Abstract: A turbocharger assembly includes a compressor wheel with a base surface, a nose surface, a z-plane disposed between the base surface and the nose surface and a bore extending from the base surface to the nose surface and a shaft that includes a first pilot surface disposed in the bore of the compressor wheel at a position between the z-plane and the nose surface, a second pilot surface disposed in the bore of the compressor wheel at a position between the z-plane and the base surface, and a recessed surface disposed between the first pilot surface and the second pilot surface. A nut adjustably disposed on the shaft adjacent to the nose surface can tension the shaft to apply a compressive load between the base surface and the nose surface of the compressor wheel. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbocharger has an annular bypass valve disposed in an annular portion of a bypass passage of the turbine housing. The turbine housing defines an exhaust gas chamber having separate half-annular first and second scrolls, and a portion of the bypass passage is sector-divided by a pair of dividing walls that create two 180-degree bypass sectors respectively connected to the first and second scrolls. Each dividing wall has a through-hole. The valve rotor defines a pair of valve members that close the through-holes when the bypass valve is fully closed. When the valve rotor begins to rotate toward an open position, first the valve members open the through-holes to connect the two bypass sectors, and then the bypass flow passages begin to open.

Abstract: A turbocharger has an annular bypass valve disposed in an annular portion of a bypass passage of the turbine housing. The turbine housing defines an exhaust gas chamber having separate half-annular first and second scrolls, and a portion of the bypass passage is sector-divided by a pair of dividing walls that create two 180-degree bypass sectors respectively connected to the first and second scrolls. Each dividing wall has a through-hole. The valve rotor defines a pair of valve members that close the through-holes when the bypass valve is fully closed. When the valve rotor begins to rotate toward an open position, first the valve members open the through-holes to connect the two bypass sectors, and then the bypass flow passages begin to open.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism in an air inlet for the compressor, operable to move between an open position and a closed position in the air inlet. The inlet-adjustment mechanism includes a variable-geometry orifice actuated by a rotatable actuator ring. In the closed position, the orifice's inner diameter is smaller than that of a shroud surface of the compressor housing and therefore dictates the effective inlet diameter for the compressor. In the open position the orifice no longer forms an inner diameter smaller than the shroud surface, so that the effective inlet diameter is determined by the shroud surface.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism in an air inlet for the compressor, operable to move between an open position and a closed position in the air inlet. The inlet-adjustment mechanism includes a variable-geometry conduit comprising a plurality of vanes that in the closed position collectively form a converging inlet member having a trailing edge inner diameter that is smaller than an inner diameter of the shroud surface of the compressor housing at the inducer portion of the compressor wheel such that an effective diameter of the air inlet at the inducer portion is determined by the trailing edge inner diameter of the variable-geometry conduit. The vanes in the open position are pivoted radially outwardly so as to increase the trailing edge inner diameter of the inlet member and thereby increase the effective diameter of the air inlet at the inducer portion.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism in an air inlet for the compressor, operable to move between an open position and a closed position in the air inlet. The inlet-adjustment mechanism includes a variable-geometry conduit comprising a plurality of vanes that in the closed position collectively form a converging inlet member having a trailing edge inner diameter that is smaller than an inner diameter of the shroud surface of the compressor housing at the inducer portion of the compressor wheel such that an effective diameter of the air inlet at the inducer portion is determined by the trailing edge inner diameter of the variable-geometry conduit. The vanes in the open position are pivoted radially outwardly so as to increase the trailing edge inner diameter of the inlet member and thereby increase the effective diameter of the air inlet at the inducer portion.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism in an air inlet for the compressor, operable to move between an open position and a closed position in the air inlet. The inlet-adjustment mechanism includes a variable-geometry orifice actuated by a rotatable actuator ring. In the closed position, the orifice's inner diameter is smaller than that of a shroud surface of the compressor housing and therefore dictates the effective inlet diameter for the compressor. In the open position the orifice no longer forms an inner diameter smaller than the shroud surface, so that the effective inlet diameter is determined by the shroud surface.

Abstract: An assembly for a turbocharger can include a locating washer having an axis and a perimeter that includes a chord segment defined by an apothem measured from the axis; a bearing assembly that includes an outer race having an axis and a perimeter that includes a chord segment defined by an apothem measured from the axis; and a housing that includes a bore for receipt of the bearing assembly and a recess for receipt of the locating washer to space apart the axes of the locating washer and the outer race by a distance greater than the sum of the apothems that provides for contact between the chord segments upon rotation of at least one of the locating washer in the recess and the outer race in the bore. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbocharger assembly includes: a housing with a through-bore and a cross-bore that intersects the through-bore to define an upper portion of the cross-bore with a first diameter and a lower portion of the cross-bore with a second diameter where the first diameter exceeds the second diameter; a bearing disposed in the through-bore of the housing where the bearing includes a through-bore configured to support a shaft and a cross-bore that intersects the through-bore; and a locating pin with a diameter that exceeds the second diameter of the lower portion of the cross-bore of the housing, the locating pin press-fit at least partially into the lower portion of the cross-bore of the housing and disposed at least partially in the lower portion of the cross-bore of the bearing to locate the bearing in the through-bore of the housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: An assembly can include a turbine housing that includes a bore, a wastegate seat and a wastegate passage that extends to the wastegate seat; a bushing configured for receipt by the bore; a rotatable wastegate shaft configured for receipt by the bushing; a wastegate arm extending from the wastegate shaft; and a wastegate plug extending from the wastegate arm where the wastegate plug includes a profile, defined in part by a portion of a torus, for contacting the wastegate seat to cover the wastegate passage and, for example, defined in part by a portion of a modified sphere or a portion of a cone. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbine assembly can include a turbine wheel, a shroud component, a turbine housing, and an expansion seal that includes a lower lip, an upper lip, and a wall that extends between the lower lip and the upper lip and that is disposed between an outer seal surface of the shroud component and an inner seal surface of the turbine housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A variable-nozzle turbocharger includes a turbine housing and a center housing, and a generally annular nozzle ring and an array of vanes rotatably mounted to the nozzle ring such that the vanes can be pivoted about their axes for regulating exhaust gas flow to the turbine wheel. The vanes extend between the nozzle ring and an opposite wall formed by an insert in the turbine housing. A vane sealing member is supported on the insert, and has a portion disposed between distal ends of the vanes and the insert. This portion of the vane sealing member is configured to be contacted by the distal ends of the vanes when the vanes are in the closed position, while a clearance exists between the portion of the vane sealing member and the distal ends of the vanes when the vanes are in the open position.

