Numerical and experimental investigations of a turbocharger with a compressor wheel made of additively manufactured plastic

Abstract

This study investigates the operating characteristics of a turbocharger compressor having components manufactured by multiJet printing technology. Currently, studies are being conducted worldwide that aim to develop parts of innovative fluid-flow machines through additive manufacturing techniques. This manufacturing technique has a lower production time and cost compared to conventional prototyping methods used for components with complex shapes. In this article, we focused on the application of the above-mentioned method for improving the design and optimization process of the main parts of fluid-flow machines. This article also presents a numerical model and analysis of a compressor wheel. Experimental tests were conducted at high rotational speeds (up to 100,000 rpm) with the reference material (aluminum compressor wheel) and a polymer wheel. The results obtained were compared with the results of numerical calculations. A modified automotive turbocharger was subjected to experiments on a test stand. This paper also describes the different operating nature of the tested machine compared to the standard version as observed during rundup tests. These tests were necessary in order to obtain the precise characteristics of the compressor, which was vital for performing a vibrodiagnostic analysis.