh Damage
Wheel Blade Damage
70
Lion DVD
AFA I
Foreign Object
Old Damage
Wheel Blade Damage
71
Lion DVD
AFA I
Turbocharger Problems
Design/Materials
Manufacturing
72
Lion DVD
AFA I
Design/Materials
Wheel Burst
Blade Fatigue Casting Inclusion Weak Wheel
73
Lion DVD
AFA I
Wheel Burst
74
Lion DVD
AFA I
Wheel Burst
75
Lion DVD
AFA I
Wheel Burst
76
Lion DVD
AFA I
Wheel Burst
77
Lion DVD
AFA I
Blade Fatigue
78
Lion DVD
AFA I
Blade Fatigue
79
Lion DVD
AFA I
80
Lion DVD
AFA I
Casting Inclusion
81
Lion DVD
AFA I
Casting Inclusion
82
Lion DVD
AFA I
Casting Inclusion
83
Lion DVD
AFA I
Casting Inclusion
84
Lion DVD
AFA I
Manufacturing
Weak Inertial/Friction Weld
Bent Shafts Rough Bores Misdrilled Oil Holes Balancing Errors
85
Lion DVD
AFA I
86
Lion DVD
AFA I
87
Lion DVD
AFA I
88
Lion DVD
AFA I
Bent Shaft
Use T bar when tightening Compressor nut
89
Lion DVD
AFA I
Bent Shaft
90
Lion DVD
AFA I
Misdrilled Oil Holes
91
Lion DVD
AFA I
Misdrilled Oil Holes
92
Lion DVD
AFA I
Missed Oil Holes
93

Turbo Charger

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Turbo Charger

Caricato da

Copyright:

Formati disponibili

Lion DVD

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Normalize Air Supply

Boost 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

Service Training Malaga

Service Training Malaga

Service Training Malaga

Hollow thermal barrier Centering Pin

Service Training Malaga

Induction hardened Shaft

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Free-floating journal bearings

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

Service Training Malaga

Service Training Malaga

Bearing stationary Washer full shaft RPM

Service Training Malaga

Service Training Malaga

Service Training Malaga

Turbos are matched

Service Training Malaga

Turbo spin 80 000 Rpm Surface speed 30m/second

Service Training Malaga

Little leak past the seal ring

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Why Turbos Fail

Service Training Malaga

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

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Service Training Malaga

Adhesive wear and Thermal cracking

Service Training Malaga

Service Training Malaga

Ductile Fracture Discoloration