Hwang, Joonsik; Karathanassis, Ioannis K.; Koukouvinis, Phoevos; Nguyen, Tuan; Tagliante, Fabien; Pickett, Lyle M.; Sforzo, Brandon A.; Powell, Christopher F.
As modern gasoline direct injection (GDI) engines utilize sophisticated injection strategies, a detailed understanding of the air-fuel mixing process is crucial to further improvements in engine emission and fuel economy. In this study, a comprehensive evaluation of the spray process of single-component iso-octane (IC8) and multi-component gasoline surrogate E00 (36 % n-pentane, 46 % iso-octane, and 18 % n-undecane, by volume) fuels was conducted using an Engine Combustion Network (ECN) Spray G injector. High-speed extinction, schlieren, and microscopy imaging campaigns were carried out under engine-like ambient conditions in a spray vessel. Experimental results including liquid/vapor penetration, local liquid volume fraction, droplet size, and projected liquid film on the nozzle tip were compared under ECN G1 (573 K, 3.5 kg/m3), G2 (333 K, 0.5 kg/m3), and G3 (333 K, 1.01 kg/m3) conditions. In addition to the experiments, preferential evaporation process of the E00 fuel was elucidated by Large–Eddy Simulations (LES). The three-dimensional liquid volume fraction measurement enabled by the computed tomographic reconstruction showed substantial plume collapse for E00 under the G2 and G3 conditions having wider plume growth and plume-to-plume interaction due to the fuel high vapor pressure. The CFD simulation of E00 showed an inhomogeneity in the way fuel components vaporized, with more volatile components carried downstream in the spray after the end of injection. The high vapor pressure of E00 also results in ∼4 μm smaller average droplet diameter than IC8, reflecting a higher rate of initial vaporization even though the final boiling point temperature is higher. Consistent with high vapor pressure, E00 had a wider plume cone angle and enhanced interaction with the wall to cover the entire surface of the nozzle tip in a film. However, the liquid fuel underwent faster evaporation, so the final projected tip wetting area was smaller than the IC8 under the flash-boiling condition.
A predictive thermodynamic model is utilized for the calculation of fuel properties of oxymethylene dimethyl ethers (OME3–4), surrogates for gasoline, diesel and aviation fuel, as well as alcohol blends with gasoline and diesel. The alcohols used for these blends are methanol, ethanol, propanol, butanol and pentanol; their mixing ratio ranges from 10 to 50% by volume. The model is based on the Perturbed-Chain Statistical Association Fluid Theory (PC-SAFT) equation of state (EoS) and Vapor Liquid Equilibrium (VLE) calculations at constant temperature, density and composition. The model includes the association term, with the assumption of two association sites (2B scheme), to enable the modeling of alcohols. The pure-component parameters are estimated based on the Group Contribution (GC) method of various sources, as well as a parametrization model specifically designed for the case of OME3–4. The results of the computational model for the density, vapor pressure and distillation curves at various conditions, including high-pressure, high-temperature (HPHT), are compared to experimental and computational data available in the literature. In the cases where no measurements are available for the surrogates, experimental data for the corresponding target fuel are used, taking into consideration the inherent deviation in properties between real and surrogate fuel. Overall, the results are in good agreement with the data from the literature, with the average deviation not exceeding 12% for temperature (Kelvin) on the distillation curves, 10% for density and 46% for vapor pressure and the general trend being captured successfully. The use of different pure component parameter estimation techniques can further improve the prediction quality in the cases of OME3–4 and the aviation fuel surrogate, especially for the vapor pressure, leading to an average deviation lower than 18%. These results demonstrate the predictive capabilities of the model, which extend to a wide range of fuel types and pressure/temperature conditions. Through this investigation, the present work aims to establish the limits of applicability of this thermodynamic property prediction methodology.
