This Academy covers the diesel engine engineering principles and practices necessary to effectively understand a modern diesel engine. Types of engines addressed include naturally aspirated, turbocharged, pre-chamber, open chamber, light duty, and heavy duty. It is an intensive learning experience comprised of lecture and structured practical sessions, including a team-solved case study problem. Evening sessions are included.

Attendees will receive a copy of the textbook, Diesel Emissions and Their Control, by lead instructor Magdi K. Khair and W. Addy Majewski.

Practical Component

This Academy includes several practical activities, including a team-solved case study and a diesel engine facility tour.

Pre-Academy Activity

Prior to the Academy, you will be asked to complete a pre-assessment. Results will be shared with the lead instructor to help customize the learning experience to specific attendee needs.

• Articulate basic diesel engine terminology and principles
• Describe the key features of the basic types of diesel engines
• Compare various diesel fuel injection systems and their components
• Analyze the effects of different fuels on engine performance and longevity
• Compare the function and applicability of various air management systems
• List the various emission standards and testing requirements
• Detail the elements of post-combustion emission control devices
• Discuss emerging diesel engine technologies

• Passenger cars
• Light trucks
• Heavy trucks
• Off-highway vehicles
• Farm machinery

***Please be advised that this course involves one or more of the following: driving and/or riding in a vehicle; participating in a vehicle demonstration; and/or taking part in an offsite tour using outside transportation. You will be required to sign a waiver on-site and produce a valid driver¿s license from your state/country of residence.***

• Terminology and Performance Parameters
• The Case for the Diesel Engine
• Air Management Systems
  • Turbocharging and supercharging -- Purpose of turbocharging; Supercharging vs. turbocharging; Thermodynamic principle of turbocharging; Description of turbocharger; Performance of turbomachinery (swallowing-lines); Types of turbochargers (fixed, variable, waste-gate); Special arrangements (sequential, turbo compounding); An exercise in turbomatching; New role of turbochargers in EGR control
  • Superchargers -- Mechanically driven; Electrically driven; Hydraulically driven; Role of superchargers in modern diesels
• Fuel Injection Systems
  • Requirements and function
  • Injection timing
  • Injection metering
  • The fuel injection system
  • Types of fuel injection systems and main components
  • Diesel control -- Mechanical Governor; Electronic control systems
  • Nozzle and nozzle holders
  • Application
• European Diesel Engines
• Modern Technology Engines & Fuel Systems

• Thermodynamics I
  • First Law -- Energy balance for a closed system; Energy balance for an open system; Property Evaluation
  • Second Law -- Definition of entropy; Irreversibility; Entropy balance for a closed system; Entropy balance for an open system; Definition of availability; Availability balance
  • Air standard cycle analysis -- Otto cycle; Diesel, Dual, Atkinson, Miller cycles; Lessons to be learned from air standard cycles
  • Chemical reactions -- Stoichiometry (balancing chemical reactions); Definition of equivalence ratio; Calculating exhaust gas composition from F/A ratio; Calculating F/A ratio from exhaust gas composition; Computation of brake specific emissions
  • Energy equation with chemical reactions (combustion reactions) -- Adiabatic flame temperature; Higher/lower heating value
  • Detailed example of energy balance on engine -- Fuel energy in=coolant + exhaust + work out
• Thermodynamics II: Combustion in Diesel Engines
  • Basic combustion theory - definitions and concepts
  • Complete combustion vs. equilibrium composition (dissociation) -- Equilibrium assumption vs. kinetics (rate limited reactions); Global vs. elementary reactions; Basic flame theory (Ignition, flame propagation & speed, quenching, flammability limits); Autoignition theory; Hydrocarbon combustion; Laminar and turbulent flame speeds; Premixed and diffusion combustion
  • Diesel combustion -- Phenomenological description of diesel combustion; Ignition delay, premixed combustion, diffusion combustion; Burning rate diagram (heat release diagram)
  • Combustion chamber design considerations -- Relationship between air motion, fuel injection system (injection pressure, number of nozzle holes, orifice size), and combustion chamber geometry (bowl size and shape)
  • Modeling the diesel combustion process -- Fuel-air standard Otto cycle/Diesel cycle (Assumptions, Thermodynamics); Single zone models-heat release type (Assumptions, Thermodynamics); Multi-zone models, phenomenological models; CFD modeling; Lessons to be learned from each approach; Advantages/disadvantages of each approach
  • Heat release analysis -- Collection of cylinder pressure data (transducers, encoders, data acquisition); Analysis of cylinder pressure data (smoothing, frequency characteristics, mean effective pressure); Heat release model (Krieger and Borman assumptions); Interpretation of heat release diagrams
• Diesel Combustion & Emissions in DI Engines
  • Premixed/diffusion combustion -- Effect of low temperature, low cetane number; Effect of turbocharging
  • Factors affecting the combustion process -- Injection pressure; Air swirl; Atomization; Penetration; Drop size distribution; Vaporization; Ignition delay
  • Combustion influence on fuel economy -- Effect of heat release; Effect of heat transfer -Compare to "adiabatic" engine results
  • Combustion influence on emissions -- Origin of hydrocarbon emissions; Origin of carbon monoxide; Origin of NOx emissions; Relation to premixed combustion, aromatic content of fuel, cetane number; Origin of particulates and smoke; Relation to diffusion combustion; Effect of fuel sulfur
  • Tradeoffs -- BSFC vs. NOx; NOx vs. particulates; HC vs. ignition delay
  • Effect of ignition timing on heat release rate and cylinder pressure -- Effect of timing of combustion, ignition delay
  • Effect of injection pressure on heat release rate and cylinder pressure -- Effect of mixing rate on diffusion combustion
• Fuels Technologies

