Being an expensive piece of equipment, turbocharger reconditioning is a cost-effective alternative to renewing partly or completely. In addition, the advances in engine development, in order to meet emission requirements and reduce fuel consumption, have prompted development of new turbocharger types with higher pressure ratios and efficiency. This has caused earlier turbocharger types to be discontinued by the manufacturers, in some cases making it difficult to readily obtain new parts for such types still in service.
In order to meet the above-mentioned challenges, we offer turbocharger reconditioning of most types. At a fraction of the cost of new components, this allows the clients to maintain their turbochargers in good condition throughout the full service life. Apart from being cost effective, and for older turbocharger types often the only viable alternative to retrofitting a newer type, reconditioning is also less of a drain on the natural resources and thus being more sustainable than just replacing with new components.
Turbocharger Reconditioning Services Include:
- Turbocharger Shafts
- Blades and Nozzle Rings
- Turbocharger Balancing
Reconditioning of Turbocharger Shafts
We offer repair and reconditioning of all rotating shafts by hot and cold metal spraying. All shaft journals, threaded areas, pump spigots and seal areas can be repaired by metal spraying and then machine to the original specification. Unlike a cold repair process, metal spraying allows a shaft to be restored to its original dimensions and strength.The metal spraying procedure employed by us is approved by Lloyd’s Register.
Reconditioning of Blades and Nozzle Rings
When reconditioning turbochargers, the key competence is the ability to rebuild turbine blades, compressor wheels and nozzle rings. We do this by a specialized procedure, approved by Classification Societies, carried out by highly qualified technicians.
The turbine blades are dismantled, cleaned ultrasonically and accurately measured. A non-destructive inspection by ultra-violet light is performed to detect possible fractures. Fractured blades are replaced with new ones.
Our turbine blade welding is based on a procedure developed through extensive research by metallurgists. The method used is TIG (Tungsten Inert Gas) welding – a technique using a non-fusing electrode at low amperage, shielded by an inert gas.
The welding is carried out under strictly controlled conditions. Only a small zone may be exposed to heating, and the operation must be carried out in a closed welding chamber, free from dirt particles and air turbulence, as any draught would disperse the shielding gas and result in poor welding quality.
After welding the turbine blade is machined and ground back into its specified shape, inspected for cracks using both ultra-violet light and dye penetrant inspection and the weight is verified.
In order to achieve the correct weight distribution, a computer calculates the sequence in which the blades should be mounted on the rotor in preparation for the balancing.
Similar processes are employed to recondition nozzle rings and compressor wheels.
In case of high-speed rotating components, turbocharger balancing is of the essence – both for the sake of safety and time between overhauls. We employ state of the art equipment – not only for the balancing of turbocharger rotors, but for balancing of high-speed rotating components for a wide variety of applications.
We balance all components separately and correct for static unbalance. In order to check the balance after assembly, the complete unit will finally be checked for dynamic unbalance.
We have the latest equipment for balancing components in two planes, from the smallest size up to a length of 3,000 mm and a diameter of 1,200 mm, with three balancing machines available to cater for every need:
- SCHENCK H20/H40 BUTL with CAB 920
- SCHENCK H10BU with CAB 610
- SCHENCK HEC121 with CAB590