This a project on turbocharger. How they are made how they function.

1. TURBOCHARGERS

2. WHAT IS A TURBOCHARGER ?
• A turbocharger, colloquially known as a turbo, is a turbine-driven,
forced induction device
• It increases an internal combustion engine's efficiency and power output
by forcing extra compressed air into the combustion chamber. .

3. HISTORY OF TURBOCHARGERS
 The birth of turbocharger dates back to 1905 when
Alfred Büchi, a Swiss engineer working at Gebrüder
Sulzer patented a new technique of forced induction
which was then considered to be the birth of the
turbocharger.
 The first commercial application of a turbocharger was
in 1925, when Alfred Büchi successfully installed
turbochargers on ten-cylinder diesel engines, increasing
the power output from 1,300 to 1,860 kilowatts (1,750 to
2,500 hp). This engine was used by the German Ministry
of Transport for two large passenger ships .

4.  Before Automobile and truck manufacturers began
research into turbocharged engines during the
1950s, Turbochargers were used on several aircraft
engines during World War II, beginning with the
Boeing B-17 Flying Fortress in 1938, which used
turbochargers produced by General Electric.
 Following the 1973 oil crisis and the 1977 Clean
Air Act amendments, turbocharging became more
common in automobiles, as a method to reduce fuel
consumption and exhaust emissions

5. WORKING OF A
TURBOCHARGER
1. Air enters the engine's air intake and heads
toward the compressor.
2. The compressor fan helps to suck air in.
3. The compressor squeezes and heats up the
incoming air and blows it out again.
4. Hot, compressed air from the compressor
passes through the heat exchanger, which
cools it down.
5. Cooled, compressed air enters the cylinder's
air intake. The extra oxygen helps to burn
fuel in the cylinder at a faster rate.

6.  6. Since the cylinder burns more fuel, it
produces energy more quickly and can
send more power to the wheels via the
piston, shafts, and gears.
 7. Waste gas from the cylinder exits
through the exhaust outlet.
 8. The hot exhaust gases blowing past
the turbine fan make it rotate at high
speed.
 9. The spinning turbine is mounted on
the same shaft as the compressor (shown
here as a pale orange line). So, as the
turbine spins, the compressor spins too.
 10. The exhaust gas leaves the car,
wasting less energy than it would
otherwise.

8. CONSTRUCTION OF
TURBOCHARGERS.

9.  A turbocharger consists of a compressor wheel and
exhaust gas turbine wheel coupled together by a solid
shaft and that is used to boost the intake air pressure of
an internal combustion engine.
 In most automotive-type applications, both the
compressor and turbine wheel are of the radial flow type.
 Some applications, such as medium- and low- speed
diesel engines, can use an axial flow turbine wheel
instead of a radial flow turbine. The flow of gases through
a typical turbocharger with radial flow compressor and
turbine wheels is shown

10. TURBOCHARGER COMPONENTS
Components of The Turbocharger of Our
Project are
• Turbine.
• Air compressor
• Shaft
• Waste gate
• Lube holes or groove
• Snap rings
• Thrust
• Bearing
• Compressor &Turbine Housing

11. TURBINE
The exhaust from the cylinders passes through the
turbine blades, causing the turbine to spin.
There are two main turbine types: axial and radial flow used.
Material: K18(Special type of
stainless steel)
No Of Blades: 12 no’s
Wheel Diameter: 40mm

12. THE COMPRESSOR
Increases both density and pressure and across its vanes.
Centrifugal flow compressors are the most common in .
Air is drawn in axially, accelerated to high velocityand
then expelled in a radial direction.
Material: High quality, high
strength aluminium
alloys.
No Of Blades: 8no’s
Wheel Diameter: 50mm

13. SHAFT
It transmits the rotational motion and torque from
the turbine to the compressor.
Length: 120 mm
Diameter: Diameter is variable. MaxDiameter =8mm,Min
Diameter=5mm,
Material: K18(Special type of stainless steel)

14. Housing
Compressor housings are made of a cast aluminium alloy.
Turbine housings are made of ductile irons or nickel alloyed
ductile irons.

