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Wastegates Explained


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A wastegate is a valve that diverts exhaust gases away from the turbine wheel in a turbocharged engine system. Diversion of exhaust gases regulates the turbine speed, which in turn regulates the rotating speed of the compressor. The primary function of the wastegate is to regulate the maximum boost pressure in turbocharger systems, to protect the engine and the turbocharger.

Wastegate Types
External
An external wastegate is a separate self-contained mechanism typically used with turbochargers that do not have internal wastegates. An external wastegate requires a specially constructed turbo manifold with a dedicated runner going to the wastegate. The external wastegate may be part of the exhaust housing itself. External wastegates are commonly used for regulating boost levels more precisely than internal wastegates in high power applications, where high boost levels can be achieved. External wastegates can be much larger since there is no constraint of integrating the valve or spring into the turbocharger and turbine housing. It is possible to use an external wastegate with an internally gated turbocharger. This can be achieved through a specially designed bracket that easily bolts on and restricts the movement of the actuator arm, keeping it from opening. Another route involves welding the internal wastegate shut which permanently keeps it from opening, but failure of the weld can allow it to open again.
External wastegates generally use a valve similar to the poppet valve found in the cylinder head. However they are controlled by pneumatics rather than a camshaft and open in the opposite direction. External wastegates can also use a butterfly valve, though that is far more rare.

Atmospheric/Divorced Wastegates
A divorced wastegate dumps the gases directly into the atmosphere, instead of returning them with the rest of an engine's exhaust. This is done to prevent turbulence to the exhaust flow and reduce total back pressure in the exhaust system. Divorced wastegate dumper pipes are commonly referred to as "screamer pipes" due to the unmuffled waste exhaust gases and the associated loud noises they produce..

Control
The simplest control for a wastegate is to supply boost pressure directly from the charge air side to the wastegate actuator. A small hose can connect from the turbocharger compressor outlet, charge pipes, or intake manifold to the nipple on the wastegate actuator. The wastegate will open further as the boost pressure pushes against the force of the spring in the wastegate actuator until equilibrium is obtained. More intelligent control can be added by integrating an electronic boost controller.
Standard wastegates have one port for attaching the boost control line from the charge air supply line or boost control solenoid. This is the most common configuration and the only type of configuration found on internal wastegates.
A dual port wastegate adds a second port on the opposite side of the actuator. Air pressure allowed to enter this second port aids the spring to push harder in the direction of closing the wastegate. This is exactly the opposite of the first port. The ability to help the wastegate remain closed as boost pressure builds can be increased. This also adds further complexity to boost control, requiring more control ports on the solenoid or possibly a complete second boost control system with its own separate solenoid. Use of the second port is not necessary. Secondary ports, unlike primary ports, cannot be simply attached to a boost control line and require electronic control to be useful. C02 can also be used to apply pressure to the second port, in order to control boost on a much finer level.

Wastegate Chatter Myth
There is confusion in the automotive world about so called "wastegate chatter", "dose" or "turbo flutter". A noise created on lifting off the throttle in a turbocharged car, commonly described as a chipmunk or a rattlesnake, is often stated incorrectly as being a result of the turbo's wastegate closing.
The noise is in fact the air compressed by the turbo passing back through the compressor wheel of the turbo after the airflow is abruptly halted by the throttle plate closing, called compressor surge. However, in some cases, i.e. where the throttle plate doesn't open fast enough or is set up to only react to high boost, some chatter will remain. Surge can occur on diesels when the turbo is attempting to pressurize the air at a higher pressure ratio than the compressor wheel can flow at a given speed. Diesel engines have no use for a blow off valve as they do not have a throttle plate.
The chatter noise is very noticeable on World Rally Cars, where anti-lag is used.
A compressor stall like this can cause excess stress and wear on the turbo's shaft or bearings under higher load applications of the turbo (around 15 psi (1.0 bar) and greater depending on the trim and flow rate of the compressor side).
Actual wastegate flutter occurs instead under partial boost conditions such as partial throttle near the boost threshold. It sounds like FftFftFft not ShuShuShu and is caused by the rapid opening and closing of the wastegate at boost levels near the spring pressure. It is commonly heard more clearly and may be more prominent on cars with modified intake silencers, up-pipes, and or downpipes, and is not harmful.

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