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 turbocharger includes a variable vane mechanism includes a unison ring and at least one bearing member that is fixed to the unison ring. The bearing member includes a bearing surface that supports rotation of the unison ring within the variable vane mechanism. The unison ring and the at least one bearing member have independent material characteristics.

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 turbocharger includes a variable vane mechanism includes a unison ring and at least one bearing member that is fixed to the unison ring. The bearing member includes a bearing surface that supports rotation of the unison ring within the variable vane mechanism. The unison ring and the at least one bearing member have independent material characteristics.

Abstract: An assembly for a two-stage turbocharger can include a first turbocharger stage and a second turbocharger stage where one of the stages includes a boss that includes a bore; an exhaust bypass valve that includes an arm pivotable to orient the exhaust bypass valve in an open state and a closed state; a valve shaft disposed at least in part in the bore and operatively coupled to the exhaust bypass valve where the valve shaft includes an inner end, an outer end and an axial stop disposed between the inner end and the outer end; an outer bushing disposed at least in part in the bore and located axially along the valve shaft; and an inner bushing disposed at least in part in the bore and located axially along the valve shaft between the axial stop and a portion of the arm of the exhaust bypass valve.

Abstract: An assembly for a two-stage turbocharger can include a first turbocharger stage and a second turbocharger stage where one of the stages includes a boss that includes a bore; an exhaust bypass valve that includes an arm pivotable to orient the exhaust bypass valve in an open state and a closed state; a valve shaft disposed at least in part in the bore and operatively coupled to the exhaust bypass valve where the valve shaft includes an inner end, an outer end and an axial stop disposed between the inner end and the outer end; an outer bushing disposed at least in part in the bore and located axially along the valve shaft; and an inner bushing disposed at least in part in the bore and located axially along the valve shaft between the axial stop and a portion of the arm of the exhaust bypass valve.

Abstract: An assembly can include a valve seat for an exhaust bypass valve of a serial turbocharger system; and a gasket that includes a planar portion that defines a perimeter and that includes a tab that extends from the perimeter of the planar portion for engagement with the valve seat to secure the gasket to the valve seat. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: An assembly can include a valve seat for an exhaust bypass valve of a serial turbocharger system; and a gasket that includes a planar portion that defines a perimeter and that includes a tab that extends from the perimeter of the planar portion for engagement with the valve seat to secure the gasket to the valve seat. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A fluid pressure actuator for a turbocharger system's turbine bypass valve comprises a piston slidable in a cylinder so as to define a chamber containing a compression spring assembly operable to exert a spring force on the piston. The cylinder can be selectively subjected to a vacuum or pressure for exerting a fluid pressure force on the piston in a direction opposite from the spring force. The spring assembly comprises a first spring arranged to be compressed by the piston throughout a first range of motion of the piston in a compression direction, and at least a second spring arranged to be compressed by the piston throughout a second range of motion that is smaller than and co-terminal with the first range of motion but to be uncompressed during an initial part of the first range of motion of the piston in the compression direction.

Abstract: A subassembly of a system including an exhaust gas turbocharger system coupled with an internal combustion engine exhaust system, includes first and second components secured to each other, wherein the components are heated to an operational temperature by engine exhaust gases during engine operation. The components are secured to each other by or with a “low-melt material” whose melting temperature is less than the operational temperature, such that the low-melt material melts or at least loses its securing and/or positioning functionality upon operation of the engine and turbocharger system, and thus no longer performs any fastening or positioning function for the components. In some embodiments, temporary fasteners made of or including the low-melt material are employed for temporarily securing and positioning the components.

Abstract: A fluid pressure actuator for a turbocharger system's turbine bypass valve comprises a piston slidable in a cylinder so as to define a chamber containing a compression spring assembly operable to exert a spring force on the piston. The cylinder can be selectively subjected to a vacuum or pressure for exerting a fluid pressure force on the piston in a direction opposite from the spring force. The spring assembly comprises a first spring arranged to be compressed by the piston throughout a first range of motion of the piston in a compression direction, and at least a second spring arranged to be compressed by the piston throughout a second range of motion that is smaller than and co-terminal with the first range of motion but to be uncompressed during an initial part of the first range of motion of the piston in the compression direction.

Abstract: A subassembly of a system including an exhaust gas turbocharger system coupled with an internal combustion engine exhaust system, comprises first and second components secured to each other, wherein the components are heated to an operational temperature by engine exhaust gases during engine operation. The components are secured to each other by or with a “low-melt material”, i.e., a material whose melting temperature is less than the operational temperature, such that the low-melt material melts or at least loses its securing and/or positioning functionality upon operation of the engine and turbocharger system, and thus no longer performs any fastening or positioning function for the components. In some embodiment, temporary fasteners made of or including the low-melt material are employed for temporarily securing and positioning the components.