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1. 1
Service Training Malaga
AFA I
Lion DVD CHAPTER: Turbochargers
Turbochargers

2. 2
Service Training Malaga
AFA I
Lion DVD CHAPTER: Turbochargers

3. 3
Service Training Malaga
AFA I
Lion DVD
In This Presentation
• Function
• Design
• Operation
• Normal wear
• Why Turbos Fail
CHAPTER: Turbochargers

4. 4
Service Training Malaga
AFA I
Lion DVD
Function
CHAPTER: Turbochargers

5. 5
Service Training Malaga
AFA I
Lion DVD
Function
CHAPTER: Turbochargers

6. 6
Service Training Malaga
AFA I
Lion DVD
Turbocharger Functions
• Normalize Air Supply
• Boost Air Supply
CHAPTER: Turbochargers

7. 7
Service Training Malaga
AFA I
Lion 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

8. 8
Service Training Malaga
AFA I
Lion DVD
Normalizing
First commercial use 1940’s in Airplane
CHAPTER: Turbochargers

9. 9
Service Training Malaga
AFA I
Lion DVD
Boosting
• More Oxygen / Increased Fuel Setting
• Higher Power
• Better Combustion
- Better Fuel Economy
- Cleaner Emissions
•Quieter
CHAPTER: Turbochargers

10. 10
Service Training Malaga
AFA I
Lion DVD
Boosting
CHAPTER: Turbochargers

11. 11
Service Training Malaga
AFA I
Lion DVD
Design
CHAPTER: Turbochargers

12. 12
Service Training Malaga
AFA I
Lion DVD
Design Waste-Gate Turbo
CHAPTER: Turbochargers

13. 13
Service Training Malaga
AFA I
Lion DVD
Design Lubrication System
Lubricating
Cooling
Cleaning
CHAPTER: Turbochargers

14. 14
Service Training Malaga
AFA I
Lion DVD
Design Lubrication System
Direct lubrication line to Turbo
CHAPTER: Turbochargers

15. 15
Service Training Malaga
AFA I
Lion DVD
Design Lubrication System
CHAPTER: Turbochargers

16. 16
Service Training Malaga
AFA I
Lion DVD
Design Lubrication System
CHAPTER: Turbochargers

17. 17
Service Training Malaga
AFA I
Lion DVD
Design Friction Welding
Hollow thermal barrier
Centering Pin
CHAPTER: Turbochargers

18. 18
Service Training Malaga
AFA I
Lion DVD
Design Induction hardened Shaft
CHAPTER: Turbochargers

19. 19
Service Training Malaga
AFA I
Lion DVD
Design Compressor wheel
High Strength Aluminum alloys
CHAPTER: Turbochargers

20. 20
Service Training Malaga
AFA I
Lion DVD
Design Compressor wheel
Balancing Notches
CHAPTER: Turbochargers

21. 21
Service Training Malaga
AFA I
Lion DVD
Design Compressor wheel
Radial milling
CHAPTER: Turbochargers

22. 22
Service Training Malaga
AFA I
Lion DVD
Design Free-floating journal bearings
Copper/tin/lead alloy or from aluminium
Lube holes or groove
CHAPTER: Turbochargers

23. 23
Service Training Malaga
AFA I
Lion DVD
Design Snap rings
Rounded edge towards the bearing
CHAPTER: Turbochargers

24. 24
Service Training Malaga
AFA I
Lion DVD
Copper/tin/lead alloy or from aluminium
Design Thrust Bearing
Bearing stationary
Washer full shaft RPM
CHAPTER: Turbochargers

25. 25
Service Training Malaga
AFA I
Lion DVD
Design Seal Rings
High temperature resistant chrome alloy
Cold side cast iron
End gap
CHAPTER: Turbochargers

26. 26
Service Training Malaga
AFA I
Lion DVD
Design Housing
Cast aluminum alloy
Cast Iron
Cast ductile iron or nickel alloy
CHAPTER: Turbochargers

27. 27
Service Training Malaga
AFA I
Lion DVD
Design Heat Shield
Protects center housing from high
exhaust temperatures
CHAPTER: Turbochargers

28. 28
Service Training Malaga
AFA I
Lion DVD
Operation Start-up
CHAPTER: Turbochargers

