Turbocharger Structural Integrity

Since the introduction of Euro VI in January 2014, all new diesel powered commercial vehicles have been equipped with turbocharged engines. It is virtually impossible to meet these emission regulations without using a turbocharger. Similarly, in the passenger car sector both on diesel and petrol (gasoline) powered vehicles, legislative pressure to reduce emissions of carbon dioxide are seeing the introduction of turbochargers across almost all new power units. Future legislation will continue this trend with engine manufacturers becoming increasingly reliant on turbocharging. As well as increasing the requirement for turbochargers, these external factors are also demanding that turbochargers become more responsive with reduced rotor inertia and lower thermal inertias. This in turn makes the task of ensuring that turbocharger components remain fit for purpose for the life of the turbocharger that much more difficult. In this paper some of the recent developments in turbocharger technology will be identified and the demands that these place on the structural components will be explored. The limitations of current methods of structural integrity assessment for some of these components will be discussed. Future developments of these methods will then be proposed

Reliability and structural integrity

An analytic model is developed to calculate the reliability of a structure after it is inspected for cracks. The model accounts for the growth of undiscovered cracks between inspections and their effect upon the reliability after subsequent inspections. The model is based upon a differential form of Bayes' Theorem for reliability, and upon fracture mechanics for crack growth

Structural integrity of hierarchical composites

Interface mechanical problems are of paramount importance in engineering and materials science. Traditionally, due to the complexity of modelling their mechanical behaviour, interfaces are often treated as defects and their features are not explored. In this study, a different approach is illustrated, where the interfaces play an active role in the design of innovative hierarchical composites and are fundamental for their structural integrity. Numerical examples regarding cutting tools made of hierarchical cellular polycrystalline materials are proposed, showing that tailoring of interface properties at the different scales is the way to achieve superior mechanical responses that cannot be obtained using standard material

Space shuttle structural integrity and assessment study

Potential nondestructive evaluation (NDE) requirements for the space shuttle vehicle during structural inspection in the refurbishment/turnaround period, are defined. Data are given on NDE limitations and defect characterization by the process. Special attention was given to the determination of fatigue cracks, stress corrosion cracks, corrosion, and adhesive disbonds of airframes

Building Engineering Feasibility Study: Herreshoff Marine Museum

Our design team was supplied with a dozen architectural designs from the students of the Roger Williams University Architectural School. After discussing the strengths and weaknesses of each our team was able to narrow our choices down to one base design to conduct our feasibility and structural integrity analysis. Currently, the structural integrity of the proposed building addition has been examined by determining the wind and the snow loads, the green roof requirements, and the column and beam loads. The feasibility of the chosen design was assessed by researching Bristol zoning regulations and developing a path through the required zoning variances, which will help in the construction phase

Space shuttle: Structural integrity and assessment study

A study program was conducted to determine the nondestructive evaluation (NDE) requirements and to develop a preliminary nondestructive evaluation manual for the entire space shuttle vehicle. The rationale and guidelines for structural analysis and NDE requirements development are discussed. Recommendations for development of NDE technology for the orbiter thermal protection system and certain structural components are included. Recommendations to accomplish additional goals toward space shuttle inspection are presented

Fluorescence microscopy for the characterization of structural integrity

The absorption characteristics of light and the optical technique of fluorescence microscopy for enhancing metallographic interpretation are presented. Characterization of thermally sprayed coatings by optical microscopy suffers because of the tendency for misidentification of the microstructure produced by metallographic preparation. Gray scale, in bright field microscopy, is frequently the only means of differentiating the actual structural details of porosity, cracking, and debonding of coatings. Fluorescence microscopy is a technique that helps to distinguish the artifacts of metallographic preparation (pullout, cracking, debonding) from the microstructure of the specimen by color contrasting structural differences. Alternative instrumentation and the use of other dye systems are also discussed. The combination of epoxy vacuum infiltration with fluorescence microscopy to verify microstructural defects is an effective means to characterize advanced materials and to assess structural integrity

Development of a robust structural health monitoring system for wind turbine foundations

The construction of onshore wind turbines has rapidly been increasing as the UK attempts to meet its renewable energy targets. As the UK’s future energy depends more on wind farms, safety and security are critical to the success of this renewable energy source. Structural integrity is a critical element of this security of supply. With the stochastic nature of the load regime a bespoke low cost structural health monitoring system is required to monitor integrity. This paper presents an assessment of ‘embedded can’ style foundation failure modes in large onshore wind turbines and proposes a novel condition based monitoring solution to aid in early warning of failure

Improve safety by reducing the impact of external corrosion on pipelines

• Proactive prevention of corrosion defects from growing to a size that ultimately impacts a pipeline’s structural integrity • Continuous assessment to identify & address where corrosion has occurred, is occurring or may occur • Repairing corrosion defects • Correcting the causes of corrosio

NASA airframe structural integrity program

NASA initiated a research program with the long-term objective of supporting the aerospace industry in addressing issues related to the aging of the commercial transport fleet. The program combines advanced fatigue crack growth prediction methodology with innovative nondestructive examination technology with the focus on multi-stage damage (MSD) at rivited connections. A fracture mechanics evaluation of the concept of pressure proof testing the fuselage to screen for MSD was completed. A successful laboratory demonstration of the ability of the thermal flux method to detect disbonds at rivited lap splice joints was conducted. All long-term program elements were initiated, and the plans for the methodology verification program are being coordinated with the airframe manufacturers