Design and Fabrication of a Retrofittable Exhaust Energy Recovery System

Experimental Prototype for Waste Heat Recovery This report documents the design, manual fabrication, and experimental testing of a retrofittable exhaust energy recovery micro-turbine. Conducted as a primary research project during the author's undergraduate tenure in Mechanical Engineering, the study explores the "Bottoming Cycle" concept by capturing waste kinetic and thermal energy from internal combustion engine (ICE) exhaust streams. Key Technical Highlights: Material Fabrication: Construction of a radial-flow turbine using 6061 Aluminum blades and a custom-welded steel housing. Mechanical Transmission: Integration of a dual-groove pulley system to drive an auxiliary alternator for DC power generation. Rotational Dynamics: Documentation of manual balancing techniques used to mitigate harmonic vibrations at high RPM. Failure Analysis: A detailed review of "heat soak" effects and the thermal decomposition of elastomeric seals at the manifold interface. Significance for Sustainability: This work serves as a foundational study for carbon-reduction retrofitting in existing transport fleets. By reclaiming waste energy, the system demonstrates a practical pathway toward improving the fuel efficiency and lifecycle sustainability of internal combustion assets in a transition-economy context.