A Computationally Efficient Method for the Thermo-Structural Analysis of a Turbocharger Turbine Wheel Under Engine Transient Operation

The accurate evaluation of thermally-induced stresses is of particular importance for life-cycle analysis of modern turbochargers. Conjugated heat transfer (CHT), steady-state calculations represent the state-of-the-art, whose temperature distribution is usually imported into a structural solver as a thermal load for carrying out thermo-structural analyses. In the case of transient analyses, however, issues arise. Indeed, due to the different timescales of convective and conductive heat-transfer mechanisms, unsteady CHT simulations are burdened by high computational costs. Moreover, in the specific case of turbocharged engines, the timescales of engine load transients and turbocharger response may differ by a factor of up to 10⁵. The present study proposes an approach for carrying out transient thermo-structural analyses of the solid domain only, characterized by a physical time in the order of 10¹ s, without the need for unsteady fluid flow calculations, which would imply the use of a solver time-step in the order of 10⁻⁵ s. In the proposed methodology, the effects of the fluid flow in the heat-transfer process are modeled by imposing adequate boundary conditions to wet surfaces of the solid domain with minimum computational effort. Indeed, by performing two steady-state CHT calculations and one steady-state computational fluid dynamics (CFD) calculation, time-dependent boundary conditions can be derived in terms of convective heat transfer coefficient and near-wall fluid temperature. The case study used for model development is a high-performance turbocharger turbine for automotive applications, responding to engine load transients of tenths of seconds. Initially, steady-state CFD and CHT models of the turbine stage are validated against experimental data. Then, transient analyses on the turbine wheel are carried out, and their results are imported as thermal loads into an unsteady structural solver, allowing for accurate transient thermo-structural analyses at sustainable computational cost.