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Turbocharger Surge
Turbocharger surge is an unstable aerodynamic condition in a turbocharger compressor when there is a disruption in the balance of airflow through the turbocharger. This imbalance causes a rapid reversal of airflow in the turbo compressor, leading to unstable operations like oscillations and distinctive fluttering noise. If such conditions remain, it may reduce performance and potentially cause premature turbo failure. Causes of Turbocharger Surge 1. Operating Outside the Compressor’s Stable Map Region - Low Mass Flow Condition: When the engine is running at low load or during rapid deceleration, the airflow through the compressor may drop below the optimal range of...
5 Commons Factors for Turbo Oil Leakage
Turbo oil leakage can result from a variety of factors, in this discussion we’ll pick 5 common factors for oil leakage – clogged air filter, poor oil return, leak in the exhaust system, increased crankcase pressure, and a collapsed turbine piston ring. A turbocharger should not leak oil under proper installation; however, oil leaks may lead to catastrophic damage to the bearing systems. Clogged Air Filter An air filter keeps dirt and debris from entering the engine. A clogged filter can lead to several problems, impeding the engine to work properly. Cause: A clogged air filter restricts airflow into the...
Choosing Between IWG or EWG
Wastegates are critical for regulating boost pressure by controlling the flow of exhaust gases into the turbo; therefore, you must carefully choose between internal wastegated (IWG) turbocharger or external wastegate (EWG) turbocharger. Internal Wastegates (IWG) Design IWGs use an actuator to control the boost output and divert excess gases from the turbine wheel. They are integrated within the turbocharger housing. Advantages: Compactness: Due to their integrated design, it saves more space for engine bays with limited room. Usually applied on OEM applications. Cost Effectiveness: IWG is much easier to install and is less costly than an EWG due to fewer...
When is water-cooling setup necessary for a turbocharger?
Every turbocharger has different cooling setups by default. Oil-cooled and water-cooled turbochargers are two common types of turbo cooling systems. In general, you see turbo with only oil-cooling system on journal bearing turbocharger, although this does not apply to all of the journal bearing turbos; some journal bearing turbos have both oil and water-cooling systems. However, due to their mechanical design nature, all ball bearing system turbos are basically required to cool by both oil and water. Below we’ll discuss about water and oil cooling differences and their various characteristics. Cooling Method As turbochargers operate under high temperature, cooling during...
Journal Bearing Turbo vs. Ball Bearing Turbo
When choosing a turbocharger, the very first thing to decide on is whether you’d like to use a journal bearing turbocharger or ball bearing turbocharger. These are two common types of bearing systems used in turbochargers, each offering unique performance characteristics. We’ll be discussing the key differences between these two systems below. Design and Operation Looking at a turbocharger from its appearance we’re unable to tell whether it’s a ball bearing or journal bearing turbo. The bearing system lies inside the cartridge; when you open up the cartridge you’ll see the design of ball bearing and journal bearing system completely...