Abstract: An exhaust gas turbocharger (1) including a compressor housing (2), a bearing housing (3), a turbine housing (4) in which a turbine wheel (5) is arranged, which has a housing inlet (6), which has a turbine spiral (7) connecting to the housing inlet (6), which has a housing outlet (8), and which has a wastegate arrangement (9), which in the open state brings the housing inlet (6) into flow connection with the housing outlet (8) for guiding a wastegate mass flow. The wastegate insert part (10) is arranged in the turbine housing (4) between the turbine wheel (5) and the housing outlet (8) and the open wastegate arrangement (9) introduces the wastegate mass flow into the wastegate insert arrangement (9).

Abstract: 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.

Abstract: A turbocharger (1) includes a compressor section and a cast turbine section. The turbine section includes a turbine wheel (4), and a turbine housing (11) that defines a gas inlet (13), a gas outlet (10), a volute (9) disposed between the gas inlet (13) and the gas outlet (10). The turbine housing (11) also includes vanes (20) that protrude integrally from, and have a fixed orientation relative to, an inner surface of the turbine housing (11). The turbine wheel (4) is disposed in the turbine housing (11) between the volute (9) and the gas outlet (10), and the vanes (20) are disposed in the turbine housing (11) between the turbine wheel (4) and the volute (9). A method of casting the turbine housing (11) and the vanes (20) together as a single piece is described.

Abstract: 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.

Abstract: A turbine (32) section of a turbocharger (30) includes a turbine wheel (37) disposed in a turbine housing (33), the turbine housing (33) defining a gas inlet (34), a volute configured to direct gas from the inlet (34) to the turbine (32) wheel, and a gas outlet. A rotary diverter valve (100, 200) is disposed in the gas inlet (34) upstream of the volute, and provides three modes of controlling exhaust gas flow about the turbocharger (30).

Abstract: An exhaust gas turbocharger (1) including a compressor housing (2), a bearing housing (3), a turbine housing (4) in which a turbine wheel (5) is arranged, which has a housing inlet (6), which has a turbine spiral (7) connecting to the housing inlet (6), which has a housing outlet (8), and which has a wastegate arrangement (9), which in the open state brings the housing inlet (6) into flow connection with the housing outlet (8) for guiding a wastegate mass flow. The wastegate insert part (10) is arranged in the turbine housing (4) between the turbine wheel (5) and the housing outlet (8) and the open wastegate arrangement (9) introduces the wastegate mass flow into the wastegate insert arrangement (9).

Abstract: A turbine (32) section of a turbocharger (30) includes a turbine wheel (37) disposed in a turbine housing (33), the turbine housing (33) defining a gas inlet (34), a volute configured to direct gas from the inlet (34) to the turbine (32) wheel, and a gas outlet. A rotary diverter valve (100, 200) is disposed in the gas inlet (34) upstream of the volute, and provides three modes of controlling exhaust gas flow about the turbocharger (30).

Abstract: A turbocharger (1) includes a compressor section and a cast turbine section. The turbine section includes a turbine wheel (4), and a turbine housing (11) that defines a gas inlet (13), a gas outlet (10), a volute (9) disposed between the gas inlet (13) and the gas outlet (10). The turbine housing (11) also includes vanes (20) that protrude integrally from, and have a fixed orientation relative to, an inner surface of the turbine housing (11). The turbine wheel (4) is disposed in the turbine housing (11) between the volute (9) and the gas outlet (10), and the vanes (20) are disposed in the turbine housing (11) between the turbine wheel (4) and the volute (9). A method of casting the turbine housing (11) and the vanes (20) together as a single piece is described.

Abstract: A turbocharger (1) includes compressor and turbine wheels (4, 5) and a shaft (6) that connects the compressor wheel (5) to the turbine wheel (4). The shaft (6) is supported by a thrust bearing assembly (20) that includes a pair of thrust washers (42a, 42b) mounted on the shaft (6), a hollow, cylindrical spacer (80) disposed on the shaft (6) between and abutting first faces (44) of the thrust washers (42a, 42b), and a thrust bearing (100) supported on the spacer (80) between the thrust washers (42a, 42b). One of the thrust bearing (100) or the first and second thrust washers (42a, 42b) includes a copper-alloy lining (60) where the lining (60) is provided in a first region (58a) and in a second region (58b), and the remainder of the thrust bearing (100) or the first and second thrust washers (42a, 42b) is lining free.

Abstract: 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.

Abstract: 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.

Abstract: 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.