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The use of hydrogen in internal combustion engines is an effective approach to significantly support the reduction of CO2 emissions from the transportation sector using technically affordable solutions. The use of direct injection is the most promising approach to fully exploit hydrogen potential as a clean fuel, while preserving targets in terms of power density and emissions. In this frame, the development of an effective combustion system largely relies on the hydrogen-air mixture formation process, so to adequately control the charge stratification to mitigate pre-ignitions and knock and to minimize NOx formation. Hence, improving capabilities of designing a correct gas jet-air interaction is of paramount importance. In this paper the analysis of the evolution of a high-pressure gas jet produced by a single-hole prototype injector operated with different pressure ratios is presented.

After-treatment sensors are used in the ECU feedback control to calibrate the engine operating parameters. Due to their contact with exhaust gases, especially NOx sensors are prone to soot deposition with a consequent decay of their performance. Several phenomena occur at the same time leading to sensor contamination: thermophoresis, unburnt hydrocarbons condensation and eddy diffusion of submicron particles. Conversely, soot combustion and shear forces may act in reducing soot deposition. This study proposes a predictive 3D-CFD model for the analysis of the development of soot deposition layer on the sensor surfaces. Alongside with the implementation of deposit and removal mechanisms, the effects on both thermal properties and shape of the surfaces are taken in account. The latter leads to obtain a more accurate and complete modelling of the phenomenon influencing the sensor overall performance.

Proton Exchange Fuel Cells (PEMFCs) are considered one of the most prominent technologies to decarbonize the transportation sector, with emphasis on long-haul/long-range trucks, off-highway, maritime and railway. The flow field of reactants is dictated by the layout of machined channels in the bipolar plates, and several established designs (e.g., parallel channels, single/multi-pass serpentine) coexist both in research and industry. In this context, the flow behavior at cathode embodies multiple complexities, namely an accurate control of the inlet/outlet humidity for optimal membrane hydration, pressure losses, water removal at high current density, and the limitation of laminar regime. However, a robust methodology is missing to compare and quantify such aspects among the candidate designs, resulting in a variety of configurations in use with no justification of the specific choice.

The accurate representation of Internal Combustion Engine (ICE) flows via CFD is an extremely complex task: it strongly depends on a combination of highly impacting factors, such as grid resolution (both local and global), choice of the turbulence model, numeric schemes and mesh motion technique. A well-founded choice must be made in order to avoid excessive computational cost and numerical difficulties arising from the combination of fine computational grids, high-order numeric schemes and geometrical complexity typical of ICEs. The paper focuses on the comparison between different mesh motion technologies, namely layer addition and removal, morphing/remapping and overset grids. Different grid strategies for a chosen mesh motion technology are also discussed. The performance of each mesh technology and grid strategy is evaluated in terms of accuracy and computational efficiency (stability, scalability, robustness).

The internal combustion engine technological development is today driven by the pollutants and carbon dioxide (CO2) emission reduction targets imposed by law. The request of lowering CO2 emission reflected in a push towards the improvement of engine efficiency, without sacrificing performances and drivability. The latest generations of Diesel engines for passenger cars are characterized by increasing injection pressure levels (250 MPa for the current production). Enhancing the injection pressure has the drawback of increasing the energy needed to pressurize the fuel and thus the high-pressure fuel pump energy request. A small but not negligible quantity of fuel has to be burned in order to provide this energy, generating a contribution in CO2 emission. In this frame, the injector back-flow represents a significant energy loss for the fuel injection system and for the whole engine.

The detailed study of part-load conditions is essential to characterize engine-out emissions in key operating conditions. The relevance of part-load operations is further emphasized by the recent regulations such as the new WLTP standard. Combustion development at part-load operations depends on a complex interplay between moderate turbulence levels (low engine speed and tumble ratio), low in-cylinder pressure and temperature, and stoichiometric-to-lean mixture quality (to maximize fuel efficiency). From a modelling standpoint, the reduced turbulence intensity compared to full-load operations complicates the interaction between different sub-models (e.g., reconsideration of the flamelet hypothesis adopted by common combustion models). In this article, the authors focus on chemistry-based simulations for laminar flame speed of gasoline surrogates at conditions typical of part-load operations. The analysis is an extension of a previous study focused on full-load operations.

Large-eddy simulation (LES) applications for internal combustion engine (ICE) flows are constantly growing due to the increase of computing resources and the availability of suitable CFD codes, methods and practices. The LES superior capability for modeling spatial and temporal evolution of turbulent flow structures with reference to RANS makes it a promising tool for describing, and possibly motivating, ICE cycle-to-cycle variability (CCV) and cycle-resolved events such as knock and misfire. Despite the growing interest towards LES in the academic community, applications to ICE flows are still limited. One of the reasons for such discrepancy is the uncertainty in the estimation of the LES computational cost. This in turn is mainly dependent on grid density, the CFD domain extent, the time step size and the overall number of cycles to be run. Grid density is directly linked to the possibility of reducing modeling assumptions for sub-grid scales.