In recent years, the Engine Combustion Network (ECN) has developed as a worldwide reference for understanding and describing engine combustion processes, successfully bringing together experimental and numerical efforts. Since experiments and numerical simulations both target the same boundary conditions, an accurate characterization of the stratified environment that is inevitably present in experimental facilities is required. The difference between the core-, and pressure-derived bulk-temperature of pre-burn combustion vessels has been addressed in various previous publications. Additionally, thermocouple measurements have provided initial data on the boundary layer close to the injector nozzle, showing a transition to reduced ambient temperatures. The conditions at the start of fuel injection influence physicochemical properties of a fuel spray, including near nozzle mixing, heat release computations, and combustion parameters. To address the temperature stratification in more detail, thermocouple measurements at larger distances from the spray axis have been conducted. Both the temperature field prior to the pre-combustion event that preconditions the high-temperature, high-pressure ambient, as well as the stratification at the moment of fuel injection were studied. To reveal the cold boundary layer near the injector with a better spatial resolution, Rayleigh scattering experiments and thermocouple measurements at various distances close to the nozzle have been carried out. The impact of the boundary layers and temperature stratification are illustrated and quantified using numerical simulations at Spray A conditions. Next to a reference simulation with a uniform temperature field, six different stratified temperature distributions have been generated. These distributions were based on the mean experimental temperature superimposed by a randomized variance, again derived from the experiments. The results showed that an asymmetric flame structure arises in the computed results when the temperature stratification input is used. In these predictions, first-stage ignition is advanced by 24μs, while second-stage ignition is delayed by 11μs. At the same time a lift-off length difference between the top and the bottom of up to 1.1 mm is observed. Furthermore, the lift-off length is less stable over time. Given the shown dependency, the temperature data is made available along with the vessel geometry data as a recommended basis for future numerical simulations.
Fireballs produced from the detonation of high explosives often contain particulates primarily composed of various phases of carbon soot. The transport and concentration of these particulates is of interest for model validation and emission characterization. This work proposes ultra-high-speed imaging techniques to observe a fireball's structure and optical depth. An extinction-based diagnostic applied at two wavelengths indicates that extinction scales inversely with wavelength, consistent with particles in the Rayleigh limit and dimensionless extinction coefficients which are independent of wavelength. Within current confidence bounds, the extinction-derived soot mass concentrations agree with expectations based upon literature reported soot yields. Results also identify areas of high uncertainty where additional work is recommended.
This work investigates the low- and high-temperature ignition and combustion processes, applied to the Engine Combustion Network Spray A flame, combining advanced optical diagnostics and large-eddy simulations (LES). Simultaneous high-speed (50 kHz) formaldehyde (CH2O) planar laser-induced fluorescence (PLIF) and line-of-sight OH* chemiluminescence imaging were used to measure the low- and high-temperature flame, during ignition as well as during quasi-steady combustion. While tracking the cool flame at the laser sheet plane, the present experimental setup allows detection of distinct ignition spots and dynamic fluctuations of the lift-off length over time, which overcomes limitations for flame tracking when using schlieren imaging [Sim et al.Proc. Combust. Inst. 38 (4) (2021) 5713–5721]. After significant development to improve LES prediction of the low-and high-temperature flame position, both during the ignition processes and quasi-steady combustion, the simulations were analyzed to gain understanding of the mixture variance and how this variance affects formation/consumption of CH2O. Analysis of the high-temperature ignition period shows that a key improvement in the LES is the ability to predict heterogeneous ignition sites, not only in the head of the jet, but in shear layers at the jet edge close to the position where flame lift-off eventually stabilizes. The LES analysis also shows concentrated pockets of CH2O, in the center of jet and at 20 mm downstream of the injector (in regions where the equivalence ratio is greater than 6), that are of similar length scale and frequency as the experiment (approximately 5–6 kHz). The periodic oscillation of CH2O match the frequency of pressure waves generated during auto-ignition and reflected within the constant-volume vessel throughout injection. The ability of LES to capture the periodic appearance and destruction of CH2O is particularly important because these structures travel downstream and become rich premixed flames that affect soot production.
Imaging using THz waves has been a promising option for penetrative measurements in environments that are opaque to visible wavelengths. However, available THz imaging systems have been limited to relatively low frame rates and cannot be applied to study fast dynamics. This work explores the use of upconversion imaging techniques based on nonlinear optics to enable wavelength-flexible high frame rate THz imaging. UpConversion Imaging (UCI) uses nonlinear conversion techniques to shift the THz wavelengths carrying a target image to shorter visible or near-IR wavelengths that can be detected by available high-speed cameras. This report describes the analysis methodology used to design a prototype high-rate THz UCI system and gives a detailed explanations of the design choices that were made. The design uses a high-rate pulse-burst laser system to pump both THz generation and THz upconversion detection, allowing for scaling to acquisition rates in excess of 10 kHz. The design of the prototype system described in this report has been completed and all necessary materials have been procured. Assembly and characterization testing is on-going at the submission of this report. This report proposes future directions for work on high-rate THz UCI and potential applications of future systems.
