Spray analysis of a gasoline direct injector by means of two-phase PIV

The hollow-cone spray of a high-pressure swirl injector for a direct-injection spark-ignition (DISI) engine was investigated inside a pressure vessel by means of particle image velocimetry (PIV). As the interaction between the spray droplets and the ambient air is of particular interest for the mixture preparation process, two-phase PIV techniques were applied. To allow phase discrimination, fluorescent seeding particles were used to trace the gas phase. Because of the periodicity of piston engine injection, a statistical evaluation of ensemble-averaged fields to reduce cycle-to-cycle variations and to provide more general information about the two-phase flow was performed. Besides the general spray/air interaction process the investigation of the spray collapse at elevated ambient pressures was the main focus of the study. Future investigations of transient interaction processes require simultaneous techniques in combination with a high-speed camera to resolve the transient interaction phenomena. Therefore, optical filters that attenuate Mie-scattered light and transmit fluorescent light were used to collect both phases on the same image. Consequently, phase separation techniques were employed for data analysis. A masking and a peak separation technique are described and a comparison between the results of an instantaneous two-phase flow field in the spray cone of a DISI injector is presented in the paper.     

Atomization and spray characteristics of bioethanol and bioethanol blended gasoline fuel injected through a direct injection gasoline injector

The focus of this study was to investigate the spray characteristics and atomization performance of gasoline fuel (G100), bioethanol fuel (E100), and bioethanol blended gasoline fuel (E85) in a direct injection gasoline injector in a gasoline engine. The overall spray and atomization characteristics such as an axial spray tip penetration, spray width, and overall SMD were measured experimentally and predicted by using KIVA-3V code.The development process and the appearance timing of the vortices in the test fuels were very similar. In addition, the numerical results accurately described the experimentally observed spray development pattern and shape, the beginning position of the vortex, and the spray breakup on the spray surface. Moreover, the increased injection pressure induced the occurrence of a clear circular shape in the downstream spray and a uniform mixture between the injected spray droplets and ambient air. The axial spray tip penetrations of the test fuels were similar, while the spray width and spray cone angle of E100 were slightly larger than the other fuels. In terms of atomization performance, the E100 fuel among the tested fuels had the largest droplet size because E100 has a high kinematic viscosity and surface tension.     

String flash-boiling in gasoline direct injection simulations with transient needle motion

A computational study was performed to investigate the influence of transient needle motion on gasoline direct injection (GDI) internal nozzle flow and near-field sprays. Simulations were conducted with a compressible Eulerian flow solver modeling liquid, vapor, and non-condensable gas phases with a diffuse interface. Variable rate generation and condensation of fuel vapor were captured using the homogeneous relaxation model (HRM). The non-flashing (spray G) and flashing (spray G2) conditions specified by the Engine Combustion Network were modeled using the nominal spray G nozzle geometry. Transient needle lift and wobble were based upon ensemble averaged X-ray imaging preformed at Argonne National Lab. The minimum needle lift simulated was 5 µm and dynamic mesh motion was achieved with Laplacian smoothing. The results were qualitatively validated against experimental imaging and the experimental rate of injection profile was captured accurately using pressure boundary conditions and needle motion to actuate the injection. Low needle lift is shown to result in vapor generation near the injector seat. Finally, the internal injector flow is shown to be highly complex, containing many transient and interacting vortices which result in perturbations in the spray angle and fluctuations in the mass flux. This complex internal flow also results in intermittent string flash-boiling when a strong vortex is injected and the resulting swirling spray contains a thermal non-equilibrium vapor core.     

