Durability Study of a Light-Duty High Pressure Common Rail Fuel Injection System Using E10 Gasoline 2020-01-0616
In this study, a 500-hour test cycle was used to evaluate the durability of a prototype high pressure common rail injection system operating up to 1800 bar with E10 gasoline. Some aspects of the hardware were modified from their baseline design in order to accommodate an opposed-piston, two-stroke engine application and mitigate the impacts of exposure to gasoline. Overall system performance was maintained throughout testing as fueling rate and rail pressure targets were continuously achieved. Although evidence of vapor formation in the low-pressure part of the system was observed, there was no significant physical damage to the associated components. Injectors showed no deviation in their flow characteristics after exposure to gasoline and high resolution imaging of the nozzle tips and pilot valve assemblies did not indicate the presence of cavitation damage. The high pressure pump did not exhibit any performance degradation during gasoline testing and teardown analysis after 500 hours showed no evidence of cavitation erosion. Despite the lack of lubricity-improving additives in the gasoline, all other fuel-wetted components survived the test cycle without any signs of extraordinary contact wear. Fuel and lubricating oil analysis conducted on samples taken at 50-hour intervals confirmed that there was minimal oil-in-fuel or fuel-in-oil dilution throughout most of the cycle. In summary, these results represent an important and positive step forward in validating the durability of high pressure fuel system hardware for light-duty vehicle gasoline applications.
Tom Tzanetakis, Mark Sellnau, Vincent Costanzo, Michael Traver, Tony Williams, Erol Kahraman, Jean Herve Petot, Guillaume Meissonnier, Aniket Tekawade, Brandon Sforzo, Christopher F. Powell
Aramco Research Center, Delphi Technologies, Argonne National Laboratory