Intermediate Component for Turbine Shaft Connection
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Solution Overview
Problem
Conventional connections between shafts and turbine wheels in exhaust gas turbochargers face challenges due to material compatibility issues, particularly when thermally resistant materials like titanium aluminum are used for the turbine wheel and cost-efficient materials for the shaft, making direct welding or soldering difficult and costly.
Innovation Solution
An intermediate component with a form-locking and/or force-locking connection, such as a riveted connection, is used to indirectly connect the shaft to the turbine wheel, where the intermediate component is made of a heat-resistant material like nickel alloy and connected to the turbine wheel using a form-locking method, and then welded to the shaft using friction or electron beam welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If direct welding or soldering is used to connect the shaft to the turbine wheel, then a strong connection is achieved, but material compatibility issues arise when using thermally resistant materials like titanium aluminum for the turbine wheel and cost-efficient materials for the shaft
Solution Approach 1:
An intermediate component is introduced between the shaft and turbine wheel to enable connection between incompatible materials. The intermediate component serves as a mediator that can be welded to both materials, resolving the material compatibility issue while maintaining connection strength
Solution Approach 2:
The direct connection between shaft and turbine wheel is segmented into two separate connections: one between the shaft and intermediate component, and another between the intermediate component and turbine wheel. This allows each connection to be optimized for its specific material pair
2Temperature
If thermally resistant materials like titanium aluminum are used for the turbine wheel, then thermal resistance is improved, but manufacturing cost and connection difficulty increase
Solution Approach 1:
Thermally resistant material is applied locally only to the turbine wheel where it is most needed for thermal resistance, while the shaft can use more cost-efficient materials. This localized application optimizes thermal performance while controlling manufacturing costs
3Adaptability or versatility
If a form-locking connection is used to connect the intermediate component to the turbine wheel, then material compatibility issues are avoided, but connection complexity increases
Solution Approach 1:
The intermediate component with form-locking features acts as a mediator that enables connection between incompatible materials. The form-locking mechanism, while adding some complexity, provides a reliable solution for connecting dissimilar materials where welding would fail
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for a reliable and cost-effective connection that maintains structural integrity and thermal resistance, avoiding material incompatibility issues and reducing thermal stress, while enabling the use of cost-efficient materials for the shaft and thermally resistant materials for the turbine wheel.
Implementation Method 1
The intermediate component is preferably connected to the shaft by means of a welded connection, in particular by friction welding or EB (electron beam) welding
Implementation Method 2
The intermediate component is preferably connected to the shaft by means of a welded connection, in particular by friction welding or EB (electron beam) welding
Data Source
AI summary
For connecting a shaft to a rotating component, especially of a shaft to a turbine wheel of an exhaust gas turbocharger, an intermediate component is provided by means of which the shaft is connected indirectly to the rotating component. The connection between the rotating component and the intermediate component is a form-locking and/or force-locking connection, especially a riveted connection.