A novel transient wall heat transfer approach for the start-up of SI engines with gasoline direct injection

The introduction of CO₂-reduction technologies like Start–Stop or the Hybrid-Powertrain and the worldwide stringent emission legislation require a detailed optimization of the engine start-up. The combustion concept development as well as the calibration of the engine control unit makes an explicit thermodynamic analysis of the combustion process during the start-up necessary. Initially, the well-known thermodynamic analysis of in-cylinder pressure at stationary condition was transmitted to the highly non-stationary engine start-up. For this running mode of the engine the current models for calculation of the transient wall heat fluxes were found to be misleading. With a fraction of nearly 45% of the burned fuel energy, the wall heat is very important for the calculation of energy balance and for the combustion process analysis. Based on the measurements of transient wall heat transfer densities during the start-up presented in a former work (Lejsek and Kulzer in Investigations on the transient wall heat transfer at start-up for SI engines with gasoline direct injection. SAE Paper), the paper describes the development of adaptations to the known correlations by Woschni (MTZ 31:491, 1970), Hohenberg (Experimentelle Erfassung der Wandwärme von Kolbenmotoren. TU Graz, Habil., 1980) and Bargende (Ein Gleichungsansatz zur Berechnung der instationären Wandwärmeverluste im Hochdruckteil von Ottomotoren. TH Darmstadt, PhD-Thesis, 1991) for the application during engine start-up. To demonstrate the high accuracy of the model, the results of the cyclic resolved thermodynamic analysis using the presented novel approaches were compared with the results of the measurements. It is shown, that the novel heat flux models for the engine start-up process gives a cyclic resolved thermodynamic analysis to optimize the engine start-up pretty efficient.     

The spray characteristics of a pressure-swirl injector with various exit plane tilts

The gasoline spray characteristics of a pressure-swirl injector were investigated with various exit plane tilts. The analysis focused on the correlation between tilt angle and flow angle. Mie-scattering technique and phase Doppler anemometry were employed to analyze the macroscopic spray development and droplet size distribution of the spray. An analytical method for mass flux estimation was applied to understand the velocity distribution at the nozzle exit. The results showed that the spray shape and velocity distribution of the spray were more asymmetrical at high tilt angles. In particular, an opened hollow cone spray was formed when the tilt angle is greater than the complementary flow angle. The pressure drop inside the spray, one of the crucial factors for the swirl spray collapse at various surrounding conditions, was attenuated in this opened hollow cone spray since the pressure inside the spray was assimilated to the surrounding air pressure. The spray collapse at high fuel temperature and back pressure conditions did not appear when the tilt angle is larger than the complementary flow angle due to the reduced pressure drop inside the spray. However, tilt angle should be optimized to fulfill the requirements of spray robustness and avoid the locally rich area. The droplet size of 70° tilted nozzle spray shows a value similar to that of the original swirl spray in the plane that includes nozzle axis and the major axis of exit surface ellipse (Major axis plane) while it shows an increased value in the plane that includes nozzle axis and the minor axis of exit surface ellipse (Minor axis plane).     

Spray features in the near field of a flow-blurring injector investigated by high-speed visualization and time-resolved PIV

In a flow-blurring (FB) injector, atomizing air stagnates and bifurcates at the gap upstream of the injector orifice. A small portion of the air penetrates into the liquid supply line to create a turbulent two-phase flow. Pressure drop across the injector orifice causes air bubbles to expand and burst thereby disintegrating the surrounding liquid into a fine spray. In previous studies, we have demonstrated clean and stable combustion of alternative liquid fuels, such as biodiesel, straight vegetable oil and glycerol by using the FB injector without requiring fuel pre-processing or combustor hardware modification. In this study, high-speed visualization and time-resolved particle image velocimetry (PIV) techniques are employed to investigate the FB spray in the near field of the injector to delineate the underlying mechanisms of atomization. Experiments are performed using water as the liquid and air as the atomizing gas for air to liquid mass ratio of 2.0. Flow visualization at the injector exit focused on a field of view with physical dimensions of 2.3 mm × 1.4 mm at spatial resolution of 7.16 µm per pixel, exposure time of 1 µs, and image acquisition rate of 100 k frames per second. Image sequences illustrate mostly fine droplets indicating that the primary breakup by FB atomization likely occurs within the injector itself. A few larger droplets appearing mainly at the injector periphery undergo secondary breakup by Rayleigh–Taylor instabilities. Time-resolved PIV is applied to quantify the droplet dynamics in the injector near field. Plots of instantaneous, mean, and root-mean-square droplet velocities are presented to reveal the secondary breakup process. Results show that the secondary atomization to produce fine and stable spray is complete within a few diameters from the injector exit. These superior characteristics of the FB injector are attractive to achieve clean combustion of different fuels in practical systems.     