Abstract: A turbocharger includes a variable-nozzle assembly that includes an insert having a tubular portion received into a stepped bore of a turbine housing and having a nozzle portion extending radially out from one end of the tubular portion, and a generally annular nozzle ring axially spaced from the nozzle portion and an array of vanes rotatably mounted to the nozzle ring. Sealing of the interface between the tubular portion of the insert and the turbine housing is provided by a sealing ring formed as a generally annular body having a U- or V-shaped cross-section oriented such that an open side of the U- or V-shaped cross-section faces in a radial direction. The U- or V-shaped cross-section defines two opposing legs, one of the legs being engaged against an end face of the tubular portion of the insert and the other leg being engaged against an upstream-facing step surface of the turbine housing bore.

Abstract: An assembly can include a turbine housing that includes a bore, a wastegate seat and a wastegate passage that extends to the wastegate seat; a bushing configured for receipt by the bore; a rotatable wastegate shaft configured for receipt by the bushing; a wastegate arm extending from the wastegate shaft; and a wastegate plug extending from the wastegate arm where the wastegate plug includes a profile, defined in part by a portion of a torus, for contacting the wastegate seat to cover the wastegate passage and, for example, defined in part by a portion of a modified sphere or a portion of a cone. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: An assembly for a turbocharger can include a locating washer having an axis and a perimeter that includes a chord segment defined by an apothem measured from the axis; a bearing assembly that includes an outer race having an axis and a perimeter that includes a chord segment defined by an apothem measured from the axis; and a housing that includes a bore for receipt of the bearing assembly and a recess for receipt of the locating washer to space apart the axes of the locating washer and the outer race by a distance greater than the sum of the apothems that provides for contact between the chord segments upon rotation of at least one of the locating washer in the recess and the outer race in the bore. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbine assembly can include a turbine wheel, a shroud component, a turbine housing, and an expansion seal that includes a lower lip, an upper lip, and a wall that extends between the lower lip and the upper lip and that is disposed between an outer seal surface of the shroud component and an inner seal surface of the turbine housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: An exemplary assembly includes a component of a turbocharger that includes a bore that extends between an inner, exhaust gas side of the component and an outer, ambient side of the component; a shaft that includes a pin portion and a head portion; a sleeve positioned on the pin portion of the shaft; and a bushing positioned over at least part of the sleeve and over at least part of the head portion of the shaft where the bushing seats the shaft and the sleeve in the bore. During operation of a turbocharger that includes such an assembly, the shaft, the sleeve and the bushing restrict flow of exhaust gas from the inner, exhaust gas side of the component to the outer, ambient side of the component. Various other exemplary devices, assemblies, methods, etc., are also disclosed.

Abstract: A turbocharger assembly includes: a housing with a through-bore and a cross-bore that intersects the through-bore to define an upper portion of the cross-bore with a first diameter and a lower portion of the cross-bore with a second diameter where the first diameter exceeds the second diameter; a bearing disposed in the through-bore of the housing where the bearing includes a through-bore configured to support a shaft and a cross-bore that intersects the through-bore; and a locating pin with a diameter that exceeds the second diameter of the lower portion of the cross-bore of the housing, the locating pin press-fit at least partially into the lower portion of the cross-bore of the housing and disposed at least partially in the lower portion of the cross-bore of the bearing to locate the bearing in the through-bore of the housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbocharger assembly includes a compressor wheel with a base surface, a nose surface, a z-plane disposed between the base surface and the nose surface and a bore extending from the base surface to the nose surface and a shaft that includes a first pilot surface disposed in the bore of the compressor wheel at a position between the z-plane and the nose surface, a second pilot surface disposed in the bore of the compressor wheel at a position between the z-plane and the base surface, and a recessed surface disposed between the first pilot surface and the second pilot surface. A nut adjustably disposed on the shaft adjacent to the nose surface can tension the shaft to apply a compressive load between the base surface and the nose surface of the compressor wheel. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A variable-nozzle turbocharger includes a turbine housing and a center housing, and a generally annular nozzle ring and an array of vanes rotatably mounted to the nozzle ring such that the vanes can be pivoted about their axes for regulating exhaust gas flow to the turbine wheel. The vanes extend between the nozzle ring and an opposite wall formed by an insert in the turbine housing. A vane sealing member is supported on the insert, and has a portion disposed between distal ends of the vanes and the insert. This portion of the vane sealing member is configured to be contacted by the distal ends of the vanes when the vanes are in the closed position, while a clearance exists between the portion of the vane sealing member and the distal ends of the vanes when the vanes are in the open position.