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Recent advancements in internal combustion engine due to stricter emission regulations require the turbocharger to function with a higher efficiency over the entire operation range. Furthermore, the need for higher boosting pressure requires the extension of rotation speed margin forcing the inclusion of resonance speeds for high order vibration modes, posing a threat on the reliability of the turbine. This paper introduces new variable geometry nozzle vanes and turbine rotor designed based on the understanding and control of tip leakage flows, utilizing both low and high fidelity CFD simulations. Low fidelity single passage steady state simulations were used for vane profile tuning and high fidelity full-scale unsteady simulations for evaluating stator-rotor interactions respectively. The new vane design is comprised of a three-dimensional stacking in the span wise direction which has been found effective in reducing the nozzle tip leakage loss.

Catalytic converters have been considered as an integral part of the vehicle powertrain for over a decade now, their application along with the engines increased significantly with the constant evolution of emission standards. Recent regulations keep a strict control on the major four pollutants of engine exhaust gas, i.e., Carbon Monoxide (CO), Nitrogen Oxides (NOx), Hydrocarbons (HC) & Particulate Matter (PM), which demands a highly efficient aftertreatment system. Efforts are continuously being made to downsize the engine for better fuel economy and low emissions, this puts additional requirement of designing a compact aftertreatment system equipped with Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR). Compact catalytic converters experience larger vibration force transferred from the vehicle and hence the durability of the product is significantly impacted.