An experimental study of fuel injection strategies in CAI gasoline engine

Combustion of gasoline in a direct injection controlled auto-ignition (CAI) single-cylinder research engine was studied. CAI operation was achieved with the use of the negative valve overlap (NVO) technique and internal exhaust gas re-circulation (EGR). Experiments were performed at single injection and split injection, where some amount of fuel was injected close to top dead centre (TDC) during NVO interval, and the second injection was applied with variable timing. Additionally, combustion at variable fuel-rail pressure was examined.Investigation showed that at fuel injection into recompressed exhaust fuel reforming took place. This process was identified via an analysis of the exhaust-fuel mixture composition after NVO interval. It was found that at single fuel injection in NVO phase, its advance determined the heat release rate and auto-ignition timing, and had a strong influence on NO_X emission. However, a delay of single injection to intake stroke resulted in deterioration of cycle-to-cycle variability. Application of split injection showed benefits of this strategy versus single injection. Examinations of different fuel mass split ratios and variable second injection timing resulted in further optimisation of mixture formation. At equal share of the fuel mass injected in the first injection during NVO and in the second injection at the beginning of compression, the lowest emission level and cyclic variability improvement were observed.     

Analysis of misfires in a direct injection engine using proper orthogonal decomposition

Previous work demonstrated that the occasional misfired and partially burned cycles (MF) in a stratified-charge, spark-ignited direct injection engine always achieved an early flame kernel, but failed to reach and inflame the fuel in the bottom of the piston bowl. This conclusion was derived from intra-cycle crank angle resolved velocity and fuel concentration images that were recorded simultaneously using high-speed particle image velocimetry and planar laser-induced fluorescence. In this study, both ensemble average analysis, conditionally sampled on either MF or Well Burned (WB) cycles and proper orthogonal decomposition (POD) are applied separately to the velocity and fuel distributions. POD of the velocity and fuel distributions near the spark plug were performed, and the mode energy and structure of the modes are compared. This analysis is used to assess the similarity and differences between the MF and the WB cycles and to identify physical insight gained by POD. The POD modes were determined from the combined set of 200 WB and 37 MF cycles to create two sets of 237 orthogonal modes, one set for the velocity, V, and one for the equivalence ratio, ε. Then, conditionally sampled averages of the POD coefficients could be used to quantify the extent to which each mode contributed to the MFs. Also, the probability density functions of the coefficients quantified the cyclic variability of each mode’s contribution. The application of proper orthogonal decomposition to velocity and equivalence ratio images was useful in identifying and analyzing the differences in flow and mixture conditions at the time of spark between well-burning and misfiring cycles. However, POD results alone were not sufficient to identify which of the cycles were misfiring cycles, and additional information was required for conditional sampling.     

Effects of turbulence enhancement on combustion process using a double injection strategy in direct-injection spark-ignition (DISI) gasoline engines

