4.5" Experimenter's Tesla Turbine, construction details, baseplate, bearing housing end plates, hot rotor housing, case ring, Phoenix Turbine Builders Club

4.5" Experimenter's Tesla Turbine

Construction Details - Part I

October 2005

Last month we concluded our discussion of solar collectors, and are moving on to a firsthand look at our new, complete 4.5-inch Tesla turbine.

We'll begin this month's article by showing methods of constructing parts of the turbine.

Photo 1 shows how we cut 6-foot lengths of 6061 aluminum for the base plate, bearing housing and plates, and hot rotor housing end plate. We use a 10-inch carbide circular blade and slowly slice the slab into appropriate lengths.
Photo 2 shows round billet 6061 aluminum before and after boring for bearings.
In Photo 3 we have bored and tapped the bearing housing for air and oil fittings.
Photo 4 shows the 5-inch hot rotor case ring with the inlet and inlet flange wire welded together, and just prior to cutting the inner and outer ring diameters. Since the aluminum is soft, the inlet material protruding into the case ring is simply cut at the same time with a lathe bit. If we were using stainless steel for the ring, it would be necessary to first grind the excess inlet material prior to turbine on the lathe.

Photo 5 shows a batch of finished turbine parts on the left - including alloy and stainless hardware for completing the turbine case.

On the right we see the completely assembled turbine case.

Photo 6 - Tesla Turbine case In Photo 6 we see a close-up of our completed Tesla turbine case - awaiting the shaft, bearings, and hot rotor.

That should give you an idea of both the quality and complexity of the numerous parts that go into a Tesla turbine.

Next month we'll continue examining a completely built-up turbine including the nozzle, air seal ports and oil ports. Until then, keep working on your own projects and let us know what discoveries you've made.

Ken Rieli