Abstract: A method of manufacturing a variable vane mechanism includes arranging a vane and a spacer between a first support structure and a tool member of a tool. The method also includes abutting a first inner surface of the first support structure against a first side surface of the vane and a second side surface of the vane against an opposing surface of the tool member, leaving a control surface of the spacer projecting from the first support structure at a predetermined distance. The method further includes fixedly attaching the spacer to the first support structure with the control surface of the spacer projecting from the first support structure at the predetermined distance. The method further includes abutting a second support structure on the control surface of the spacer to define a gap between the first support structure and the second support structure with the vane disposed within the gap.

Abstract: A method of manufacturing a variable vane mechanism includes arranging a vane and a spacer between a first support structure and a tool member of a tool. The method also includes abutting a first inner surface of the first support structure against a first side surface of the vane and a second side surface of the vane against an opposing surface of the tool member, leaving a control surface of the spacer projecting from the first support structure at a predetermined distance. The method further includes fixedly attaching the spacer to the first support structure with the control surface of the spacer projecting from the first support structure at the predetermined distance. The method further includes abutting a second support structure on the control surface of the spacer to define a gap between the first support structure and the second support structure with the vane disposed within the gap.

Abstract: A turbine housing assembly seal can include a cylindrical portion that defines an opening having an axis where the cylindrical portion is disposed at a cylinder radius from the axis; a lower edge disposed at a lower edge radius that exceeds the cylinder radius; an sloped annular portion that extends radially inwardly from the lower edge; a lower bend that extends from the sloped annular portion to a lower axial position of the cylindrical portion; an upper bend that extends from an upper axial position of the cylindrical portion; and an upper edge that extends radially outwardly from the upper bend to an upper edge radius that exceeds the cylinder radius and that is less than the lower edge radius.

Abstract: A turbocharger having a variable-nozzle turbine formed by pivotable vanes supported by a nozzle ring includes a locator that is radially elastically deformable and is disposed between a radially outwardly facing surface of the center housing and an opposing surface of the nozzle ring for radially locating the nozzle ring relative to the center housing. At least one vent is defined in either a radially outermost surface of the locator or the surface of the nozzle ring to allow pressure communication between spaces on axially opposite sides of the locator.

Abstract: An exhaust gas variable geometry turbine assembly can include a number of pivotable vanes that define throats within an exhaust gas nozzle where each of the pivotable vanes includes a corresponding post, where each of the pivotable vanes is made of a first alloy that includes a first amount of nickel by mass, where each of the corresponding posts is made of a second alloy that includes a second amount of nickel by mass and where the second amount of nickel by mass exceeds the first amount of nickel by mass.

Abstract: A turbocharger having a variable-nozzle turbine formed by pivotable vanes supported by a nozzle ring includes an elastically deformable locator disposed between a radially outwardly facing surface of the center housing and an opposing surface of the nozzle ring. In one embodiment the locator is a metallic ring having a radially undulating waveform shape that repeats a plurality of times about a circumference of the locator. In another embodiment the locator is a metallic ring having a C-shaped cross-section in a radial-axial plane. In still another embodiment the locator is a metallic ring having an S-shaped cross-section in a radial-axial plane. In a further embodiment the locator is a plurality of circumferentially spaced, radial locator pins affixed in the center housing and received in radial slots formed in the nozzle ring, the pins restraining the nozzle ring circumferentially and axially but allowing thermal expansion of the nozzle ring.

Abstract: A turbocharger having a variable-nozzle turbine formed by pivotable vanes supported by a nozzle ring includes a locator that is radially elastically deformable and is disposed between a radially outwardly facing surface of the center housing and an opposing surface of the nozzle ring for radially locating the nozzle ring relative to the center housing. At least one vent is defined in either a radially outermost surface of the locator or the surface of the nozzle ring to allow pressure communication between spaces on axially opposite sides of the locator.

Abstract: A variable-nozzle turbocharger includes a variable vane mechanism that has an annular nozzle ring supporting an array of rotatable vanes, an insert having a tubular portion sealingly received into a bore of the turbine housing and having a nozzle portion extending radially out from one end of the tubular portion and being axially spaced from the nozzle ring with the vanes therebetween, and a plurality of two-piece self-centering spacer assemblies connected between the nozzle portion of the insert and the nozzle ring. Each spacer assembly comprises a tubular sleeve and a separate pin that passes through the through-passage of the sleeve, end portions of the pin being secured respectively to the nozzle ring and the nozzle portion. One end of each sleeve has a conical surface and engages in a corresponding conical countersink in the adjacent face of the nozzle ring or nozzle portion.

Abstract: An assembly can include a turbine wheel; a turbine housing that includes a lower turbine housing surface that extends from an exhaust volute to a cylindrical surface that defines an upper portion of a turbine wheel space; a shroud component that includes a contoured surface disposed between an inner end of an upper shroud component surface and an inner end of a lower shroud component surface where the contoured surface defines a lower portion of a turbine wheel space; and a seal mechanism where the turbine housing and the shroud component form an axial gap between a lower axial position of the cylindrical surface and an upper axial position of the contoured surface where the axial gap is axially positioned between an axial position of an inducer portion of the turbine wheel and an axial position of an exducer portion of the turbine wheel.

Abstract: A turbocharger having a variable-nozzle turbine formed by pivotable vanes supported by a nozzle ring includes an elastically deformable locator disposed between a radially outwardly facing surface of the center housing and an opposing surface of the nozzle ring. In one embodiment the locator is a metallic ring having a radially undulating waveform shape that repeats a plurality of times about a circumference of the locator. In another embodiment the locator is a metallic ring having a C-shaped cross-section in a radial-axial plane. In still another embodiment the locator is a metallic ring having an S-shaped cross-section in a radial-axial plane. In a further embodiment the locator is a plurality of circumferentially spaced, radial locator pins affixed in the center housing and received in radial slots formed in the nozzle ring, the pins restraining the nozzle ring circumferentially and axially but allowing thermal expansion of the nozzle ring.

