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The combustion of fossil-based fuels in ICEs, resulting in a huge amount of greenhouse gases (GHG) and leading to an immense global temperature rise, are the root causes of the more stringent emission legislations to safeguard health and that encourage further investigations on alternative carbon-neutral fuels. In this respect, the hydrogen has been considered as one of the potential clean fuels because of its zero-carbon nature. The current development of hydrogen-based ICEs focuses on the direct injection (DI) strategy as it allows better engine efficiency than the port fuel injection one. The behavior of the fuel jet is a fundamental aspect of the in-cylinder air-fuel mixing ratio, affecting the combustion process, the engine performances, and the pollutants emissions. In the present study, comprehensive investigations on the hydrogen jet behavior, generated by a Compressed Hydrogen Gas (CHG) injector under different operative conditions, were performed.

Nowadays, in the perspective of a full electric automotive scenario, internal combustion engines can still play a central role in the fulfilment of different needs if the efficiency will be improved, and the tailpipe emission will be further limited. Gasoline Compression Ignition engines can offer a favourable balance between NOx, particulate, operating range. Stable operations are ensured by ultra-high gasoline injection pressure and tailored injection patterns in order to design the most proper local fuel distribution. In this context, engine simulations by means of CFD codes can provide insights on the design of the injection parameters, and emphasis must be placed on the capture of spray-wall impingement behaviour under those non-conventional conditions. This paper aims to analyse the spray-wall impingement behaviour of ultra-high gasoline spray using a combined experimental-CFD approach.

Heating devices are effective technologies to strengthen emission robustness of AfterTreatment Systems (ATS) and to guarantee emission compliance in the new boundaries given by upcoming legislations. Moreover, they allow to manage the ATS warm-up independently from engine operating conditions, thereby reducing the need for specific combustion strategies. Within heating devices, an attractive solution to provide the required thermal power without mandating a 48V platform is the fuel burner. In this work, a model-based control coordinator to manage the interaction between engine, ATS and fuel burner device has been developed, virtually validated, and optimized. The control function features a burner model and a control logic to deliver the needed amount of thermal energy, while ensuring ATS hardware protection.

The urban mobility electrification has been proposed as the main solution to the vehicle emission issues in the next years. However, internal combustion engines have still great potential to decarbonize the transport sector through the use of low/zero-carbon fuels. Alcohols such us methanol, have long been considered attractive alternative fuels for spark ignition engines. They have properties similar to those of gasoline, are easy to transport and store. Recently, great attention has been devoted to gaseous fuels that can be used in existing engine after minor modification allowing to drastically reduce the pollutant emissions. In this regard, this study tries to provide an overview on the use of alternative fuels, both liquid and gaseous in spark ignition engines, highlighting the benefits as well as the criticalities. The investigation was carried out on a small displacement spark ignition engine capable to operate both in port fuel and direct injection mode.

Ultra-high injection pressures, as well as flash-boiling occurrence, are among the most important research fields recently explored for improving Gasoline Direct Injection (GDI) engine performance. Both of them play a key role in the enhancement of the air/fuel mixing process, in the reduction of tailpipe pollutant emissions, as well as in the investigation of new combustion concepts. Injector manufacturers are even more producing devices with ultra-high injection pressures capable of working with flashing sprays. Flash-boiling of fuel sprays occurs when a super-heated fuel is discharged into an environment whose pressure is lower than the saturation pressure of the fuel and can dramatically alter spray formation due to complex two-phase flow effects and rapid droplet vaporization. In GDI engines, typically, it occurs during the injection process when high fuel temperatures make its saturation pressures higher than the in-cylinder one.

Direct injection spark ignition engines represent an effective technology to achieve the goal of carbon dioxide emission reduction. Further reduction of the carbon footprint can be achieved by using carbon-neutral fuels. Oxygenated alcohols are well consolidated fuels for spark ignition engines providing also the advantages of knock resistance and low soot tendency production. Methanol and ethanol are possible candidates as alternative fuels to gasoline due to their similar properties. In this study a blend at 25 % v/v of ethanol in gasoline (E25) and a blend with 80% gasoline, 5 % v/v ethanol and 15% v/v of methanol (GEM) were tested. These blends were considered since E25 is already available at fuel pump in some countries. The GEM blend, instead, could represent a valid alternative in the next future. Experiments were carried out on a high performance, turbocharged 1.8 L direct injection spark ignition engine over the Worldwide Harmonized Light Vehicles Test Cycle.