Wall impingement and fuel film deposition in gasoline direct injection engines under cold start conditions are major concerns for emissions reduction. However, it is challenging to study the dynamics of film deposition under realistic conditions because of the difficulty of measuring the thicknesses of these microscale films. Low-coherence interferometry provides a quantitative optical film thickness measurement technique that can be applied to study this problem. This work presents the first high-speed spectral low-coherence interferometry measurements of impinging gasoline direct injection sprays. The feasibility and practical concerns associated with high-speed low-coherence interferometry systems are explored. Two approaches to spectral low-coherence interferometry: Michelson interferometry and Fizeau interferometry, were implemented and are compared. The results show that Fizeau interferometry is the better option for measurements of impinging sprays in closed spray vessels. The high-speed low-coherence interferometry system was applied in the Fizeau configuration to measure time-resolved film thickness of impinging sprays under engine-relevant conditions to demonstrate its capabilities.
Injector performance in gasoline Direct-Injection Spark-Ignition (DISI) engines is a key focus in the automotive industry as the vehicle parc transitions from Port Fuel Injected (PFI) to DISI engine technology. DISI injector deposits, which may impact the fuel delivery process in the engine, sometimes accumulate over longer time periods and greater vehicle mileages than traditional combustion chamber deposits (CCD). These higher mileages and longer timeframes make the evaluation of these deposits in a laboratory setting more challenging due to the extended test durations necessary to achieve representative in-use levels of fouling. The need to generate injector tip deposits for research purposes begs the questions, can an artificial fouling agent to speed deposit accumulation be used, and does this result in deposits similar to those formed naturally by market fuels? In this study, a collection of DISI injectors with different types of conditioning, ranging from controlled engine-stand tests with market or profould fuels, to vehicle tests run over drive cycles, to uncontrolled field use, were analyzed to understand the characteristics of their injector tip deposits and their functional impacts. The DISI injectors, both naturally and profouled, were holistically evaluated for their spray performance, deposit composition, and deposit morphology relative to one another. The testing and accompanying analysis reveals both similarities and differences among naturally fouled, fouled through long time periods with market fuel, and profouled injectors, fouled artificially through the use of a sulfur dopant. Profouled injectors were chemically distinct from naturally fouled injectors, and found to contain higher levels of sulfur dioxide. Also, profouled injectors exhibited greater volumes of deposits on the face of the injector tip. However, functionally, both naturally-fouled and profouled injectors featured similar impacts on their spray performance relative to clean injectors, with the fouled injector spray plumes remaining narrower, limiting plume-to-plume interactions, and altering the liquid-spray penetration dynamics., insights from which can guide future research into injector tip deposits.
In this work, we present a detailed implementation and validation of the droplet modeling framework proposed by Dahms and Oefelein (2016) into the engine commercial CFD software CONVERGE using the User Defined Function (UDF) interface. The model accounts for the nonlinear deformation and oscillation experienced by liquid spray droplet injected into high pressure and temperature. Lagrangian spray simulations of Engine Combustion Network (ECN) Spray A are performed. Model validation against standard experimental measurements of liquid velocity, vapor mixture fraction is conducted. To perform more rigorous model validation, new experimental measurements based on Diffused Back Illumination (DBI) are introduced. The new measurements are processed for Projected Liquid Volume (PLV), which offers as close as possible one-to-one model validation for liquid penetration while offering new insights into the spray physics. Comparison with a One-D model based on adiabatic mixing theory by Siebers (1999) and Desantes et al. (2007) are also conducted. Through these model validation exercises, it is shown that the new framework improves liquid-phase penetration predictions, following a tendency for enhanced evaporation, compared to the standard approach for both Reynolds Average Navier Stokes (RANS) and Large Eddy Simulation (LES). At the liquid length, maximum mixture fraction values predicted by the new approach are in good agreement those of an adiabatic mixing model. Qualitative analysis of the spray behaviors during the early stage of the injection process reveals that the proposed framework predicts significant increase in droplet evaporation rate with lower drop drag compared to the current standard approach.
Current state-of-the-art gasoline direct-injection (GDI) engines use multiple injections as one of the key technologies to improve exhaust emissions and fuel efficiency. For this technology to be successful, secured adequate control of fuel quantity for each injection is mandatory. However, nonlinearity and variations in the injection quantity can deteriorate the accuracy of fuel control, especially with small fuel injections. Therefore, it is necessary to understand the complex injection behavior and to develop a predictive model to be utilized in the development process. This study presents a methodology for rate of injection (ROI) and solenoid voltage modeling using artificial neural networks (ANNs) constructed from a set of Zeuch-style hydraulic experimental measurements conducted over a wide range of conditions. A quantitative comparison between the ANN model and the experimental data shows that the model is capable of predicting not only general features of the ROI trend, but also transient and non-linear behaviors at particular conditions. In addition, the end of injection (EOI) could be detected precisely with a virtually generated solenoid voltage signal and the signal processing method, which applies to an actual engine control unit. A correlation between the detected EOI timings calculated from the modeled signal and the measurement results showed a high coefficient of determination.