Direct-injection spark-ignition (DISI) gasoline engines have been spotlighted due to their high thermal efficiency. Increase in the compression ratio that result from the heat absorption effect of fuel vaporization induces higher thermal efficiency than found in port fuel injection (PFI) engines. Since fuel is injected at the cylinder directly, various fuel injection strategies can be used. In this study, turbulent intensity was improved by a double injection strategy while maintaining mixture homogeneity. To analyze the turbulence enhancement effects using the double injection strategy, a side fuel injected, homogeneous-charge-type DISI gasoline engine with a multi-hole-type injector was utilized. The spray model was evaluated using experimental data for various injection pressures and the combustion model was evaluated for varied ignition timing. First and second injection timing was swept by 20 degree interval. The turbulent kinetic energy and mixture inhomogeneity index were mapped. First injection at the middle of the intake stroke and second injection early in the compression stroke showed improved turbulent characteristics that did not significantly decrease with mixture homogeneity. A double injection case that showed improved turbulent intensity while maintaining an adequate level of mixture homogeneity and another double injection case that showed significantly improved turbulent intensity with a remarkable decrease in mixture homogeneity were considered for combustion simulation. We found that the improved turbulent intensity increased the flame propagation speed. Also, the mixture homogeneity affected the pressure rise rate.     

Flow structure and skin friction in the vicinity of a streamwise-angled injection hole fed by a short pipe

The velocity field and skin friction distribution around a row of five jets issuing into a crossflow from short (L/D ≃ 1) pipes inclined by 35° with respect to the streamwise direction, (i.e., “short holes”) are presented for two different jet supply flow directions. Velocity was measured using PIV, while the skin friction was measured with oil-film interferometry. The flow features are compared with previously published data for jets issuing through holes oriented normal to the crossflow and with numerical simulations of similar geometries. The distinguishing features of the flow field include a reduced recirculation region in comparison to the 90° case and markedly different in-hole flow physics. The jetting process caused by in-hole separations force the bulk of the jet fluid to issue from the leading half of the streamwise-angled injection hole, as previously reported by Brundage et al. (Tech Rep ASME 99-GT-35, 1999) and predicted by Walters and Leylek (ASME J Turbomach 122:101–112, 2000). The flow structure impacts the skin friction distribution around the holes, resulting in higher near-hole shear stress for a counter-flow supply plenum (jet fluid supplied by a high speed plenum flowing opposite to the free stream direction). In contrast, the counter-flow supply plenum was previously found to have the lowest near-hole wall shear stress for normal injection holes (Peterson and Plesniak in Exp Fluids 37:497–503, 2004b). Streamwise-angled injection generally reduces the near-hole skin friction due to the reduced jet trajectory resulting from the lower wall-normal jet momentum. Far downstream, the skin friction distributions are similar for the two injection angle cases.     

Towards the optimization of a pulsatile three-stream coaxial airblast injector

A large-scale parametric air–water test stand (AWTS) study involving more than 40 evaluations was carried out for the purposes of three-stream airblast reactor feed injector characterization and optimization; a subset of seven air stream combinations is discussed here. The role of CFD as a supplement to, or a replacement for, air–water testing is of great industrial interest. To this end a set of CFD simulations was carried out to complement the AWTS study. Pressure responses, spray opening characteristics near the feed injector face, and spray distribution were primary measures for both the AWTS and CFD programs. It was found that, over the range of variables studied, there was somewhat of a match between CFD and AWTS results. A self-exciting, pulsatile spray pattern was achieved in CFD and AWTS (frequencies between 75 and 600 Hz), and an interesting transition in spray bursting character occurred at moderate inner air flows. The oscillatory flow pattern mimics prior work in terms of the energy of the fluctuations, but the fact that the present fluctuations occur at an order of magnitude lower frequency is apparently related to the comparatively low gas/liquid momentum ratio in the current study. Overall, it is shown that the CFD method contained herein can be used to supplement, but not replace, air–water testing for said injector configuration.     

