Relief valve for a turbocharger and process for manufacturing a relief valve

Patent metadata

Field	Value
Publication number	US-2022049650-A1
Application number	US-201917275811-A
Country	US
Kind code	A1
Filing date	Sep 12, 2019
Priority date	Sep 12, 2018
Publication date	Feb 17, 2022
Grant date	—

Abstract

The present invention relates to a relief valve (1) for a turbocharger, in which the crank arm (3) is made of a first material and the shaft (4) is made of a second material different from the first material used for manufacturing the crank arm (3), each of the materials containing a composition that provides the necessary properties according to the application of each component of the relief valve (1). The present invention also relates to a process for manufacturing the relief valve (1), which allows the crank arm (3) and the shaft (4) to be manufactured separately, using different materials for the manufacture of each component.

First claim

1 - 15 . (canceled)

16 . A relief valve ( 1 ) for a turbocharger, the relief valve ( 1 ) comprising:
a valve flap ( 2 ); and a support element, the support element being formed by a crank arm ( 3 ) and a shaft ( 4 ), wherein:
the crank arm ( 3 ) is made of a first material; and
the shaft ( 4 ) is made of a second material different to the first material used for manufacturing the crank arm ( 3 ).

17 . The relief valve ( 1 ) according to claim 16 , wherein the first material used for manufacturing the crank arm ( 3 ) is composed of a nickel-based material with at least 30% nickel by weight.

18 . The relief valve ( 1 ) according to claim 17 , wherein the first material used for manufacturing the crank arm ( 3 ) contains up to 0.08% carbon by weight, 0.5% silicon by weight, up to 0.5% manganese by weight, up to 0.015% phosphorus by weight, up to 0.01% sulphur by weight, between 13.5% and 15.5% chrome by weight, between 30% and 33.5% nickel by weight, between 0.4% and 1% molybdenum by weight, between 1.6% and 2.2% aluminum by weight, and iron as residue.

19 . The relief valve ( 1 ) according to claim 16 , wherein the first material used for manufacturing the crank arm ( 3 ) is composed of an austenitic stainless steel with at least 10% chrome by weight and 15% nickel by weight.

20 . The relief valve ( 1 ) according to claim 16 , wherein the first material used for manufacturing the crank arm ( 3 ) contains up to 0.15% carbon by weight, up to 0.75% silicon by weight, up to 2% manganese by weight, up to 0.045% phosphorus by weight, up to 0.03% sulphur by weight, between 24% and 26% chrome by weight, between 19% and 22% nickel by weight, and iron as residue.

21 . The relief valve ( 1 ) according to claim 16 , wherein the second material used for manufacturing the shaft ( 4 ) is composed of a nickel-based material with at least 60% nickel by weight.

22 . The relief valve ( 1 ) according to claim 16 , wherein the second material used for manufacturing the shaft ( 4 ) contains between 0.04% 0.10% carbon by weight, up to 1% silicon by weight, up to 1% manganese by weight, up to 0.02% phosphorus by weight, up to 0.015% sulphur by weight, between 18% and 21% chrome by weight, at least 65% nickel by weight, between 1% and 1.8% aluminum by weight, and up to 3% iron by weight.

23 . The relief valve ( 1 ) according to claim 16 , wherein the valve flap ( 2 ) is made of the first material used in the manufacture of the crank arm ( 3 ).

24 . The relief valve ( 1 ) according to claim 16 , wherein the valve flap ( 2 ) is made of the second material used in the manufacture of the shaft ( 4 ).

25 . The relief valve ( 1 ) according to claim 16 , wherein the valve flap ( 2 ), the crank arm ( 3 ) and the shaft ( 4 ) receive a ceramic coating, PVD or CVD, or a nitriding treatment or a hardening treatment.

26 . A process for manufacturing the relief valve ( 1 ) as defined in claim 16 , the process comprising the steps of:
forging the valve flap ( 2 ); forging the crank arm ( 3 ) and the shaft ( 4 ) in separate parts; and carrying out an attrition welding connecting process for the association between the crank arm ( 3 ) and the shaft ( 4 ).

27 . The process according to claim 26 , wherein the valve flap ( 2 ), the crank arm ( 3 ) and the shaft ( 4 ) receive a ceramic coating, PVD or CVD, or a nitriding treatment or a hardening treatment.

28 . A process for manufacturing the relief valve ( 1 ) as defined in claim 16 , the process comprising the steps of:
forging the valve flap ( 2 ); machining of crank arm ( 3 ) and the shaft ( 4 ) in separate parts; and carrying out an attrition welding connecting process for the association between the crank arm ( 3 ) and the shaft ( 4 ).

29 . The process according to claim 28 , wherein the valve flap ( 2 ), the crank arm ( 3 ) and the shaft ( 4 ) receive a ceramic coating PVD or CVD, or a nitriding treatment or a hardening treatment.

30 . A relief valve ( 1 ) for a turbocharger formed by a valve flap ( 2 ) and a support element, the support element being formed by a crank arm ( 3 ) and a shaft ( 4 ), wherein the relief valve is obtained by a process comprising the steps of:
forging the valve flap ( 2 ); forging or machining the crank arm ( 3 ) and the shaft ( 4 ) in separate parts; and carrying out an attrition welding connecting process for the association between the crank arm ( 3 ) and the shaft ( 4 ).

Assignees

• Mahle Metal Leve Sa
• Mahle Int Gmbh

Inventors

• Bettini Rabello Rafael
• Lerman Pedro
• Uehara Samantha

Classifications

• C22C38/40

  with nickel · CPC title

• B21K1/20

  valve parts · CPC title

• F05D2220/40

  in turbochargers · CPC title

• F05D2230/25

  by forging · CPC title

• F05D2230/313

  by physical vapour deposition · CPC title