Heidari-Koochi, Milad; Karathanassis, Ioannis K.; Koukouvinis, Phoevos; Hwang, Joonsik; Pickett, Lyle M.; Spivey, David
Research on renewable and alternative fuels is crucial for improving the energy and environmental efficiency of modern gasoline internal combustion engines. To highlight the influence of fuel rheological and thermodynamic properties on phase change and atomisation processes, three types of gasoline blends were tested. More specifically, the campaign comprised a reference gasoline, an ethanol/gasoline blend (10% v/v) representative of renewable fuels, and an additised gasoline sample treated with viscoelasticity-inducing agents. High-speed imaging of the transient two-phase flow field arising in the internal geometry and the near-nozzle spray region of gasoline injectors was performed employing Diffuse Backlight Illumination. The metallic body of a commercial injector was modified to fit transparent tips realising two nozzle layouts, namely a two-hole real size model resembling the Engine Combustion Network spray G injector and an enraged replica with an offset hole. Experiments were conducted at realistic operating conditions comprising an injection pressure of 100 bar and ambient pressures in the range of 0.1–6.0 bar to cover the entire range of chamber pressures prevailing in Gasoline Direct Injection engines. The action of viscoelastic additives was verified to have a suppressive effect on in-nozzle cavitation (6% reduction in cavitation extent), while also enhancing spray atomisation at flash-boing conditions, in a manner resembling the more volatile gasoline/ethanol blends. Finally, persisting liquid ligaments were found to form after the end of injection for the additised sample, owing to the surfactant nature of the additives.
The detonation of explosives produces luminous fireballs often containing particulates such as carbon soot or remnants of partially reacted explosives. The spatial distribution of these particulates is of great interest for the derivation and validation of models. In this work, three ultra-high-speed imaging techniques: diffuse back-illumination extinction, schlieren, and emission imaging, are utilized to investigate the particulate quantity, spatial distribution, and structure in a small-scale fireball. The measurements show the evolution of the particulate cloud in the fireball, identifying possible emission sources and regions of high optical thickness. Extinction measurements performed at two wavelengths shows that extinction follows the inverse wavelength behavior expected of absorptive particles in the Rayleigh scattering regime. The estimated mass from these extinction measurements shows an average soot yield consistent with previous soot collection experiments. The imaging diagnostics discussed in the current work can provide detailed information on the spatial distribution and concentration of soot, crucial for validation opportunities in the future.
Large-Eddy Simulations (LES) of a gasoline spray, where the mixture was ignited rapidly during or after injection, were performed in comparison to a previous experimental study with quantitative flame motion and soot formation data [SAE 2020-01-0291] and an accompanying Reynolds-Averaged Navier–Stokes (RANS) simulation at the same conditions. The present study reveals major shortcomings in common RANS combustion modeling practices that are significantly improved using LES at the conditions of the study, specifically for the phenomenon of rapid ignition in the highly turbulent, stratified mixture. At different ignition timings, benchmarks for the study include spray mixing and evaporation, flame propagation after ignition, and soot formation in rich mixtures. A comparison of the simulations and the experiments showed that the LES with Dynamic Structure turbulence were able to capture correctly the liquid penetration length, and to some extent, spray collapse demonstrated in the experiments. For early and intermediate ignition timings, the LES showed excellent agreement to the measurements in terms of flame structure, extent of flame penetration, and heat-release rate. However, RANS simulations (employing the common G-equation or well-stirred reactor) showed much too rapid flame spread and heat release, with connections to the predicted turbulent kinetic energy. With confidence in the LES for predicted mixture and flame motion, the predicted soot formation/oxidation was also compared to the experiments. The soot location was well captured in the LES, but the soot mass was largely underestimated using the empirical Hiroyasu model. An analysis of the predicted fuel–air mixture was used to explain different flame propagation speeds and soot production tendencies when varying ignition timing.