15. BEARINGS
 The turbocharger bearing system appears simple in design but
it plays a key role in a number of critical functions. Some of
the more important ones include: the control of radial and axial
motion of the shaft and wheels and the minimization of friction
losses in the bearing system
 The bearings that support the shaft are usually located between
the wheels in an overhung position. This flexible rotor design
ensures that the turbocharger will operate above its first, and
possibly second, critical speeds and hence be subject to rotor
dynamic conditions such as whirl and synchronous vibration.

16. SEALS
 Seals are located at both ends of the bearing housing.
 These seals primarily serve to keep intake air and
exhaust gas out of the center housing.
 The piston ring type seal is one type that is often used.
It consists of a metal ring, similar in appearance to a
piston ring

17. TURBOCHARGERS
WITH ALL
COMPONENTS

18. MATERIALS USED TO MAKE
THE COMPONENTS OF A
TURBOCHARGER
 Material called “Niresist” is used for turbine casings. It
contains: 11- 16% Ni, 2.5% Si, up to 2% Mn, 4% Cr and 8%
Cu. This material has a high heat resistance, resistance to
abrasion and corrosion.
 To build the hulls of compressors we use aluminum alloys.
 For turbine rotors material is used with the name
“Inconel” (an alloy of nickel, chromium, cobalt, iron and
nickel content of 46-65%), “MarM247 ‘(19% Cr, 9% Fe, 5%
Nb, 3% Mo, 0 9% Ti, 0.6% Al, and 0.05% C), or titanium.

19.  All of these materials used for turbine rotors are
characterized by high heat resistance, and hence high
resistance to high operating temperatures and corrosion
resistance.
 Chromiumnickel-tungsten (containing 0.25% C, 0.4% Mn,
1.5% Cr, 4.2% Ni and 1% W), in other words, structural
steels for quenching and tempering are applied to the
construction of Turbocharger.
 Bearings, which must be characterized by resistance to
high operating temperatures and abrasion resistance
usually are made of bronze alloys B102.

20. .
• It uses some of the unused energy contained
in the hot exhaust gases.
• Using turbochargers increase the engine`s power
output for the same size of engine.
• An engine fitted with a turbocharger is much
smaller and lighter than an engine producing the
same power without a turbocharger, so it provides
better fuel economy in that respect.
• They burn fuel with more oxygen, they tend to
burn it more thoroughly and cleanly, hence
producing less air pollution
WHY
TURBOCHARGERS??

21. THE EXTRA POWER.
 Turbochargers give a car more power, but that
extra power is not coming directly from the waste
exhaust gas—and that sometimes confuses people.
 A turbocharger, harnesses some of the energy in
the exhaust to drive the compressor, which allows
the engine to burn more fuel each second. This
extra fuel is where the car's extra power comes
from.
 All the exhaust gas is doing is powering the
turbocharger and, because the turbocharger isn't
connected to the car's crankshaft or wheels, it's
not directly adding to the car's driving power in
any way. It's simply enabling the same engine to
burn fuel at a faster rate, so making it more
powerful.

22. WHY TURBOCHARGERS ? NOT SUPRECHARGERS
• The turbocharger does not drain power from the engine.
• By connecting a turbocharger as much as 40% to 50% of
waste energy we can use.
EXHAUST
INTAKE AIR
CARBURETOR

23. FUEL/AIR
MIXTURE
Some of the power created is wasted to drive the
Supercharger as it is driven directly from the
engine.
EXHAUST
GASES

24. TURBOCHARGER WORKING
CONDITIONS
 The working conditions of modern turbochargers are quite heavy. As
a result, the exhaust gas temperature and pressure pulsations to
the present exhaust is necessary to use quenched and materials on
such elements as impellers, turbine casings, compressors, shafts
and plain bearings.
 For long term operations, frequent oil changes with oil filter and
air filter are required in avoiding getting particles of different
materials to the impeller of the compressor, which is very precise
and sensitive to such contaminants part.
 The most frequent damage to the turbocharger includes: impurities
in the intake air (dust, dirt, sand) impurities in the exhaust gas
(extraneous matter coming from the fuel tank, valves, etc. or
debris.) oil pollution, the oil level is too low, carbon residue
resulting from the exhaust gas temperature is too high.

