Turbo Failure analysed

We received a failed CHRA aswell as an additional compressor wheel from a client who wanted us to provide an indication into the failure mechanism. This is not a simple failure, and involves alot more than a simple "one of the 4 big killers of turbochargers" I hope you enjoy this - lets interact in the comments section below --

[bryanwilliams]

I’m an engineer and I absolutely loved this. Thanks for taking the time to bother. So much on failure modes is just generic level, which has a place, but I loved hearing a little more depth on the science

[ericn]

Brilliant deductive work, Chris. Kudos to you and your team.

P.S. Compliments too to the camera person for zooming in and out at the appropriate moments. The production quality of the channel has really grown in leaps and bounds!

[floydgould]

Chris you are truly the professor of turbos, love your vids mate.

[charlesbartholomew]

Excellent explanation. I like technical, the more the better, it forces me to delve deeper and learn more. Thank you for sharing!

[mikebaz]

I had an om605 engine with a bent blade just like this and heavy erosion on the leading edge, interesting analysis

[beeyotch]

That was awesome!! Most enjoyable, as it kept me on the edge of my seat. Great story telling, my friend. Yes, I learned something - LOL

[jamesreid]

Hey Chris, love the video. From the information you have given, and from from what I can see. I am thinking it is from the PCV system. The newer low tension compression rings on the piston rings causing lots of blow by. The carbon builds up in the hoses and gets broken off hitting the blade. The only reason I am saying that is I work on Turbine fan blades are not that dirty. However they have erosion.

[Garage]

Wow that's very interesting. At first when you were discussing the CNC process I thought perhaps two cuts of the point mill had fallen along the same line creating extra thin areas in the blade. The erosion makes so much sense though. Also interesting to think about how the very small channels created by the milling will create air channels and therefore areas of more and less erosion. I wonder if a different milling pattern alone could make a large difference. Great video!

[BlueHoodie]

That is one amazing explanation. That clearly gives a perfect reason why mine failed.

[Gazr]

8 54 I worked at a turbo charger manufacturer up to 1999, all the compressor wheels were cast via investment casting technique, then turned on a CNC lathe to various profiles to suit compressor cover profiles.
Gaz UK.

[hondatrix]

Seen it on older PSA engines, also used in Fords. OEM's turn a blind eye though...

[pravinmarathe]

Very Practical Analysis.Thanks Chris!!

[Archiemosses]

Really good video. Thanks for the info!

[patrickvanrooyen]

Hi thx for a wonderful analysis. Iv a massive radial play just three working days after fitting new core. So much so that oil is leaking through the exhaust side and its burning the oil. Please advise

[frontlinemedia]

I had a turbo fail. The shaft broke right before the exhaust wheel. It appears to have had plenty of oil for lubrication. No signs of heat damage. So trying to figure reasons for this to even happen. This is a garett turbo

[benjaminvandewoestyne]

Hello, very informative video, what's your opinion on water injection pre turbo? So right into to compressor wheel? I build a set up with this, and planning to map it to it's absolute limit (3.5 bar 60mm compressor wheel) with the water injection. Mainly to keep the engine cool. Should i worry about the compressor wheel failing? It is a oem billet wheel. Thanks in advance

[allenrearden]

due to speed and hardness of the metal it would take impact at a relatively high speed strange its only one blade no glancing signs or recoshae after straightening boat props you have to be particularly careful how you reverse the damage that thin of metal cant take much stress .

[brianbrigg]

Looks like a good catch can would help a lot with this sort of problem.
One question. How thick is the blade originally?
Watching this video and seeing the speed of the outer parts of the blades has made me wonder how many compressor and turbine wheels exceed Mach 1. The engineers must have had their jobs cut out looking at the effects on the airflow with sonic shock waves being formed.

[fredjones]

excellent presentation. When you started calculating tip speeds, I though it might lead to trans sonic shock waves due to overspeeding. ie constantly cycling above and below mach 1, with corrections for air density and humidity. ie maybe a low working altitude with high humidity (deep mining application). Your explanation is far less esoteric. did a catch can solve the issues?

[annbrown]

I've a 3 year old car and it's been diagnosed as to much end float, splines have to much movement, does this mean it's on its way out? Please advise me what to do