Euro 7/VII regulations are currently under discussion and are expected to be the last big regulatory step in Europe. From available documentation, it is clear the aim of further regulating the extended conditions of use which are still responsible of high emission events (e. g. cold start or altitude) as well as regulating secondary emissions such as NH3, N2O, CH4, Aldehydes (HCHO). Even if not completely fixed yet, the EU7 limits will be challenging for internal combustion engines and even more for Diesel. Despite a consistent reduction of market share, Diesel engines are expected to remain a significant portion in certain sectors such as Heavy duty (HD) and Light-commercial vehicle (LCV) for some decades. In order to reach the new limits being proposed, besides minimizing engine-out emissions, Diesel powertrain will need an aftertreatment system able to work at very high efficiency right after engine start and in almost every working and environmental condition.

Direct injection of gaseous fuels usually involves the presence of under-expanded jets. Understanding the physics of such process is imperative for developing Direct Injection (DI) internal combustion engines fueled, for example, by methane or hydrogen. An experimental-numerical characterization of the under-expanded jets issued from an innovative multi-hole injector, designed for application in heavy-duty engines, is carried out. The experimental characterization of the jet evolution was recorded by means of schlieren imaging technique and, then, a numerical simulation procedure was validated, allowing a comprehensive injection process analysis. A high-order and density-based solver, capable of reproducing the most relevant features of the under-expanded jets, was developed within OpenFOAM framework. Initially the effects of the upstream-to-downstream pressure ratio, namely Net Pressure Ratios (NPR), on the spray morphology were investigated.

Among the others, natural gas (NG) is regarded as a potential solution to enhance the environmental performance of internal combustion engines. Low carbon-to-hydrogen ratio, worldwide relatively homogeneous distribution and reduced price are the reason as, lately, many researchers efforts have been put in this area. In particular, this work focuses on the characterization of the injection process inside a constant volume chamber (CVC), which could provide a contribution to the development of direct injection technologies for a gaseous fuel. Direct injection of a gaseous fuel involves the presence of under-expanded jets whose knowledge is fundamental to achieve the proper mixture formation prior to the combustion ignition. For this reason, a density based solver was developed within the OpenFOAM library in order to simulate the jet issued from an injector suitable for direct injection of methane.

In view of the new emission regulations seeking to lower the particle cut-off size down to the current 23 nm, an extensive comprehension on the nature of sub-23 nm particles is crucial. In this regard, a new challenge lies ahead considering an even more massive use of biofuels. The objective of this research study was to characterize the sub-23 nm particles and to evaluate their volatile organic fraction (VOF) from a high performance, 1.8 L gasoline direct injection (GDI) engine under the Worldwide harmonized Light vehicles Test Cycle (WLTC). Particle emissions were measured through an Engine Exhaust Particle Sizer (EEPS) capable of particle sizing and counting in the range 5.6 - 560 nm. The sampling and conditioning were performed by both a single diluter and the Dekati Engine Exhaust Diluter (DEED) a Particle Measurement Programme (PMP) compliant sample conditioning system.

Within the context of environmental impact reduction for small size spark ignition (SI) engines, especially green-house gas emissions, this study looked at laminar flame speed as an optimization parameter for hydrogen-methane fueled micro-generators. To this aim, SI engine operation was modeled in a 0D/1D simulation framework, so as to identify the best choice of methane-hydrogen ratios in different conditions. Starting from experimental data recorded on a small size engine, an optimization method was implemented for achieving the proposed goal. One of the main conclusions is that high concentrations of hydrogen and resulting fast burn rates are beneficial at high engine speed settings, while the opposite is true at low engine speed. Hydrogen addition was also considered as an additional control margin during lean operation, given that stable combustion can be achieved even with very low equivalence ratios.

In the framework of an increasing demand for a more sustainable mobility, where the fuel consumption reduction is a key driver for the development of innovative internal combustion engines, Turbulent Jet Ignition (TJI) represents one of the most promising solutions to improve the thermal efficiency. However, details concerning turbulent jet assisted combustion are still to be fully captured, and therefore the design and the calibration of efficient TJI systems require the support of reliable simulation tools that can provide additional information not accessible through experiments. To this aim, an experimental investigation combined with a 3D-CFD study was performed to analyze the TJI combustion characteristics in a single-cylinder spark-ignition (SI) engine. Firstly, the model was validated against experiments considering stoichiometric mixture at 3000 rpm, wide open throttle operating conditions.

The numerical reconstruction of the liquid jet generated by a multi-hole injector, operating in flash-boiling conditions, has been developed by means of a Eulerian- Lagrangian CFD code and validated thanks to experimental data collected with schlieren and Mie scattering imaging techniques. The model has been tested with different injection parameters in order to recreate various possible engine thermodynamic conditions. The work carried out is framed in the growing interest present around the gasoline direct-injection systems (GDI). Such technology has been recognized as an effective way to achieve better engine performance and reduced pollutant emissions. High-pressure injectors operating in flashing conditions are demonstrating many advantages in the applications for GDI engines providing a better fuel atomization, a better mixing with the air, a consequent more efficient combustion and, finally, reduced tailpipe emissions.

