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Spray motion visualization, mixture strength measurement, flame spectral analyses and flame behavior observation were performed in order to elucidate the mixture preparation and the combustion processes in Mitsubishi GDI engine. The effects of in-cylinder flow called reverse tumble on the charge stratification were clarified. It preserves the mixture inside the spherical piston cavity, and extends the optimum injection timing range. Mixture strength at the spark plug and at the spark timing can be controlled by changing the injection timing. It was concluded that reverse tumble plays a significant role for extending the freedom of mixing. The characteristics of the stratified charge combustion were clarified through the flame radiation analyses. A first flame front with UV luminescence propagates rapidly and covers all over the combustion chamber at the early stage of combustion.

Hydrocarbon thermal ignition in internal combustion engines is controlled by the balance of heat release rate by chemical reactions and internal energy formation or removal rate by adiabatic compression or expansion. Heat release rate can be described by a simple “Universal Rule”, that the heat release rate during the thermal ignition preparation period is determined by H2O2 loop composed of four elementary reactions. This rule was validated by sensitivity analysis and response analysis to perturbation of intermediate species concentrations. The rule was applied to clarify several subjects with experimental backgrounds, such as ignition characteristics of higher octane number fuels, an old and well-known knocking model and the influence of H2 addition.

A two-stage combustion is one of the Mitsubishi GDI™ technologies for a quick catalyst warm-up on a cold-start. However, when the combustion is continued for a long time, an increase in the fuel consumption is a considerable problem. To solve the problem, a stratified slight-lean combustion is newly introduced for utilization of catalysis. The stratified mixture with slightly lean overall air-fuel ratio is prepared by the late stage injection during the compression stroke. By optimizing an interval between the injection and the spark timing, the combustion simultaneously supplies substantial CO and surplus O2 to a catalyst while avoiding the soot generation and the fouling of a spark plug. The CO oxidation on the catalyst is utilized to reduce the cold-start emissions. Immediately after the cold-start, the catalyst is preheated for the minimum time to start the CO oxidation by using the two-stage combustion. Following that, the stratified slight-lean combustion is performed.

An extensive effort has been made, at Mitsubishi Motors, in the technology field of new catalysts and of the catalyst reaction control for the purpose of further improvement of the emission control with the GDI engines [1-2]. A new NOx-trap catalyst has been developed to satisfy the required higher catalyst performance under high-temperature condition. The new catalyst contains potassium (K) of excellent NOx-storage capacity under high-temperature region in the catalytic atmosphere, and to retain K stability zeolite is mixed in the catalyst layer as well as the substrate is coated with silica (SiO2). This new catalyst has been proven of the improved NOx conversion efficiency, and solved the long-pending problems particularly those experienced under high-temperature operation.

NOx adsorber has already been used for the after-treatment system of series production vehicle installed with a lean burn or direct injection engine [1,2,3]. In order to improve NOx adsorbability at high temperatures, many researchers have recently been trying an addition of potassium (K) as well as other conventional NOx adsorbents. Potassium, however, reacts easily with the cordierite honeycomb substrate at high temperatures, and not only causes a loss in NOx adsorbability but also damages the substrate. Three new technologies have been proposed in consideration of the above circumstances. First, a new concept of K-capture is applied in washcoat design, mixed with zeolite, to improve thermal stability of K and to keep high NOx conversion efficiency, under high temperatures, of NOx adsorber catalyst. Second, another new technology, pre-coating silica over the boundary of a substrate and washcoat, is proposed to prevent the reaction between potassium and cordierite.

Ignition process chemistry was analyzed using a detailed chemical kinetic model of n-heptane generated by KUCRS (Knowledge-basing Utilities for Complex Reaction Systems), wherein pressure-dependent rate constants of the O₂ addition to alkyl radicals and hydroperoxy alkyl radicals and the thermal decomposition of ketohydroperoxides have been introduced. Then, the effect of the initial pressure and the individual effects of the initial fuel, O₂ and N₂ molar concentrations on a relationship between the initial temperature and the ignition delay were discussed. When the initial temperature increases, the branch of C₇H₁₄OOH removal into the second O₂ addition and the decomposition into C₇H₁₄cyO and OH is more sensitive to the pressure and the O₂ concentration, and thus, the LTO preparation phase is more affected by the pressure and the O₂ concentration. The LTO phase terminates mainly by the OH removal by intermediate species.

A systematic chemical lumping method has been proposed, based on the detailed kinetic analysis of hydrocarbon fuel ignitions. The model constructed by using this method contains two reaction sets, RO2 and fragment reaction package. The ignition characteristics of each fuel can be reflected by only adjusting several rate parameters in RO2 reaction package. From the comparison with detailed model, it was confirmed that this simplified model well reproduces the results of detailed one without missing the kinetics of hydrocarbon ignitions. We concluded that this new lumping approach has the possibility to be applicable to every hydrocarbon fuels.

The interaction between spark discharge and low-temperature oxidation (LTO) was investigated using an optical compression and expansion machine fueled with n-C7H16 or i-C8H18 for an equivalence ratio of 0.33. Charge pressure was adjusted so that the compression stoke could induce LTO for n-C7H16, but could not lead to high-temperature reactions. A spark was discharged in the field before, during, or after the LTO for n-C7H16 or in the field without LTO for i-C8H18. Reaction zones were induced in the field after the LTO, whereas no reaction zones were induced in the fields before the LTO and without LTO. Local ignitions were induced in the areas surrounding the propagating reaction zones. The reaction zone propagation with the low equivalence ratio must be a different phenomenon from conventional flame propagation. The reaction zones can compress or heat the surrounding areas containing H2O2 and CH2O, and accelerate an H2O2 regeneration loop in the pre-reaction zones.

One of the authors has proposed to use the decay rate of EHRR, the effective heat release rate, d2Q/dθ2 as an index for the rapid local combustion [1]. In this study, EHRR profiles and the cylinder gas pressure oscillations of the low and high speed knock are analyzed by using this index. A delayed rapid local combustion, such as an autoignition with small burned mass fraction can be detected. In the cases of the low speed knock, it has been agreed that a rapid local combustion is an autoignition. Although whether the cylinder gas oscillation is provoked by an auto ignition in a certain cycle or not is an irregular phenomenon, the auto ignition takes place in almost all of the cycles in the knocking condition. Mixture mass fraction burned by an auto ignition is large. A small auto ignition may induce a secondary auto ignition, in many cases, mass burned by the secondary auto ignition is extremely large.