29. 29
Service Training Malaga
AFA I
Lion DVD
Operation Turbos are matched
CHAPTER: Turbochargers

30. 30
Service Training Malaga
AFA I
Lion DVD
Operation Air Restriction
Turbo spin 80 000 Rpm
Surface speed 30m/second
Energy stored in rotating
component can equal the
engine HP
CHAPTER: Turbochargers

31. 31
Service Training Malaga
AFA I
Lion DVD
Normal Wear
Increased clearance
CHAPTER: Turbochargers

32. 32
Service Training Malaga
AFA I
Lion DVD
Normal Wear Hot side
Little leak past the seal ring
CHAPTER: Turbochargers

33. 33
Service Training Malaga
AFA I
Lion DVD
Normal Wear Turbine Wheel
No discoloration
Seal ring with gap separation
CHAPTER: Turbochargers

34. 34
Service Training Malaga
AFA I
Lion DVD
Normal Wear Bearings
More wear on hot side
CHAPTER: Turbochargers

35. 35
Service Training Malaga
AFA I
Lion DVD
Normal Wear Thrust Bearing
Fine abrasive wear
CHAPTER: Turbochargers

36. 36
Service Training Malaga
AFA I
Lion DVD
Normal Wear Thrust washers
CHAPTER: Turbochargers

37. 37
Service Training Malaga
AFA I
Lion DVD
• Lack of Lubrication
• Abrasive in the Oil
• High Exhaust Temperature
• Foreign Objects
• Turbo Problems
Why Turbos Fail
CHAPTER: Turbochargers

38. 38
Service Training Malaga
AFA I
Lion DVD
• Temper Colors/ Cooked Oil
• Adhesive Wear
• Weakened Metal
• Wheel Contact with Housing
• Wheel separation from Shaft
Lack of Lube Road-signs
CHAPTER: Turbochargers

39. 39
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication Housing Contact
CHAPTER: Turbochargers

40. 40
Service Training Malaga
AFA I
Lion DVD
Temper colors and cooked oil residue
Lack of Lubrication Housing Contact
CHAPTER: Turbochargers

41. 41
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

42. 42
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

43. 43
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

44. 44
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

45. 45
Service Training Malaga
AFA I
Lion DVD
Rapid Shutdown
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

46. 46
Service Training Malaga
AFA I
Lion DVD
Cooked oil residual
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

47. 47
Service Training Malaga
AFA I
Lion DVD
Quench dots/rings
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

48. 48
Service Training Malaga
AFA I
Lion DVD
Bushing stuck to shaft
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

49. 49
Service Training Malaga
AFA I
Lion DVD
Turbine wheel separation
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

50. 50
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
CHAPTER: Turbochargers

51. 51
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
Adhesive wear and
Thermal cracking
CHAPTER: Turbochargers

52. 52
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
Discoloration
CHAPTER: Turbochargers

53. 53
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication High Temperature
Ductile Fracture
Discoloration
CHAPTER: Turbochargers

54. 54
Service Training Malaga
AFA I
Lion DVD
Lack of Lubrication
WHY
CHAPTER: Turbochargers

55. 55
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil Road-signs
• Scratches, Cuts, Grooves
• Little Heat Damage
• Rapid Wear
• Embedded Debris
CHAPTER: Turbochargers

56. 56
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil Extended Oilchange Intervals
Excessive shaft motion
CHAPTER: Turbochargers

57. 57
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
CHAPTER: Turbochargers

58. 58
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
Exhaust carbon cause fine abrasive cutting
Missing Hot side Seal
CHAPTER: Turbochargers

59. 59
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
CHAPTER: Turbochargers

60. 60
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
CHAPTER: Turbochargers

61. 61
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
CHAPTER: Turbochargers

62. 62
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
New turbo failed after 3 weeks of service
CHAPTER: Turbochargers

63. 63
Service Training Malaga
AFA I
Lion 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

64. 64
Service Training Malaga
AFA I
Lion DVD
High Exhaust Temp. Road-signs
• Much Heat Damage
- Cooked Oil
- Oxidation
- Temper Colors
• Much Bearing Wear
CHAPTER: Turbochargers

