Systems and methods for protecting a turbocharger aluminum bearing housing

Abstract

In an aluminum turbocharger bearing housing, there is a potential for wear of the bearing housing at the interface with the turbine housing and/or the bearing system. One area of potential concern is the interface between the flange of the bearing housing and an abutment of the turbine housing. With a protective element at the interface, the potential for wear, and thus misalignment of the rotating assembly with the housings in which they operate can be mitigated. The protective element can be a cap for the bearing housing flange or a heat shield adapted to cover certain faces of the bearing housing flange. The protective element can be a sleeve provided within a bore in the bearing housing. The protective element can be made of a material with a higher heat resistance and/or a higher wear resistance than the aluminum bearing housing.

1 . A protective system for a turbocharger interface comprising:
 a first surface defined by a portion of an aluminum turbocharger bearing housing ( 22 );   a second surface defined by a turbocharger component; and   a protective element operatively positioned between the first and second surfaces, the protective element being made of a material that has at least one of a higher heat resistance or a higher wear resistance than the aluminum turbocharger bearing housing, whereby the protective element protects the first surface from heat and/or wear.   
     
     
         2 . The system of  claim 1 , wherein the protective element is made of one of: steel, cast iron or titanium. 
     
     
         3 . The system of  claim 1 , wherein the first surface is defined by a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ). 
     
     
         4 . The system of  claim 3 , wherein the protective element is a cap ( 70 ) having a generally U-shaped cross-section, and wherein the cap ( 70 ) covers at least a portion of the first surface of the flange ( 42 ). 
     
     
         5 . The system of  claim 3 , wherein the protective element is a cap ( 70 ) having a generally V-shaped cross-section, and wherein the cap ( 70 ) covers at least a portion of the first surface of the flange ( 42 ). 
     
     
         6 . The system of  claim 1 , wherein the protective element is a sleeve ( 78 ) that is received in a bore ( 100 ) of the aluminum turbocharger bearing housing ( 22 ). 
     
     
         7 . The system of  claim 1 , wherein the protective element is a turbine heat shield ( 46 ′), wherein the first surface includes a turbine end facing face ( 112 ) and a radially mating face ( 116 ) of a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ) that is transverse to the turbine end facing face ( 112 ), wherein the second surface is defined by a turbine housing ( 14 ), wherein the heat shield ( 46 ′) includes an axially facing surface ( 114 ) and a radially facing flange ( 118 ), and wherein the heat shield ( 46 ′) is operatively positioned between the first and second surfaces. 
     
     
         8 . The system of  claim 1 , wherein the first surface is an outer tapered surface ( 92 ) of a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ), and wherein the second surface is a portion of a retainer segment ( 54 ) of a vee-band ( 56 ). 
     
     
         9 . A method of protecting an interface in a turbocharger between a first surface and a second surface, the first surface being defined by a portion of an aluminum turbocharger bearing housing ( 22 ) and the second surface defined by a turbocharger component, the method comprising:
 providing a protective element made of a material that has at least one of a higher heat resistance or a higher wear resistance than the aluminum turbocharger bearing housing; and   operatively positioning the protective element between the first and second surfaces such that at least a portion of the first surface is protected from heat and/or wear.   
     
     
         10 . The method of  claim 9 , wherein the protective element is made of one of: steel, cast iron or titanium. 
     
     
         11 . The system of  claim 9 , wherein the first surface is defined by a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ). 
     
     
         12 . The system of  claim 9 , wherein the protective element is a cap ( 70 ), wherein the operatively positioning includes providing the cap ( 70 ) over at least a portion of a radial surface ( 72 ), a first axial surface ( 74 ) and/or a second axial surface ( 76 ) of the flange ( 42 ). 
     
     
         13 . The system of  claim 12 , wherein the cap ( 70 ) has one of generally V-shaped cross-section or a generally U-shaped cross-section. 
     
     
         14 . The system of  claim 9 , wherein the protective element is a sleeve ( 78 ) and the first surface is a bore ( 36 ) in the aluminum turbocharger bearing housing ( 22 ), and wherein the sleeve ( 78 ) covers at least a portion of the bore ( 100 ). 
     
     
         15 . The system of  claim 9 , wherein the protective element is a turbine heat shield ( 46 ′), wherein the first surface includes a turbine end facing face ( 112 ) and a radially mating face ( 116 ) of a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ) that is transverse to the turbine end facing face ( 112 ), wherein the second surface is defined by a turbine housing ( 14 ), wherein the heat shield ( 46 ′) includes an axially facing surface ( 114 ) and a radially facing flange ( 118 ), and wherein the heat shield ( 46 ′) is operatively positioned between the first and second surfaces such that the axially facing surface ( 114 ) protects the turbine end facing face ( 112 ) and such that the radially facing flange ( 118 ) protects the radially mating face ( 116 )). 
     
     
         16 . The system of  claim 9 , wherein the first surface is an outer tapered surface ( 92 ) of a flange ( 42 ) of the aluminum turbocharger bearing housing ( 22 ), and wherein the second surface is a portion of a retainer segment ( 54 ) of a vee-band ( 56 ).