Heat flux characteristics of spray wall impingement with ethanol,butanol, iso-octane,gasoline and E10 fuels

Future fuel stocks for spark-ignition engines are expected to include a significant portion of bio-derived components with quite different chemical and physical properties to those of liquid hydrocarbons. State-of-the-art high-pressure multi-hole injectors for latest design direct-injection spark-ignition engines offer some great benefits in terms of fuel atomisation, as well as flexibility in in-cylinder fuel targeting by selection of the exact number and angle of the nozzle’s holes. However, in order to maximise such benefits for future spark-ignition engines and minimise any deteriorating effects with regards to exhaust emissions, it is important to avoid liquid fuel impingement onto the cylinder walls and take into consideration various types of biofuels. This paper presents results from the use of heat flux sensors to characterise the locations and levels of liquid fuel impingement onto the engine’s liner walls when injected from a centrally located multi-hole injector with an asymmetric pattern of spray plumes. Ethanol, butanol, iso-octane, gasoline and a blend of 10% ethanol with 90% gasoline (E10) were tested and compared. The tests were performed in the cylinder of a direct-injection spark-ignition engine at static conditions (i.e. quiescent chamber at 1.0 bar) and motoring conditions (at full load with inlet plenum pressure of 1.0 bar) with different engine temperatures in order to decouple competing effects. The collected data were analysed to extract time-resolved signals, as well as mean and standard deviation levels of peak heat flux. The results were interpreted with reference to in-cylinder spray formation characteristics, as well as fuel evaporation rates obtained by modelling. In addition, high-speed images of single droplets of fuel impinging onto the array of the heat flux sensor were acquired with simultaneous sampling of the heat flux signal in an attempt to provide further interpretation. The single droplet tests showed ability of the signals to quantify droplet mass impinged on the sensor. Analysis of the peak heat flux at static engine conditions quantified values of fuel temperature at impingement in agreement with the wet bulb temperatures predicted by the droplet evaporation model. Comparison of the static and motoring engine heat flux signals around the bore showed the effect of the intake flow on the spray’s pattern at impingement and demonstrated fuel presence on the liner that survived at exhaust valve open timing. The general behaviour was different for the alcohols to that of the hydrocarbons, with ethanol exhibiting the effect of its high latent heat on the signals and butanol exhibiting effects related to poor atomization and slow evaporation.     

Cycle-to-cycle variation analysis of in-cylinder flow in a gasoline engine with variable valve lift

In spark ignition engines, cycle-to-cycle variation (CCV) limits the expansion of the operating range because it induces the load variations and the occurrence of misfire and/or knock. Variable valve actuation (VVA) or variable valve lift (VVL) has been widely used in SI engines to improve the volumetric efficiency or to reduce the pumping losses. It is necessary to investigate the CCV of in-cylinder gas motion and mixing processes in SI engines with VVA/VVL system. This study is aimed to analyze the CCV of the tumble flow in a gasoline direct injection (GDI) engine when VVL is employed. Cycle-resolved digital particle image velocimetry (CRD-PIV) data were acquired for the in-cylinder flow field of a motored four-stroke multi-valve GDI optical engine. The CCV of in-cylinder gas motion with a series of valve profiles and different maximum valve lift (MVL) was analyzed, including cyclic variation characteristics of bulk flow (tumble centre and tumble ratio), large- and small-scale fluctuation, total kinetic energy, and circulation. The results show that the CCV of the in-cylinder flow is increased with reduced MVL. With lower MVLs, stable tumble flow cannot be formed in the cylinder, and the ensemble-averaged tumble ratio decreases to zero before the end of the compression stroke due to violent variation. In addition, the evolution of the circulation shows larger variation with lower MVLs that indicates the ??spin?? of the small-scale eddy in the flow field presents violent fluctuation from one cycle to another, especially at the end of the compression stroke. Moreover, the analyze of the kinetic energy indicates the total energy of the flow field with lower MVLs increases significantly comparing with higher MVL conditions due to the intake flow jet at the intake valve seat in the intake stroke. However, the CCV of the in-cylinder flow becomes more violent under lower MVL conditions, especially for the low-frequency fluctuation kinetic energy. Thus, present strong tumble flow can lower the CCV of the air motion. It is necessary to manage strong tumble or other bulk flow (such as swirl flow) in order to improve the stability of ignition and combustion for GDI engines with VVL, especially at the lower MVL conditions.     