25. TURBOCHARGER FAILURES
1. Thermal cracking, creep or oxidation of
parts
• Cracked turbine housing.
• Rubbing or distortion of turbine housings due to over-heating.
• Compressor housing distortion due to over-heating.
• Compressor wheel failure due to creep.
2. Fatigue of rotating parts
• Cracked compressor wheel.
• Cracked turbine wheel.
• Turbine wheel blade loss.
3. Structural failure of the turbocharger or
attached parts
• Loose bolts. • Cracked flanges.

26. SOME PARAMETERS TO AVOID THESE
FAILURES
4. Failure due to out of specification engine
conditions
• High exhaust back pressure under engine braking.
• High or variable exhaust back pressure due to aftertreatment.
5. Problems in the engine causing turbocharger
failure
• Dirty oil.
• Broken engine parts going through the turbocharger.
1. Turbocharger speed 2. Temperature • Turbine inlet
temperature. • Compressor outlet temperature. 3.
Structural loads • External load limitations. • Weight and
torque reaction of external parts. • Maximum vibration
levels. • Built in stresses due to assembly.

27. SOME PARAMETERS TO AVOID
THESE FAILURES
1. Turbocharger speed
2. Temperature
• Turbine inlet temperature.
• Compressor outlet temperature.
3. Structural loads
• External load limitations.
• Weight and torque reaction of external parts.
• Maximum vibration levels.
• Built in stresses due to assembly.
4. General ‘not to exceed limits’
• Exhaust braking back pressure. • Oil pressure.
Oil delivery delay after startup.

28. HOW TO EXTEND THE LIFE OF
TURBOCHARGERS
1. Change the engine oil regularly and religiously. Turbo impellers
reach intensely high speeds and keeping turbochargers impeller
shaft and bearing well lubricated is the first order of business.
2. Engine oil thickens when it’s cold, meaning that it doesn’t
flow as freely around the engine bay. This means that until the
oil has warmed and thinned, moving parts are at an increased
risk of wear and tear – and this is especially true of turbos. For
the first 10 minutes of driving a cold car, go easy on the
accelerator pedal to limit the strain on the oil pump and
prevent unnecessary wear and tear on the turbo system.
3. Keep the flow of air to and from the turbo as clear as can be.
4. Do not ignore the intercooler. Most turbocharged cars have
one, either air to air or air to liquid, help lower compressed air
temperatures and introduce denser air in the mixture. Always
make a note of looking over intercoolers for bent fins, debris,
or dents

29. 5. Always flush coolant regularly, and even more often if
possible.
6. Whether driving up a long hill, overtaking on road or
accelerating into the fast lane on the motorway, downshifting
into a lower gear is a safer long-term option than relying
purely on the turbocharger. Gears were built for aiding
performance up and down the rev range, so using a
combination of gear changes and turbo boost will help to limit
the wear and tear suffered through the turbo system.
7. Pressing the accelerator causes the rotating turbines in the
turbo to spin; when the engine is switched off, the flow of oil
lubricating these moving parts will stop, but the turbines
won’t stop spinning. This puts strain on the bearings, causing
friction and a build-up of heat which can lead to a failure in
the turbo system

30. o Diesel Powered Cars.
o Gasoline PoweredCars.
o Motorcycles.
o Trucks.
o Aircraft.
o Marine Engine.
o Otto cycle and diesel cycle
combustion engines.
Application Range

31. Firstly, we would like to thank our BME professor, Mr. Vishav
Kamal for approving our topic of project. Through this project
we got to know about the importance of a turbo in fuel
efficiency, more power delivery and how important it is in the
modern day world. Working on this project was an enriching
experience for us.

32. THANK YOU