In recent years, the GDI (Gasoline Direct Injection) technology has significantly spread over the automotive market under the continuous push toward the adoption of combustion systems featuring high thermodynamic conversion efficiency and moderate pollutant emissions. Following this path, the injection pressure level has been progressively increased from the initial 5-15 MPa level nowadays approaching 35 MPa. The main reason behind the progressive injection pressure increase in GDI engines is the improved spray atomization, ensuring a better combustion process control and lower soot emissions. On the other hand, increasing injection pressure implies more power absorbed by the pumping system and hence a penalty in terms of overall efficiency. Therefore, the right trade-off has to be found between soot formation tendency reduction thanks to improved atomization and the energetic cost of a high pressure fuel injection system.

The present paper describes the effect of thermal conditions on the hydraulic behavior of Diesel common rail injectors, with a particular focus on low temperatures for fuel and injector body. The actual injection system thermal state can significantly influence both the injected quantity and the injection shape, requiring proper amendments to the base engine calibration in order to preserve the combustion efficiency and pollutant emissions levels. In particular, the introduction of the RDE (Real Driving Emission) test cycle widens the effective ambient temperature range for the homologation cycle, this way stressing the importance of the thermal effects analysis. An experimental test bench was developed in order to characterize the injector in an engine-like configuration, i.e. fuel pump, piping, common rail, pressure control system and injectors.

The increasing interest in the application of Large Eddy Simulation (LES) to Internal Combustion Engines (hereafter ICEs) flows is motivated by its capability to capture spatial and temporal evolution of turbulent flow structures. Furthermore, LES is universally recognized as capable of simulating highly unsteady and random phenomena driving cycle-to-cycle variability (CCV) and cycle-resolved events such as knock and misfire. Several quality criteria were proposed in the recent past to estimate LES uncertainty: however, definitive conclusions on LES quality criteria for ICEs are still far to be found. This paper describes the application of LES quality criteria to the TCC-III single-cylinder optical engine from University of Michigan and GM Global R&D; the analyses are carried out under motored condition.

In order to optimize gasoline direct injection combustion systems, a very accurate control of the fuel flow rate from the injector must be attained, along with appropriate spray characteristics in terms of drop sizing and jets global penetration/diffusion in the combustion chamber. Injection rate measurement is therefore one of the crucial tasks to be accomplished in order both to develop direct injection systems and to properly match them with a given combustion system. Noticeably, the hydraulic characteristics of GDI injectors should be determined according to a non-intrusive measuring approach. Unfortunately, the operation of all conventional injection analyzers requires the injection in a volume filled with liquid and the application of a significant counter-pressure downstream of the injector. This feature prevents any operation with low pressure injection systems such as PFIs.

In the present paper an innovative approach for the shot-to-shot hydraulic characterization of low pressure injection systems is experimentally assessed. The proposed methodology is an inverse application of the Zeuch’s method, which in this case is applied to a closed volume upstream the injector instead of downstream of it as in conventional injection analyzers. By this approach, the well-known constraint of having a finite volume pressurized with the injected liquid downstream the injector is circumvented. As a consequence, with the proposed instrument low pressure injectors - such as PFI, fed with gasoline or water, SCR injectors - can operate with the prescribed upstream-downstream pressure differential. Further, the injector can spray directly in atmosphere or in any ambient at arbitrary pressure and temperature conditions, allowing the simultaneous application of other diagnostics such as imaging, momentum flux measurement or sizing instruments.

In the present paper, a new methodology for the estimation of the mass delivered by a single hole of a GDI injector is presented and discussed. The GDI injector used for the activity featured a five-hole nozzle characterized by three holes with the same diameter and two holes with a larger diameter. The different holes size guarantees a significant difference in terms of mass flow. This new methodology is based on global momentum flux measurement of each single plume and on its combination with the global mass measurement made with the gravimetric principle. The momentum flux is measured by means of a dedicated test bench that detects the impact force of the single spray plume at different distances. The sensing device is moved in different positions and, in each point, the force trace averaged over several injection events is acquired. The global mass delivered by the injector is measured by collecting and weighing the fuel flown during a defined number of consecutive injections.

