Have you ever wondered how a turbocharger is made? How it works? What is a turbocharger? A device that spins in excess of 100,000+ RPM must be very precisely engineered and balanced or it will simply not work. Modern engines only turn at a maximum average of 7,000 RPM, so imagine what it takes to get a turbo to spin this insane level of energy? This is pinnacle of forced induction technology; say hello to "turbo".
Video: How a turbocharger is made
First, lets start off with how a turbocharger functions. Basically, it is like house fan, but instead of using electricity from an outlet, it uses thermal energy from your exhaust. Heat leaves the combustion chamber, makes contact with the turbocharger's turbine, and the heat pressure forces through the blades thus converting the thermal energy into mechanical energy.
The spinning turbine is connected to a compressor wheel through a CHRA housing featuring either a journal or ball bearing, a shaft, and a housing which feeds oil and coolant. This spinning mechanical energy is directed 100% towards the compressor wheel, which sits on the intake side of the turbocharger. Creating a vortex of air and mass amounts of vacuum, the compressor wheel sucks in air much like a vacuum cleaner and spins it around the compressor housing. As the air spins, it condenses on the outer most rim of the compressor housing, thus creating hot, pressurized air.
Hot air is not good for engines, so all turbochargers must have some sort of cooling device or chemical applied. Many use air-to-air intercoolers, water-to-air intercoolers, or for racing applications; methanol or alcohol injection. The hot air passes through either an intercooler or a barrier of cooling chemical injected by a fine mist jet nozzle. Once the air is cooled down to 100*F or less, it is acceptable to be used with 93 octane fuel in a modern combustion engine.
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