Pollutant emission of vehicle cars is nowadays a fundamental aspect to take into account. In the last decays, the company have been forced to study new solutions, such as alternative fuel and learn burn mixture strategy, to reduce the vehicle’s pollutants below the limits imposed by emission regulations. Pre-chamber ignition system presents potential reductions in emission levels and fuel consumption, operating with lean burn mixtures and alternative fuels. As alternative fuels, methane is considered one of the most interesting. It has wider flammable limits and better anti-knock properties than gasoline. Moreover, it is characterized by lower CO2 emissions. The aim of this work is to study the evolution of the plasma jets in a different in-cylinder conditions. The activity was carried out in a research optical small spark ignition engine equipped alternatively with standard ignition system and per-chamber.

Compressed Natural Gas (CNG) is regarded as a promising fuel for spark-ignited (SI) internal combustion engines (ICE) to improve engine thermal efficiency and reduce both carbon dioxide and pollutant emissions. Significant advantages of CNG are higher-octane number, higher hydrogen to carbon ratio, and lower energy-specific CO2 emissions compared with gasoline. More, it can be produced in renewable ways, and is more widespread and cheaper than conventional liquid fossil fuels. In this regard, the direct injection of CNG engines can be considered a promising technology for highly efficient and low-emission future engines. This work reports an experimental and numerical characterization of high-pressure methane jets from a multi-hole injector for direct injection engines.

In recent years, the increase of gasoline fuel injection pressure is a way to improve thermal efficiency and lower engine-out emissions in GDI homogenous combustion concept. The challenge of controlling particulate formation as well in mass and number concentrations imposed by emissions regulations can be pursued improving the mixture preparation process and avoiding mixture inhomogeneity with ultra-high injection pressure values up to 100 MPa. The increase of the fuel injection pressure in GDI homogeneous systems meets the demand for increased injector static flow, while simultaneously improves the spray atomization and mixing characteristics with consequent better combustion performance. Few studies quantify the effects of high injection pressure on transient gasoline spray evolution. The aim of this work was to simulate with OpenFOAM the spray morphology of a commercial gasoline injected in a constant volume vessel by a prototypal GDI injector.

The use of lean or ultra-lean ratios is an efficient and proven strategy to reduce fuel consumption and pollutant emissions. However, the lower fuel concentration in the cylinder hinders the mixture ignition, requiring greater energy to start the combustion. The prechamber is an efficient method to provide high energy favoring the ignition process. It presents the potential to reduce the emission levels and the fuel consumption, operating with lean burn mixtures and expressive combustion stability. In this paper the analysis of the combustion process of SI engines equipped with an innovative architecture and operating in different injection modes was described. In particular, the effect of the prechamber ignition on the engine stability and the efficiency was investigated in stoichiometric and lean-burn operation conditions. The activity was carried out in two parts.

With the aim of identifying technical solutions to lower the particulate matter emissions, the engine research community made a consistent effort to investigate the root causes leading to soot formation. Nowadays, the computational power increase allows the use of advanced soot emissions models in 3D-CFD turbulent reacting flows simulations. However, the adaptation of soot models originally developed for Diesel applications to gasoline direct injection engines is still an ongoing process. A limited number of studies in literature attempted to model soot produced by gasoline direct injection engines, obtaining a qualitative agreement with the experiments. To the authors’ best knowledge, none of the previous studies provided a methodology to quantitatively match particulate matter, particulate number and particle size distribution function measured at the exhaust without a case-by-case soot model tuning.

In the last years, increasing concerns about environmental pollution and fossil sources depletion led transport sectors research and development towards the study of new technologies capable to reduce vehicles emissions and fuel consumption. Direct-injection systems (DI) for internal combustion engines propose as an effective way to achieve these goals. This technology has already been adopted in Gasoline Direct Injection (GDI) engines and, lately, a great interest is growing for its use in natural gas fueling, so increasing efficiency with respect to port-fuel injection ones. Alone or in combination with other fuels, compressed natural gas (CNG) represents an attractive way to reduce exhaust emission (high H/C ratio), can be produced in renewable ways, and is more widespread and cheaper than gasoline or diesel fuels. Gas direct-injection process involves the occurrence of under-expanded jets in the combustion chamber.

Very high pressures for injecting gasoline in internal combustion (i.c.) engines are recently explored for improving the air/fuel mixing process in order to control unburned hydrocarbons (UBHC) and particulate matter emissions such as for investigating new combustion concepts. The challenge remains the improvement of the spray parameters in terms of atomization, smaller droplets and their spread in the combustion chamber in order to enhance the combustion efficiency. In this framework, the raise of the injection pressure plays a key role in GDI engines for the trade-off of CO2 vs other pollutant emissions. This study aims contributing to the knowledge of the physical phenomena and mechanisms occurring when fuel is injected at ultra-high pressures for mapping and controlling the mixture formation.