It is widely recognized that spatial and temporal evolution of both macro- and micro- turbulent scales inside internal combustion engines affect air-fuel mixing, combustion and pollutants formation. Particularly, in spark ignition engines, tumbling macro-structure induces the generation of a proper turbulence level to sustain the development and propagation of the flame front. As known, 3D-CFD codes are able to describe the evolution of the in-cylinder flow and turbulence fields with good accuracy, although a high computational effort is required. For this reason, only a limited set of operating conditions is usually investigated. On the other hand, thanks to a lower computational burden, 1D codes can be employed to study engine performance in the whole operating domain, despite of a less detailed description of in-cylinder processes. The integration of 1D and 3D approaches appears hence a promising path to combine the advantages of both.

In the present paper, two different methodologies are adopted and critically integrated to analyze the knock behavior of a last generation small size spark ignition (SI) turbocharged VVA engine. Particularly, two full load operating points are selected, exhibiting relevant differences in terms of knock proximity. On one side, a knock investigation is carried out by means of an Auto-Regressive technique (AR model) to process experimental in-cylinder pressure signals. This mathematical procedure is used to estimate the statistical distribution of knocking cycles and provide a validation of the following 1D-3D knock investigations. On the other side, an integrated numerical approach is set up, based on the synergic use of 1D and 3D simulation tools. The 1D engine model is developed within the commercial software GT-Power™. It is used to provide time-varying boundary conditions (BCs) for the 3D code, Star-CD™.

The paper critically discusses Large-Eddy Simulation (LES) potential to investigate cycle-to-cycle variability (CCV) in internal combustion engines. Particularly, the full load/peak power engine speed operation of a high-performance turbocharged GDI unit, for which ample cycle-to-cycle fluctuations were observed during experimental investigations at the engine test bed, is analyzed through a multi-cycle approach covering 25 subsequent engine cycles. In order to assess the applicability of LES within the research and development industrial practice, a modeling framework with a limited impact on the computational cost of the simulations is set up, with particular reference to the extent of the computational domain, the computational grid size, the choice of boundary conditions and numerical sub-models [1, 2, 3].

In the present paper, a detailed numerical and experimental analysis of a spray momentum flux measurement device capability is presented. Particular attention is devoted to transient, engine-like injection events in terms of spray momentum flux measurement. The measurement of spray momentum flux in steady flow conditions, coupled with knowledge of the injection rate, is steadily used to estimate the flow mean velocity at the nozzle exit and the extent of flow cavitation inside the nozzle in terms of a velocity reduction coefficient and a flow section reduction coefficient. In the present study, the problem of analyzing spray evolution in short injection events by means of jet momentum flux measurement was approached. The present research was based on CFD-3D analysis of the spray-target interaction in a momentum measurement device.

In the present work, an experimental and numerical analysis of high pressure Diesel spray evolution is carried out in terms of spray momentum flux time history and instantaneous injection rate. The final goal of spray momentum and of injection rate analyses is the evaluation of the nozzle outlet flow characteristics and of the nozzle internal geometry possible influences on cavitation phenomena, which are of primary importance for the spray evolution. Further, the evaluation of the flow characteristics at the nozzle exit is fundamental in order to obtain reliable boundary conditions for injection process 3D simulation. In this paper, spray momentum data obtained in ambient temperature, high counter-pressure conditions at the Perugia University Spray Laboratory are presented and compared with the results of 3D simulations of the momentum rig itself.

The paper aims at providing information about the in-cylinder flow structure and its evolution of a high speed direct injection (HSDI) four valve per cylinder engine for off-highway applications. Fully transient CFD analyses by means of state-of-the-art tools and methodologies are carried out for the whole intake and compression strokes, in order to evaluate port effects on both engine permability and in-cylinder flow field evolution. Organized mean motions (i.e., swirl, tumble and squish) are investigated, trying to establish general rules in the port design optimization process, addressing relationships between the relative port orientation and the in-cylinder flow structure. Different port configurations are compared, each deriving from the rotation of the BASE port configuration on two different planes, the former being perpendicular to the cylinder axis, while the latter being parallel to the cylinder axis.

The recent introduction of electronic controlled, high pressure injection systems has deeply changed the scenario for light duty, automotive diesel engines. This change is mainly due to the enhanced flexibility in obtaining the desired injection law (time history and injected fuel quantity), while high injection pressures also favour a suitable mixture formation. This results in higher engine performance (efficiency and power) and in better pollutant emissions control. At the same time, in order to reduce the greenhouse gases net production, research is analyzing alternative resources, such as bio-derived fuels. In particular, methyl esters derived by different vegetable oils are characterized by high cetane numbers and very small sulfur content. The present work reports the results of a comparative analysis performed on a modern DI, common-rail, turbocharged engine by using three different bio-derived fuels (rape seed, soybean, waste cooked oil) and conventional fossil diesel fuel.