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There is an increasing recognition of injector deposit (ID) formation in fuel injection equipment as direct injection spark ignition (DISI) engine technologies advance to meet increasingly stringent emission legislation and fuel economy requirements. While it is known that the phenomena of ID in DISI engines can be influenced by changes in fuel composition, including increasing usage of aliphatic alcohols and additive chemistries to enhance fuel performance, there is however still a great deal of uncertainty regarding the physical and chemical structure of these deposits, and the mechanisms of deposit formation. In this study, a mechanical cracking sample preparation technique was developed to assess the deposits across DISI injectors fuelled with gasoline and blends of 85% ethanol (E85).

Combustion in direct injection spark ignition (DISI) engines is strongly influenced by the in-cylinder charge motion. The charge motion depends both on the injection strategy as well as the geometry of the combustion chamber/air intake system and the physical location of the injectors (side mounted vs. centrally mounted). For boosted and downsized DISI engines, many manufacturers are favouring a single late injection or a split injection strategy. This has the advantage of creating high levels of turbulence which leads to faster combustion and improved thermodynamic efficiency. Furthermore the charge cooling offers enhanced knock resistance, thereby allowing more spark advance. The calibration of such engines is critical: the prize of greater thermodynamic efficiency must be balanced against the risks of charge inhomogeneity, namely excessive particulate emissions and poor drivability.

Injector nozzle deposits can have a profound effect on particulate emissions from vehicles fitted with Gasoline Direct Injection (GDI) engines. Several recent publications acknowledge the benefits of using Deposit Control Additives (DCA) to maintain or restore injector cleanliness and in turn minimise particulates, but others claim that high levels of DCA could have detrimental effects due to the direct contribution of DCA to particulates, that outweigh the benefits of injector cleanliness. Much of the aforementioned work was conducted in laboratory scenarios with model fuels. In this investigation a fleet of 7 used GDI vehicles were taken from the field to determine the net impact of DCAs on particulates in real-world scenarios. The vehicles tested comprised a range of vehicles from different manufacturers that were certified to Euro 5 and Euro 6 emissions standards.