65. 65
Service Training Malaga
AFA I
Lion DVD
High Exhaust Temp.
Open Turbo and look inside
CHAPTER: Turbochargers

66. 66
Service Training Malaga
AFA I
Lion DVD
High Exhaust Temp.
CHAPTER: Turbochargers

67. 67
Service Training Malaga
AFA I
Lion DVD
Foreign Object Road-signs
• Wheel Blade Damage
• Bent Center Shaft
• Normal Bearing Wear
• Wheel Separation
CHAPTER: Turbochargers

68. 68
Service Training Malaga
AFA I
Lion DVD
Foreign Object Wheel Blade Damage
CHAPTER: Turbochargers

69. 69
Service Training Malaga
AFA I
Lion DVD
Foreign Object Wheel Blade Damage
Uniform Bending
CHAPTER: Turbochargers

70. 70
Service Training Malaga
AFA I
Lion DVD
Foreign Object Wheel Blade Damage
“Fresh Damage”
CHAPTER: Turbochargers

71. 71
Service Training Malaga
AFA I
Lion DVD
Foreign Object Wheel Blade Damage
Old Damage
CHAPTER: Turbochargers

72. 72
Service Training Malaga
AFA I
Lion DVD
Turbocharger Problems
• Design/Materials
• Manufacturing
CHAPTER: Turbochargers

73. 73
Service Training Malaga
AFA I
Lion DVD
Design/Materials
• Wheel Burst
• Blade Fatigue
•Casting Inclusion
•Weak Wheel
CHAPTER: Turbochargers

74. 74
Service Training Malaga
AFA I
Lion DVD
Wheel Burst
CHAPTER: Turbochargers

75. 75
Service Training Malaga
AFA I
Lion DVD
Wheel Burst
CHAPTER: Turbochargers

76. 76
Service Training Malaga
AFA I
Lion DVD
Wheel Burst
CHAPTER: Turbochargers

77. 77
Service Training Malaga
AFA I
Lion DVD
Wheel Burst
CHAPTER: Turbochargers

78. 78
Service Training Malaga
AFA I
Lion DVD
Blade Fatigue
CHAPTER: Turbochargers

79. 79
Service Training Malaga
AFA I
Lion DVD
Blade Fatigue
CHAPTER: Turbochargers

80. 80
Service Training Malaga
AFA I
Lion DVD CHAPTER: Turbochargers

81. 81
Service Training Malaga
AFA I
Lion DVD
Casting Inclusion
CHAPTER: Turbochargers

82. 82
Service Training Malaga
AFA I
Lion DVD
Casting Inclusion
CHAPTER: Turbochargers

83. 83
Service Training Malaga
AFA I
Lion DVD
Casting Inclusion
CHAPTER: Turbochargers

84. 84
Service Training Malaga
AFA I
Lion DVD
Casting Inclusion
CHAPTER: Turbochargers

85. 85
Service Training Malaga
AFA I
Lion DVD
Manufacturing
• Weak Inertial/Friction Weld
• Bent Shafts
• Rough Bores
• Misdrilled Oil Holes
• Balancing Errors
CHAPTER: Turbochargers

86. 86
Service Training Malaga
AFA I
Lion DVD
Weak Inertial/Friction Weld
CHAPTER: Turbochargers

87. 87
Service Training Malaga
AFA I
Lion DVD
Weak Inertial/Friction Weld
CHAPTER: Turbochargers

88. 88
Service Training Malaga
AFA I
Lion DVD
Weak Inertial/Friction Weld
CHAPTER: Turbochargers

89. 89
Service Training Malaga
AFA I
Lion DVD
Bent Shaft
Use T bar when tightening Compressor nut
CHAPTER: Turbochargers

90. 90
Service Training Malaga
AFA I
Lion DVD
Bent Shaft
CHAPTER: Turbochargers

91. 91
Service Training Malaga
AFA I
Lion DVD
Misdrilled Oil Holes
CHAPTER: Turbochargers

92. 92
Service Training Malaga
AFA I
Lion DVD
Misdrilled Oil Holes
CHAPTER: Turbochargers

93. 93
Service Training Malaga
AFA I
Lion DVD
Missed Oil Holes
CHAPTER: Turbochargers