1 service training malaga afa i lion dvd chapter: turbochargers turbochargers
TRANSCRIPT
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1Service Training Malaga
AFA ILion DVD CHAPTER: Turbochargers
Turbochargers
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2Service Training Malaga
AFA ILion DVD CHAPTER: Turbochargers
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3Service Training Malaga
AFA ILion DVD
In This Presentation
• Function
• Design
• Operation
• Normal wear
• Why Turbos Fail
CHAPTER: Turbochargers
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4Service Training Malaga
AFA ILion DVD
Function CHAPTER: Turbochargers
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5Service Training Malaga
AFA ILion DVD
Function CHAPTER: Turbochargers
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6Service Training Malaga
AFA ILion DVD
Turbocharger Functions
• Normalize Air Supply
• Boost Air Supply
CHAPTER: Turbochargers
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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
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8Service Training Malaga
AFA ILion DVD
NormalizingFirst commercial use 1940’s in Airplane
CHAPTER: Turbochargers
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9Service Training Malaga
AFA ILion DVD
Boosting
• More Oxygen / Increased Fuel Setting
• Higher Power
• Better Combustion
- Better Fuel Economy
- Cleaner Emissions
•Quieter
CHAPTER: Turbochargers
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10Service Training Malaga
AFA ILion DVD
BoostingCHAPTER: Turbochargers
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11Service Training Malaga
AFA ILion DVD
DesignCHAPTER: Turbochargers
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12Service Training Malaga
AFA ILion DVD
Design Waste-Gate Turbo
CHAPTER: Turbochargers
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13Service Training Malaga
AFA ILion DVD
Design Lubrication System
Lubricating Cooling Cleaning
CHAPTER: Turbochargers
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14Service Training Malaga
AFA ILion DVD
Design Lubrication System
Direct lubrication line to Turbo
CHAPTER: Turbochargers
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15Service Training Malaga
AFA ILion DVD
Design Lubrication System
CHAPTER: Turbochargers
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16Service Training Malaga
AFA ILion DVD
Design Lubrication System
CHAPTER: Turbochargers
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17Service Training Malaga
AFA ILion DVD
Design Friction Welding
Hollow thermal barrierCentering Pin
CHAPTER: Turbochargers
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18Service Training Malaga
AFA ILion DVD
Design Induction hardened Shaft
CHAPTER: Turbochargers
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19Service Training Malaga
AFA ILion DVD
Design Compressor wheel
High Strength Aluminum alloys
CHAPTER: Turbochargers
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20Service Training Malaga
AFA ILion DVD
Design Compressor wheel
Balancing Notches
CHAPTER: Turbochargers
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21Service Training Malaga
AFA ILion DVD
Design Compressor wheel
Radial milling
CHAPTER: Turbochargers
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22Service Training Malaga
AFA ILion DVD
Design Free-floating journal bearings
Copper/tin/lead alloy or from aluminium Lube holes or groove
CHAPTER: Turbochargers
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23Service Training Malaga
AFA ILion DVD
Design Snap rings
Rounded edge towards the bearing
CHAPTER: Turbochargers
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24Service Training Malaga
AFA ILion DVD
Copper/tin/lead alloy or from aluminium
Design Thrust Bearing
Bearing stationaryWasher full shaft RPM
CHAPTER: Turbochargers
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25Service Training Malaga
AFA ILion DVD
Design Seal Rings
High temperature resistant chrome alloyCold side cast iron
End gap
CHAPTER: Turbochargers
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26Service Training Malaga
AFA ILion DVD
Design Housing
Cast aluminum alloyCast IronCast ductile iron or nickel alloy
CHAPTER: Turbochargers
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27Service Training Malaga
AFA ILion DVD
Design Heat Shield
Protects center housing from high exhaust temperatures
CHAPTER: Turbochargers
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28Service Training Malaga
AFA ILion DVD
Operation Start-up
CHAPTER: Turbochargers
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29Service Training Malaga
AFA ILion DVD
Operation Turbos are matched
CHAPTER: Turbochargers
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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
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31Service Training Malaga
AFA ILion DVD
Normal WearIncreased clearance
CHAPTER: Turbochargers
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32Service Training Malaga
AFA ILion DVD
Normal Wear Hot side
Little leak past the seal ring
CHAPTER: Turbochargers
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33Service Training Malaga
AFA ILion DVD
Normal Wear Turbine Wheel
No discoloration Seal ring with gap separation
CHAPTER: Turbochargers
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34Service Training Malaga
AFA ILion DVD
Normal Wear Bearings
More wear on hot side
CHAPTER: Turbochargers
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35Service Training Malaga
AFA ILion DVD
Normal Wear Thrust Bearing
Fine abrasive wear
CHAPTER: Turbochargers
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36Service Training Malaga
AFA ILion DVD
Normal Wear Thrust washers
CHAPTER: Turbochargers
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37Service Training Malaga
AFA ILion DVD
• Lack of Lubrication
• Abrasive in the Oil
• High Exhaust Temperature
• Foreign Objects
• Turbo Problems
Why Turbos FailCHAPTER: Turbochargers
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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
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39Service Training Malaga
AFA ILion DVD
Lack of Lubrication Housing Contact CHAPTER: Turbochargers
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40Service Training Malaga
AFA ILion DVD
Temper colors and cooked oil residue
Lack of Lubrication Housing Contact CHAPTER: Turbochargers