Effect of distributed gas injection on aerodynamic characteristics of a body of revolution in a supersonic flow

Results of experimental and numerical investigations of the effect of gas injection through a permeable porous surface on the drag coefficient of a cone-cylinder body of revolution in a supersonic flow with the Mach number range M _h = 3–6 are presented. It is demonstrated that gas injection through a porous nose cone with gas flow rates being 6–8% of the free-stream flow rate in the mid-section leads to a decrease in the drag coefficient approximately by 5–7%. The contributions of the decrease in the drag force acting on the model forebody and of the increase in the base pressure to the total drag reduction are approximately identical. Gas injection through a porous base surface with the flow rate approximately equal to 1% leads to a threefold increase in the base pressure and to a decrease in the drag coefficient. Gas injection through a porous base surface with the flow rate approximately equal to 5% gives rise to a supersonic flow zone in the base region.     

Estimates of thermoelastic characteristics of composites reinforced by short anisotropic fibers

We construct a mathematical model describing thermomechanical interaction between composite structure elements (isotropic particles of the matrix and anisotropic short fibers) and the macroscopically isotropic elastic medium with desired thermoelastic characteristics. At the first stage of this model, the self-consistency method is used to obtain relations determining the elasticity moduli of the composite, and at the second stage, the model permits determining its linear thermal expansion coefficient. The dual variational statement of the linear thermoelasticity problem in an inhomogeneous solid permits obtaining two-sided estimates for the bulk elasticity modulus, shear modulus, and linear thermal expansion coefficient of the composite under study. The calculated dependencies presented in the paper permit predicting the thermoelastic characteristics of a composite reinforced by anisotropic short fibers (including those in the form of nanostructure elements).     

LES and RANS modelling of under-expanded jets with application to gaseous fuel direct injection for advanced propulsion systems

A density-based solver with the classical fourth-order accurate Runge-Kutta temporal discretization scheme was developed and applied to study under-expanded jets issued through millimetre-size nozzles for applications in high-pressure direct-injection (DI) gaseous-fuelled propulsion systems. Both large eddy simulation (LES) and Reynolds-averaged Navier-Stokes (RANS) turbulence modelling techniques were used to evaluate the performance of the new code. The computational results were compared both quantitatively and qualitatively against available data from the literature. After initial evaluation of the code, the computational framework was used in conjunction with RANS modelling (k-ω SST) to investigate the effect of nozzle exit geometry on the characteristics of gaseous jets issued from millimetre-size nozzles. Cylindrical nozzles with various length to diameter ratios, namely 5, 10 and 20, in addition to a diverging conical nozzle, were studied. This study is believed to be the first to provide a direct comparison between RANS and LES within the context of nozzle exit profiling for advanced high-pressure injection systems with the formation of under-expanded jets. It was found that reducing the length of the straight section of the nozzle by 50% resulted in a slightly higher level of under-expansion (∼2.6% higher pressure at the nozzle exit) and ∼1% higher mass flow rate. It was also found that a nozzle with 50% shorter length resulted in ∼6% longer jet penetration length. At a constant nozzle pressure ratio (NPR), a lower nozzle length to diameter ratio resulted in a noticeably higher jet penetration. It was found that with a diverging conical nozzle, a fairly higher penetration length could be achieved if an under-expanded jet formed downstream of the nozzle exit compared to a jet issued from a straight nozzle with the same NPR. This was attributed to the radial restriction of the flow and consequently formation of a relatively smaller reflected shock angle. With the conical nozzle used in this study and a 30 bar injection pressure, an under-expanded hydrogen jet exhibited ∼60% higher penetration length compared to an under-expanded nitrogen jet at 100 μs after start of injection. Moreover, the former jet exhibited ∼22% higher penetration compared to a nitrogen jet issued through the conical profile with 150 bar injection pressure.