• The Role of Lube Oil in Modern Diesel Engines
  • How are Lubricants Specified
  • Viscosity Grades, Quality
  • Lubricant Performance Categories:
  • North America
  • Europe
  • Japan
  • OEM Specifications
  • Future Developments - Low Emission Fluids
  • Composition of Typical Crankcase Lubricants
  • Drivers for Novel Lubricant Development
  • Aftertreatment Compatible Lubricants: SAPS
  • Beyond Current Lubricant Specification - System Approach
• Engine Controls I
  • Electronic fuel injection system control
  • Control system architectures and hardware
  • Fundamentals of control
  • Design approaches for diesel engine controls
  • Development methods
  • Application requirements -- Fuel injection volume, timing and rate shaping
• Engine Controls II
  • Vehicle aspects
  • Ancillary system control and integration
  • Variable geometry turbocharger control
  • EGR scheduling and control
  • Control of other subsystems - today and tomorrow
  • Adaptive controls and the future
• On-Board Diagnostics
  • Legal Requirements
  • Fault Detection
  • Fault Resolution
  • Diagnostic Tools - OBD and General
  • Future Paths
  • Noise
  • Simulation in Diesel Engines
• In-Cylinder Measures to Control Emissions I and II

• In-Cylinder Measures to Control Emissions III
• Diesel Exhaust Aftertreatment I
  • Exhaust system-based emission reduction technologies (aftertreatment)
  • NOx reduction catalysts
  • Selective Catalytic Reduction -- With Supplemental HC; With Urea and Ammonia
  • Lean NOx Traps
  • Diesel Particulate Filters -- Active Regeneration Systems; Passive Regeneration Systems
• Diesel Exhaust Aftertreatment II
  • Combination Trap/Catalyst Systems -- Catalyst Assist; Catalytically Regenerated Traps
  • Special Aftertreatment Systems
  • Non-Thermal Plasma
  • Non-Thermal Plasma Assisted Catalysts
• Bosch Farmington Hills Diesel Facility Tour
  • Welcome to Bosch
  • Overview of diesel fuel-injection expertise and scope
  • Diesel fuel injection lab including live demo of fuel-injection characterization
  • Diesel dyno demonstration
  • Diesel car show: Ride and Drive plus sneak preview of two new models
  • Wrap-up including question and answer forum

• Diesel Exhaust Aftertreatment III
  • Combination Trap/Catalyst Systems -- Catalyst Assist; Catalytically Regenerated Traps
  • Special Aftertreatment Systems
  • Non-Thermal Plasma
  • Non-Thermal Plasma Assisted Catalysts
• Engine Performance Simulation
• Emerging Technologies
  • Variable Valve Actuation
  • Camless Valvetrain
  • Air Hybrids
  • Other
• Academy Wrap-up and Evaluation

