Melett Product Range

product-range

Our continuously growing range of replacement turbocharger parts includes everything from individual piece parts, oversize parts, upgrade parts and repair kits through to an extensive range of major parts including: turbine wheels, compressor wheels, bearing housings, seal plates, heat shields, thrust bearings, variable geometry nozzle ring assemblies and a large selection of oversize journal bearings and piston rings.

CHRA / Core Assemblies

CHRA / Core Assemblies

Our growing range of replacement CHRA / Core Assemblies are all assembled and VSR balanced in our in-house fully equipped UK Core Production Facility:

  • The extensive range covers many popular turbo models, including Garrett GT/VNT, Borg Warner K03/4 & KP/BV, MHI TD02/3 TF035/ TD04, Toyota CT26 and IHI RHF4/5;
  • ALL Melett CHRA / Core Assemblies are made in our UK facility, from Melett parts only — where possible we incorporate improvements in the original design and use upgraded parts — producing an improved CHRA;
  • Batch control – we can provide complete traceability of every individual component used in our Core Assemblies — Each Core Assembly is etched with a unique serial number, ensuring all genuine Melett products are fully traceable to the UK;
  • At Melett, we adhere to strict quality control processes incorporating the highest level of inspection throughout every stage of production;
  • Significant investment in the latest technology and equipment, and highly skilled technicians allows Melett to maintain a tight control over all stages of core production.

Variable Nozzle Rings

We offer a wide range of complete variable nozzle ring assemblies:

  • Covering many turbo models including: GT15-25V, TF035, TD03 & TD04, RHV4, CT16 & CT26 turbos;
  • 10, 11 and 13 blade versions available — all produced with solid vanes for improved strength;
  • Precision manufactured to the highest possible standards, all specialist materials comply with the original OEM specification to ensure reliable performance;
  • We also offer a range of CHRA and nozzle ring assembly packs, giving customers a more cost effective repair solution.

NB: During the design review of the GT15 nozzle assembly, Melett Engineers analysed failure modes of many units. Our conclusion was that the solid vane design for the 753420 GT15 nozzle ring, rather than the original welded strip metal design, was the preferred route for the aftermarket providing a stronger repair solution. This allows you to offer your customers an upgraded repair.

Turbocharger Repair Kits

Including, Individual Piece Parts, Oversize Parts and Upgraded Parts

Turbo Repair Kits

Our repair kits are ‘in stock’ for nearly all turbo models – ranging from the oldest ST50/3LD through to the latest Garrett GTB Step 3 turbos, and less popular kits e.g. Komatsu & K54.
Melett repair kits are available in:

  • Minor Kits – includes the basic components;
  • Major Kits – includes all the components needed for a full repair of a turbo;
  • Universal Kits – includes each variation to accommodate for where there are several variations of a model i.e. Flat or superback compressors wheels, straight or slender shafts etc.
  • All the products are precision manufactured and materials are matched like for like with the original OEM specification to ensure reliable performance, and improvements in the original are made where possible;
  • Manufactured to Melett specifications, mainly in the UK and Europe by TS16949 certified manufacturers:
    • TS16949 — is the International Quality Management Standard specifically written by the Automotive Industry and is a concerted effort to improve quality and assure the integrity of supplies to the industry.
  • All Melett parts are supplied from our UK premises and our quality standards are backed by the ISO international standard certification ref ISO90001 2008:
    • ISO 9001 — is the internationally recognised standard for the quality management of businesses.
  • Melett repair kits are all assembled and packed at our UK facility, and every batch produced is identified with a batch number, giving us full traceability of each kit.

Journal Bearings

We offer an extensive range of journal bearings — from the smallest KP35 models right through to the larger Komatsu KTR130:

  • Manufactured to Melett specifications, mainly in the UK and Europe by TS16949 certified manufacturers;
  • Quality inspections and testing are carried out at several points throughout the production process, with all final inspections being undertaken at Melett UK;
  • All specialist materials comply with original OEM specification to ensure reliable performance.

Thrust Bearings

At Melett, we have a thorough understanding of thrust bearing manufacture, including the main methods of producing the initial thrust bearing blank and the appropriate method required for each application, including:

  • Sliced sections of a continuous cast bar;
  • Stamped blanks;
  • Powder metal (referred to as sintering);
  • Hot forging.

All Melett thrust bearings then undergo double disc grinding, oil feed hole drilling and most importantly ramp sizing on the oil pads:

  • Oil Ramping is an extremely important feature on the thrust bearing and this critical detail is often overlooked. The ramping creates a wedge of oil as the thrust component rotates and helps to force the parts away from the surface, reducing wear and therefore increasing the turbos life.

Where possible, Melett improves the original method used i.e. K03 & K04, BV39 & BV43 thrust bearings.