This work describes the diagnostic implementation and image processing methods to quantitatively measure diesel spray mixing injected into a high-pressure, high-temperature environment. We used a high-repetition-rate pulse-burst laser developed in-house, a high-speed CMOS camera, and optimized the optical configuration to capture Rayleigh scattering images of the vaporized fuel jets inside a constant volume chamber. The experimental installation was modified to reduce reflections and flare levels to maximize the images’ signal-to-noise ratios by anti-reflection coatings on windows and surfaces, as well as series of optical baffles. Because of the specificities of the high-speed system, several image processing techniques had to be developed and implemented to provide quantitative fuel concentration measurements. These methods involve various correction procedures such as camera linearity, laser intensity fluctuation, dynamic background flare, as well as beam-steering effects. Image inpainting was also applied to correct the Rayleigh scattering signal from large scatterers (e.g. particulates). The experiments demonstrate that applying planar laser Rayleigh scattering at high repetition rate to quantitatively resolve the mixing of fuel and ambient gases in diesel jets is challenging, but possible. The thorough analysis of the experimental uncertainty and comparisons to past data prove that such measurements can be accurate, whilst providing valuable information about the mixing processes of high-pressure diesel jets.
All future high-efficiency engines will have fuel directly sprayed into the engine cylinder. Engine developers agree that a major barrier to the rapid development and design of these high-efficiency, clean engines is the lack of accurate fuel spray computational fluid dynamics (CFD) models. The spray injection process largely determines the fuel–air mixture processes in the engine, which subsequently drive combustion and emissions in both direct-injection gasoline and diesel systems, particularly at cold-start conditions when aftertreatment is ineffective. Engines must be tolerant to a range of fuels, and there must be an understanding of how specific fuel properties affect the spray mixing and evaporation processes to intentionally create better fuels and better injectors. More predictive spray combustion models will enable rapid design and optimization of future high-efficiency engines, providing more affordable vehicles and saving fuel.
The interaction of multiple injections in a diesel engine facilitates a complex interplay between freshly introduced fuel, previous combustion products, and overall combustion. To improve understanding of the relevant processes, high-speed Planar Laser-Induced Fluorescence (PLIF) with 355-nm excitation of formaldehyde and Polycyclic Aromatic Hydrocarbon (PAH) soot precursors is applied to multiple injections of n-dodecane from Engine Combustion Network Spray D, characterized by a converging 189-µm nozzle. High-speed schlieren imaging is applied simultaneously with 50-kHz PLIF excitation to visualize the spray structures, jet penetration, and ignition processes. For the first injection, formaldehyde (as an indicator of low-temperature chemistry) is first found in the jet periphery, after which it quickly propagates through the center of the jet, towards the jet head prior to high-temperature ignition. At second-stage ignition, downstream formaldehyde is consumed rapidly and upstream formaldehyde develops into a quasi-steady structure for as long as the momentum flux from the injector continues. Since the first injection in this work is relatively short, differences to a single long injection are readily observed, ultimately resulting in high-temperature combustion and PAH structures appearing farther upstream after the end of injection. For the second injection in this work, the first formaldehyde signal is significantly advanced because of the entrained high-temperature combustion products, and an obvious premixed burn event does not occur. The propensity for combustion recession after the end of the first injection changes significantly with ambient temperature, thereby affecting the level of interaction between the first- and second injection.
The low- and high-temperature ignition and combustion processes in a high-pressure spray flame of n-dodecane were investigated using simultaneous 50-kHz formaldehyde (HCHO) planar laser-induced fluorescence (PLIF) and 100-kHz schlieren imaging. PLIF measurements were facilitated through the use of a pulse-burst-mode Nd:YAG laser, and the high-speed HCHO PLIF signal was imaged using a non-intensified CMOS camera with dynamic background emission correction. The experiments were conducted in the Sandia constant-volume preburn vessel equipped with a new Spray A injector. The effects of ambient conditions on the ignition delay times of the two-stage ignition events, HCHO structures, and lift-off length values were examined. Consistent with past studies of traditional Spray A flames, the formation of HCHO was first observed in the jet peripheries where the equivalence ratio (Φ) is expected to be leaner and hotter and then grows in size and in intensity downstream into the jet core where Φ is expected to be richer and colder. The measurements showed that the formation and propagation of HCHO from the leaner to richer region leads to high-temperature ignition events, supporting the identification of a phenomenon called “cool-flame wave propagation” during the transient ignition process. Subsequent high-temperature ignition was found to consume the previously formed HCHO in the jet head, while the formation of HCHO persisted in the fuel-rich zone near the flame base over the entire combustion period.