Borgwarner Inc.

Sean Rylance

Rob Daniels

James Finley

Andrew Paul Day

Rolf Sauerstein

James Mawer

Steve Birnie

Nathan McArdle

Sanjit Chaggar

Michael Fischer

Philip Christoph Parma

Martin Bihy

Simon Malins

Kiumars Shoghi

Martin Jarvis

An exhaust gas turbocharger () including a compressor housing (), a bearing housing (), a turbine housing () in which a turbine wheel () is arranged, which has a housing inlet (), which has a turbine spiral () connecting to the housing inlet (), which has a housing outlet (), and which has a wastegate arrangement (), which in the open state brings the housing inlet () into flow connection with the housing outlet () for guiding a wastegate mass flow. The wastegate insert part () is arranged in the turbine housing () between the turbine wheel () and the housing outlet () and the open wastegate arrangement () introduces the wastegate mass flow into the wastegate insert arrangement ().

Exhaust gas turbocharger

A bearing housing, or integrated turbocharger housing, with the oil, and optionally air and water galleries, included as as-cast features, thereby avoiding the problems, design limitations and expense associated with conventional post-casting machining. The method of casting preferably uses lost foam casting, or a technique similar to lost foam casting but in which a ceramic shell is formed on the foam form prior to metal casting, but can use any of a variety of casting techniques or a combination of two or more techniques.

Integrated turbocharger casting

A turbocharger () includes a compressor section and a cast turbine section. The turbine section includes a turbine wheel (), and a turbine housing () that defines a gas inlet (), a gas outlet (), a volute () disposed between the gas inlet () and the gas outlet (). The turbine housing () also includes vanes () that protrude integrally from, and have a fixed orientation relative to, an inner surface of the turbine housing (). The turbine wheel () is disposed in the turbine housing () between the volute () and the gas outlet (), and the vanes () are disposed in the turbine housing () between the turbine wheel () and the volute (). A method of casting the turbine housing () and the vanes () together as a single piece is described.

Cast turbocharger turbine housing having guide vanes

Conventionally, turbocharger bearing housings are cast, and then oil passageways are drilled or bored into the casting. As a result, bores are limited to straight lines extending from drill access points. Greater design flexibility is provided by pre-staging in a mold a collection of metal pipes which will define one or more of oil, air and water galleries, and then casting a bearing housing around the pipes. This provides almost unlimited freedom in shaping and locating the oil bores and other features.

Turbocharger bearing housing with cast-in pipes

A turbine () section of a turbocharger () includes a turbine wheel () disposed in a turbine housing (), the turbine housing () defining a gas inlet (), a volute configured to direct gas from the inlet () to the turbine () wheel, and a gas outlet. A rotary diverter valve () is disposed in the gas inlet () upstream of the volute, and provides three modes of controlling exhaust gas flow about the turbocharger ().

Rotatable diverter valve

A product for use with a turbocharger that may include a complex sealing path between a lubricated area of a housing and a compressor wheel.

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Barnsley, United Kingdom

Sean Rylance