Melett Small Parts
 
 

 

Melett’s extensive range of precision internal piece parts, including piston rings, thrust flingers, thrust collars & thrust washers, O-rings and shaft nuts are all available individually or within our repair kits:

    • • Material specifications are matched like for like, and where possible specifications are improved to replace the older variations;
    • • Manufactured to Melett specifications, mainly in the UK and Europe by TS16949 certified manufacturers:
      • TS16949 — is the International Quality Management Standard specifically written by the Automotive Industry and is a concerted effort to improve quality and assure the integrity of supplies to the industry.
    • • All Melett parts are supplied from our UK premises and our quality standards are backed by the ISO international standard certification ref ISO90001 2008:
      • ISO 9001 — is the internationally recognised standard for the quality management of businesses.

Turbocharger Major Parts

Including: Bearing Housings, Shaft & Wheels, Compressor Wheels, Seal Plates and Heat Shields.

Bearing Housings

At Melett, we have a thorough understanding of bearing housing manufacture, and the complex processes involved to ensure they are produced correctly:

  • Our growing range of bearing housings covers a wide range of turbos;
  • Quality inspections and testing are carried out at several points throughout production, with all final inspections being undertaken at Melett UK;
  • All specialist materials comply with original OEM specification to ensure reliable performance.

Shaft & Wheels / Turbine Wheels

At Melett, we offer a large range of shaft & wheels from the smallest KP35/GT12 models up to the large HC5A, including more unusual shafts such as Komatsu applications:

  • Every shaft & wheel is produced to a Melett drawing and on Melett’s own casting tools;
  • Each batch is engraved with a batch identification number to help with traceability;
  • Fresh Inconel bar only – We do not use re-melt in our shaft & wheel production;
  • Quality inspections and testing are carried out at several points throughout production, with all final inspections being undertaken at Melett UK, before they are packaged in a Melett box.

Compressor Wheels

We have a wide range of compressor wheels available for the smallest Smart cars, through to the larger commercial vehicles and off highway applications:

  • All our compressor wheels are manufactured, cast machined and balanced at high quality facilities;
  • High balancing specification is achieved by using fully automated, OEM equivalent balancing equipment;

Material Quality

The quality of the material and the casting process is extremely important to produce a high strength cast wheel:

  • Post process treatments are critical to ensure the correct strength is achieved, if the compressor wheel is not strong enough, it will fail;
  • Many failures of low quality compressor wheels are often mistaken to be standard turbo failures e.g. loss of blade could be foreign object damage, signs of overspeeding — this could be due to poor material quality rather than the turbo overspeeding;
  • The blades bend in the heat and suffer from fatigue causing them to break off on low quality wheels;
  • Melett ensures the strength of our compressor wheels are to the correct specification;
  • Melett has the capabilities to produce threaded bore compressor wheels, like for like with the OEM specifications;
  • We also produce Machined From Solid (MFS) compressor wheels — these are becoming increasingly popular as these new developments, from the OE’s, continue to arrive in the aftermarket.

For further information on Compressor Wheels click here.

Seal Plates / Back Plates

Casting quality and machining quality are critical to give seal plates their strength:

  • Melett seal plates undergo post casting processes to strengthen the product;
  • Only high quality castings are used to ensure there are no cracks;
  • Seal plates are perceived to be a low value item — often casting companies will use re-melt and poor casting material because the product is not seen to be a major component or the casting requirements are not very high;
  • In reality, the seal plate casting has to be reliable to prevent cracking in service, due to the harsh environment in the engine bay such as high temperatures and vibrations, which can lead to cracks or failure;
  • At Melett, we do not use re-melt in our seal plate production.

Heat Shields

Heat shields are designed to shield the piston ring and the bearing housing from the hot gases, and stop the exhaust gas hitting the piston ring:

  • Quality requirements of a heat shield vary dramatically from one turbo to another, based upon the temperature of the application and design of the heat shield;
  • In some older applications, a heat shield was generally a pressed piece of stainless steel, where the material quality and dimensional accuracy was not high, relative to other parts to the turbo;
  • In the more recent turbo developments for VNT/VGT’s the dimensional accuracy has increased and the temperature the components are subjected too, is much higher as a result. Some modern heat shields are produced from high temperature material similar to the turbine wheel;
  • The correct use of material is essential or it will fail — if the material quality is not the right high temperature material, they will relax, hit the back of the shaft & wheel and smash to pieces;
  • Melett heat shields are mainly produced to go in Melett Cores, however they are available as a replaceable service item.

Core Tools

Core Assembly Building Tools
Melett’s range of Core Assembly Building Tools has been specifically developed to assist fast and efficient assembly of CHRA parts and help to prevent component damage during assembly.

From listening to our customers’ requests and following the successful use of the tools in our own Core Production Facility, the range is available for purchase. This brochure highlights the benefits of using the tools whilst also offering you a simple guide on how to use the tools correctly.

View our Core Tools Brochure