Abstract: An exhaust gas variable geometry turbine assembly can include a number of pivotable vanes that define throats within an exhaust gas nozzle where each of the pivotable vanes includes a corresponding post, where each of the pivotable vanes is made of a first alloy that includes a first amount of nickel by mass, where each of the corresponding posts is made of a second alloy that includes a second amount of nickel by mass and where the second amount of nickel by mass exceeds the first amount of nickel by mass.

Abstract: A turbine assembly for a turbocharger can include a C-shaped seal that includes an inner diameter, an outer diameter, an axis aligned parallel to a rotational axis of a turbine wheel, a lower lip that contacts a lower axial face of an outer surface of a shroud component along an annular portion of the shroud component, an upper lip that contacts a lower axial face of an inner surface of a turbine housing, and a wall portion that extends between the lower lip and the upper lip. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A compressor housing assembly for a turbocharger can include a compressor housing shell that includes an axis for alignment with a rotational axis of a compressor wheel, a wall that includes features defined in part by radii with respect to the axis, and an edge that defines in part an inlet opening of a shroud port; and an insert that includes a shroud section and a noise suppressor section that define a recirculation port where the insert is axially located by the wall of the compressor housing shell, where an internal recirculation passage is defined in part by the insert and the wall, and where an edge of the shroud section (e.g., a lowermost edge) defines in part the inlet opening of the shroud port.

Abstract: A turbine housing assembly seal can include a cylindrical portion that defines an opening having an axis where the cylindrical portion is disposed at a cylinder radius from the axis; a lower edge disposed at a lower edge radius that exceeds the cylinder radius; an sloped annular portion that extends radially inwardly from the lower edge; a lower bend that extends from the sloped annular portion to a lower axial position of the cylindrical portion; an upper bend that extends from an upper axial position of the cylindrical portion; and an upper edge that extends radially outwardly from the upper bend to an upper edge radius that exceeds the cylinder radius and that is less than the lower edge radius.

Abstract: An assembly can include a turbine wheel; a turbine housing that includes a lower turbine housing surface that extends from an exhaust volute to a cylindrical surface that defines an upper portion of a turbine wheel space; a shroud component that includes a contoured surface disposed between an inner end of an upper shroud component surface and an inner end of a lower shroud component surface where the contoured surface defines a lower portion of a turbine wheel space; and a seal mechanism where the turbine housing and the shroud component form an axial gap between a lower axial position of the cylindrical surface and an upper axial position of the contoured surface where the axial gap is axially positioned between an axial position of an inducer portion of the turbine wheel and an axial position of an exducer portion of the turbine wheel.

Abstract: A variable-nozzle turbocharger includes a variable vane mechanism that has an annular nozzle ring supporting an array of rotatable vanes, an insert having a tubular portion sealingly received into a bore of the turbine housing and having a nozzle portion extending radially out from one end of the tubular portion and being axially spaced from the nozzle ring with the vanes therebetween, and a plurality of two-piece self-centering spacer assemblies connected between the nozzle portion of the insert and the nozzle ring. Each spacer assembly comprises a tubular sleeve and a separate pin that passes through the through-passage of the sleeve, end portions of the pin being secured respectively to the nozzle ring and the nozzle portion. One end of each sleeve has a conical surface and engages in a corresponding conical countersink in the adjacent face of the nozzle ring or nozzle portion.

Abstract: An assembly can include vanes and a base configured to seat the vanes at a radial distance about an axis where each vane includes a leading edge and a trailing edge, a pair of lateral surfaces that meet at the leading edge and at the trailing edge, an extension that extends from one of the lateral surfaces and that has a contact surface, and a stop surface to form a contact with a contact surface of another vane to define a minimum flow distance between the vane and the other vane. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A variable-vane assembly for a variable nozzle turbine comprises a nozzle ring supporting a plurality of vanes affixed to vane arms that are engaged in recesses in the inner edge of a unison ring. The unison ring is rotatable about the axis of the nozzle ring so as to pivot the vane arms, thereby pivoting the vanes in unison. A plurality of guide pins for the unison ring are inserted into apertures in the nozzle ring and are rigidly affixed therein such that the guide pins are non-rotatably secured to the nozzle ring with a guide portion of each guide pin projecting axially from the face of the nozzle ring. Each guide portion defines a shoulder radially overlapping the inner edge of the unison ring such that the unison ring is restrained by the guide pins against excessive movement in both radial and axial directions.

Abstract: A compressor housing assembly for a turbocharger can include a compressor housing shell that includes an axis for alignment with a rotational axis of a compressor wheel, a wall that includes features defined in part by radii with respect to the axis, and an edge that defines in part an inlet opening of a shroud port; and an insert that includes a shroud section and a noise suppressor section that define a recirculation port where the insert is axially located by the wall of the compressor housing shell, where an internal recirculation passage is defined in part by the insert and the wall, and where an edge of the shroud section (e.g., a lowermost edge) defines in part the inlet opening of the shroud port. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbine assembly for a turbocharger can include a C-shaped seal that includes an inner diameter, an outer diameter, an axis aligned parallel to a rotational axis of a turbine wheel, a lower lip that contacts a lower axial face of an outer surface of a shroud component along an annular portion of the shroud component, an upper lip that contacts a lower axial face of an inner surface of a turbine housing, and a wall portion that extends between the lower lip and the upper lip. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.