Magdi Khair, Lead Instructor, currently holds the position of Chief Technologist at Watlow, where he is assisting with the introduction of new technologies for the diesel engine industry. Dr. Khair recently retired from the position of Institute Engineer in the Engine, Emissions, and Vehicle Research Division at Southwest Research Institute. He is experienced in the areas of engine testing and exhaust emissions control. His prior experience was with AlliedSignal Automotive Catalyst Company with the development of catalytic aftertreatment for light-duty and heavy-duty diesel engines; Ford New Holland with primary responsibility for the development of the 6.6 and 7.8 liter midrange diesel engines to meet 1991 emissions standards; Bendix Diesel Engine Controls where he led the development of advanced electronically controlled diesel fuel injection systems and also established several cooperative engineering programs with European and North American engine manufacturers; and with Chrysler Corporation where he converted the slant six gasoline engine into an open chamber, pilot injected, and electronically controlled diesel engine, supervised a combustion kinetics project, and participated in the design and development of electronic controls for a passenger car turbine engine. Dr. Khair holds 20 U.S. patents in electronic fuel injection, turbocharging, exhaust gas recirculation, and aftertreatment systems. He has also authored and co-authored numerous SAE and ASME papers. Dr. Khair is the co-author of the Diesel Emissions and their Control a text book marketed by SAE. Dr. Khair received a B.S. in Automotive Engineering from Ain Shams University, an M.S. in Thermodynamics from the University of Birmingham, England, an M.B.A. from Michigan State University, and a PhD in Engineering Management from Warren National University.

Ewa Bardasz is a Fellow at The Lubrizol Corporation, where she is currently responsible for overseeing technical activities related to lubricating novel combustion hardware, aftertreatment systems and emissions. She is experienced in the areas of crankcase lubrication, corrosion inhibition, engine testing and exhaust emissions control. Dr. Bardasz holds over 25 patents, has published multiple technical and scientific papers, authored chapters for technical books and is a frequent invited speaker at conferences throughout the U.S. and Europe. She is the recipient of the SAE International 2002 Award for Research on Automotive Lubricants, and 2009 SAE International Environmental Excellence in Transportation Award. Dr. Bardasz is a Fellow of SAE International and a Fellow of the Society of Tribologists and Lubrication Engineers (STLE) where she is also on the Board of Directors. Dr. Bardasz obtained a M.Sc. in Chemical Engineering from Warsaw Technical University and a PhD in Chemical Engineering from Case Institute of Technology.

André Boehman is a Professor of Fuel Science and Materials Science and Engineering in the Department of Energy & Geo-Environmental Engineering in the College of Earth and Mineral Sciences at the Pennsylvania State University, where he has taught courses on Energy, Fuels, Combustion and the Environment since 1994. At the Penn State Energy Institute, Prof. Boehman manages the Diesel Combustion and Emissions Laboratory. Professor Boehman's research interests are in alternative and reformulated fuels, combustion and pollution control. His present research activities are focused on alternative diesel fuels, diesel combustion and diesel exhaust aftertreatment. He is presently on the Editorial Board of Fuel Processing Technology and holds executive positions with the American Chemical Society Division of Fuel Chemistry and with the International DME Association. He has received the 1999 Alumni Achievement Award from the University of Dayton School of Engineering, the 1999 Matthew and Anne Wilson Award for Outstanding Teaching from the Penn State College of Earth and Mineral Sciences and the Philip L. Walker Jr. Faculty Fellowship in Materials Science and Engineering, from 1995-97. He also received the 1986 Charles T. Main Bronze Medal from the American Society of Mechanical Engineers. He has supervised seventeen M.S. theses and five doctoral theses at Penn State, and he has published more than 36 refereed papers and book chapters. He holds a B.S. in Mechanical Engineering from the University of Dayton (1986) and an M.S. (1987) and Ph.D. (1993) in Mechanical Engineering from Stanford University. He held a two-year postdoctoral fellowship in the Molecular Physics Laboratory at SRI International, Menlo Park, California.