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41Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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42Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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43Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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44Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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45Service Training Malaga
AFA ILion DVD
Rapid Shutdown
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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46Service Training Malaga
AFA ILion DVD
Cooked oil residual
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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47Service Training Malaga
AFA ILion DVD
Quench dots/rings
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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48Service Training Malaga
AFA ILion DVD
Bushing stuck to shaft
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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49Service Training Malaga
AFA ILion DVD
Turbine wheel separation
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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50Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature CHAPTER: Turbochargers
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51Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Adhesive wear and Thermal cracking
CHAPTER: Turbochargers
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52Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Discoloration
CHAPTER: Turbochargers
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53Service Training Malaga
AFA ILion DVD
Lack of Lubrication High Temperature Ductile FractureDiscoloration
CHAPTER: Turbochargers
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54Service Training Malaga
AFA ILion DVD
Lack of Lubrication
WHY
CHAPTER: Turbochargers
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55Service Training Malaga
AFA ILion DVD
Abrasive in the Oil Road-signs
• Scratches, Cuts, Grooves
• Little Heat Damage
• Rapid Wear
• Embedded Debris
CHAPTER: Turbochargers
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56Service Training Malaga
AFA ILion DVD
Abrasive in the Oil Extended Oilchange Intervals
Excessive shaft motion
CHAPTER: Turbochargers
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57Service Training Malaga
AFA ILion DVD
Abrasive in the OilCHAPTER: Turbochargers
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58Service Training Malaga
AFA ILion DVD
Abrasive in the Oil Exhaust carbon cause fine abrasive cutting
Missing Hot side Seal
CHAPTER: Turbochargers
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59Service Training Malaga
AFA ILion DVD
Abrasive in the Oil CHAPTER: Turbochargers
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60Service Training Malaga
AFA ILion DVD
Abrasive in the Oil CHAPTER: Turbochargers
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61Service Training Malaga
AFA ILion DVD
Abrasive in the Oil CHAPTER: Turbochargers
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62Service Training Malaga
AFA ILion DVD
Abrasive in the Oil New turbo failed after 3 weeks of service
CHAPTER: Turbochargers
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63Service Training Malaga
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
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64Service Training Malaga
AFA ILion DVD
High Exhaust Temp. Road-signs
• Much Heat Damage
- Cooked Oil
- Oxidation
- Temper Colors
• Much Bearing Wear
CHAPTER: Turbochargers
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65Service Training Malaga
AFA ILion DVD
High Exhaust Temp. Open Turbo and look inside
CHAPTER: Turbochargers
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66Service Training Malaga
AFA ILion DVD
High Exhaust Temp. CHAPTER: Turbochargers
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67Service Training Malaga
AFA ILion DVD
Foreign Object Road-signs
• Wheel Blade Damage
• Bent Center Shaft
• Normal Bearing Wear
• Wheel Separation
CHAPTER: Turbochargers
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68Service Training Malaga
AFA ILion DVD
Foreign Object Wheel Blade Damage
CHAPTER: Turbochargers
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69Service Training Malaga
AFA ILion DVD
Foreign Object Wheel Blade Damage
Uniform Bending
CHAPTER: Turbochargers
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70Service Training Malaga
AFA ILion DVD
Foreign Object Wheel Blade Damage
“Fresh Damage”
CHAPTER: Turbochargers
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71Service Training Malaga
AFA ILion DVD
Foreign Object Wheel Blade Damage
Old Damage
CHAPTER: Turbochargers
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72Service Training Malaga
AFA ILion DVD
Turbocharger Problems
• Design/Materials
• Manufacturing
CHAPTER: Turbochargers
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Design/Materials
• Wheel Burst
• Blade Fatigue
•Casting Inclusion
•Weak Wheel
CHAPTER: Turbochargers
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Wheel BurstCHAPTER: Turbochargers
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Wheel BurstCHAPTER: Turbochargers
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Wheel BurstCHAPTER: Turbochargers
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Blade FatigueCHAPTER: Turbochargers
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Blade FatigueCHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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Casting InclusionCHAPTER: Turbochargers
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85Service Training Malaga
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Manufacturing
• Weak Inertial/Friction Weld
• Bent Shafts
• Rough Bores
• Misdrilled Oil Holes
• Balancing Errors
CHAPTER: Turbochargers
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Weak Inertial/Friction WeldCHAPTER: Turbochargers
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Weak Inertial/Friction WeldCHAPTER: Turbochargers
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89Service Training Malaga
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Bent ShaftUse T bar when tightening Compressor nut
CHAPTER: Turbochargers
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Bent ShaftCHAPTER: Turbochargers
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Misdrilled Oil HolesCHAPTER: Turbochargers
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Misdrilled Oil HolesCHAPTER: Turbochargers
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Missed Oil HolesCHAPTER: Turbochargers