Bernard Challen is an independent engineering consultant, active mainly in the automotive industry. Currently serving as a member of the SAE International Board of Directors, his technical areas of interest include electronics and control, instrumentation, the use of computer-aided engineering tools, and vehicle noise & vibration. Until 1991, he was Technical Director at Ricardo Consulting Engineers where one of his responsibilities was the formation of Ricardo North America. His technical responsibilities within Ricardo included noise and vibration, instrumentation and control, large engines and the business development of Ricardo in North America. Mr. Challen is active in a number of professional societies. A recipient of the SAE Forest R. McFarland award in 1983, 1990 and 1996, he was elected a Fellow of SAE in 1997 and in 2008 he was the recipient of the SAE Medal of Honor. Mr. Challen is a Fellow of the Institution of Mechanical Engineers (IMechE) and also the Institution of Engineering Technology (IET). He has served as General Chair for the SAE Noise and Vibration Conference from 1992-2003. In addition to being a regular contributor of technical papers to SAE, he also serves on the Engineering Meetings Board. Mr. Challen earned a B.Sc.(Eng.) in Mechanical Engineering and M.Sc. Noise and Vibration, Institute of Sound and Vibration Research, from Southampton University.

Philip Dingle is a Diesel Technology Specialist in the advanced engineering Innovation Center of Delphi Diesel Systems. He received his engineering education in England, and after graduating in 1972, joined the Research and Development group of Lucas Diesel Systems where he worked on several advanced engine and fuel system technologies. Transferred to Detroit, USA in 1975, he has worked closely with several US diesel engine manufacturers on the development of FIE for their engines. In the process, he gained broad experience in achieving performance and emissions targets from both DI and IDI combustion systems. He holds twelve US or European patents for fuel system innovation.

Michael Levin holds the position of Technical Expert at Ford Motor Company. Mr. Levin has been with Ford Research and Advanced Engineering since the late 1970s. His current responsibilities include development of hydrocarbon and urea dosing for advanced Diesel aftertreatment systems. Mr. Levin co-authored 18 publications and holds 13 patents. He received his MSME in 1974 from Moscow Automobile and Road Institute in Russia.

John E. Wilken is Principal Engineer at Gamma Technologies, Inc. (GTI). As lead engineer of software design at GTI, Mr. Wilken has been instrumental in the development of GT-POWER, engine cycle simulation software for engine performance, acoustics, turbocharger matching, and combustion. Mr. Wilken is a graduate of the University of Illinois at Urbana-Champaign.

Vincent Piacenti is Manager, Systems Engineering for Bosch Corp where he is responsible for systems engineering of all diesel fuel injection systems and components used in the US, including diesel fuel injection hydraulic systems integration for North American diesel engine applications. This encompasses simulation, adaptation and testing of high-speed, high-pressure fuel injection systems with a concentration on common rail systems, both solenoid-valve and piezo. Included is research of alternative fuels for diesel engine applications. He has experience in all types of diesel fuel injection and various gasoline systems and is a contributing author to the Springer Handbook for Mechanical Engineers. Mr. Piacenti holds a B.S. in Mechanical Engineering and has been with Bosch for almost thirty years, seven of which were at the Bosch Headquarters for Diesel Fuel Injection in Stuttgart, Germany.

"Being able to learn from some of the most knowledgeable people in the industry was a fantastic opportunity. I will recommend it for others in my group."
Jeff Morris
Caterpillar Corporation

"This academy has filled in the many gaps I had in my knowledge of diesel engines, as well as those I didn't know I had. Fantastic!"
Chad Mollin
International Truck & Engine Corporation

"This Academy greatly strengthens and increases one's understanding of diesel engine technology and its methods for meeting the demands of industry and environmental regulations. As an engineer relatively new to the diesel engine industry, my competence regarding, and appreciation for, diesel engine technology has improved significantly because of this Academy."
Christopher A. Brown
Senior Project Engineer
Detroit Diesel Corporation

"Impressive! Well worth the investment. A comprehensive introduction to the modern diesel engine."
Jason Lee Jirovsky
Design Engineer
John Deere Power Systems