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An experimental study was performed to develop a more fundamental understanding of the effects of secondary air injection (SAI) on exhaust gas emissions and catalyst light-off characteristics during cold start of a modern SI engine. The effects of engine operating parameters and various secondary air injection strategies such as spark retardation, fuel enrichment, secondary air injection location and air flow rate were investigated to understand the mixing, heat loss, and thermal and catalytic oxidation processes associated with SAI. Time-resolved HC, CO and CO₂ concentrations were tracked from the cylinder exit to the catalytic converter outlet and converted to time-resolved mass emissions by applying an instantaneous exhaust mass flow rate model. A phenomenological model of exhaust heat transfer combined with the gas composition analysis was also developed to define the thermal and chemical energy state of the exhaust gas with SAI.

Mechanisms of NH₃ generation using LNT-like catalysts have been studied in a bench reactor over a wide range of temperatures, flow rates, reformer catalyst types and synthetic exhaust-gas compositions. The experiments showed that the on board production of sufficient quantities of ammonia on board for SCR operation appeared feasible, and the results identified the range of conditions for the efficient generation of ammonia. In addition, the effects of reformer catalysts using the water-gas-shift reaction as an in-situ source of the required hydrogen for the reactions are also illustrated. Computations of the NH₃ and NOx kinetics have also been carried out and are presented. Design and impregnation of the SCR catalyst in proximity to the ammonia source is the next logical step. A heated synthetic-exhaust gas flow bench was used for the experiments under carefully controlled simulated exhaust compositions.

The effects of charge motion and laminar flame speeds on combustion and exhaust temperature have been studied by using an air jet in the intake flow to produce an adjustable swirl or tumble motion, and by replacing the nitrogen in the intake air by argon or CO₂, thereby increasing or decreasing the laminar flame speed. The objective is to examine the "Late Robust Combustion" concept: whether there are opportunities for producing a high exhaust temperature using retarded combustion to facilitate catalyst warm-up, while at the same time, keeping an acceptable cycle-to-cycle torque variation as measured by the coefficient of variation (COV) of the net indicated mean effective pressure (NIMEP). The operating condition of interest is at the fast idle period of a cold start with engine speed at 1400 RPM and NIMEP at 2.6 bar. A fast burn could be produced by appropriate charge motion. The combustion phasing is primarily a function of the spark timing.

The engine and its exhaust flow behaviors are investigated in a turbo-charged gasoline direct injection engine under simulated cold-fast-idle condition. The metrics of interest are the exhaust sensible and chemical enthalpy flows, and the exhaust temperature, all of which affect catalyst light off time. The exhaust sensible enthalpy flow is mainly a function of combustion phasing; the exhaust chemical enthalpy flow is mainly a function of equivalence ratio. High sensible and chemical enthalpy flow with acceptable engine stability could be obtained with retarded combustion and enrichment. When split injection is employed with one early and one later and smaller fuel pulse, combustion retards with early secondary injection in the compression stroke but advances with late secondary injection. Comparing gasoline to E85, the latter produces a lower exhaust temperature because of charge cooling effect and because of a faster combustion.

The first 3 cycles in the cold crank-start process at 20°C are studied in a GDI engine. The focus is on the dependence of the HC and PM/PN emissions of each cycle on the injection strategy and combustion phasing of the current and previous cycles. The PM/PN emissions per cycle decrease by more than an order of magnitude as the crank-start progresses from the 1st to the 3rd cycle, while the HC emissions stay relatively constant. The wall heat transfer, as controlled by the combustion phasing, during the previous cycles has a more significant influence on the mixture formation process for the current cycle than the amount of residual fuel. The results show that the rise in HC emissions caused by the injection spray interacting with the intake valves and piston crown is reduced as the cranking process progresses. Combustion phasing retard significantly reduces the PM emission. The HC emissions, however, are relatively not sensitive to combustion phasing in the range of interest.

To meet future particle mass and particle number standards, gasoline vehicles may require particle control, either by way of an exhaust gas filter and/or engine modifications. Soot levels for gasoline engines are much lower than diesel engines; however, non-combustible material (ash) will be collected that can potentially cause increased backpressure, reduced power, and lower fuel economy. The purpose of this work was to examine the ash loading of gasoline particle filters (GPFs) during rapid aging cycles and at real time low mileages, and compare the filter performances to both fresh and very high mileage filters. Current rapid aging cycles for gasoline exhaust systems are designed to degrade the three-way catalyst washcoat both hydrothermally and chemically to represent full useful life catalysts. The ash generated during rapid aging was low in quantity although similar in quality to real time ash. Filters were also examined after a low mileage break-in of approximately 3000 km.

In order to understand better the operation of spark-ignition engines during the warm-up period, a computer model had been developed which simulates the thermal processes of the engine. This model is based on lumped thermal capacitance methods for the major engine components, as well as the exhaust system. Coolant and oil flows, and their respective heat transfer rates are modeled, as well as friction heat generation relations. Piston-liner heat transfer is calculated based on a thermal resistance method, which includes the effects of piston and ring material and design, oil film thickness, and piston-liner crevice. Piston/liner crevice changes are calculated based on thermal expansion rates and are used in conjunction with a crevice-region unburned hydrocarbon model to predict the contribution to emissions from this source.

Selective catalytic reduction (SCR) of nitrogen oxides (NOx) is used in diesel-fueled mobile applications where urea is an added reducing agent. We show that the Ultera® dual-stage catalyst, with intercooling aftertreatment system, intrinsically performs the function of the SCR method in nominally stoichiometric gasoline vehicle engines without the need for an added reductant. We present that NOx is reduced during the low-temperature operation of the dual-stage system, benefiting from the typically periodic transient operation (acceleration and decelerations) with the associated swing in the air/fuel ratio (AFR) inherent in mobile applications, as commonly expected and observed in real driving. The primary objective of the dual-stage aftertreatment system is to remove non-methane organic gases (NMOG) and carbon monoxide (CO) slip from the vehicle’s three-way catalyst (TWC) by oxidizing these constituents in the second stage catalyst.

This paper reviews the relevant literature on the effects of sulfated ash, phosphorus, and sulfur on DPF, LNT, and SCR catalysts. Exhaust backpressure increase due to DPF ash accumulation, as well as the rate at which ash is consumed from the sump, were the most studied lubricant-derived DPF effects. Based on several studies, a doubling of backpressure can be estimated to occur within 270,000 to 490,000 km when using a 1.0% sulfated ash oil. Postmortem DPF analysis and exhaust gas measurements revealed that approximately 35% to 65% less ash was lost from the sump than was expected based on bulk oil consumption estimates. Despite significant effects from lubricant sulfur and phosphorus, loss of LNT NOX reduction efficiency is dominated by fuel sulfur effects. Phosphorus has been determined to have a mild poisoning effect on SCR catalysts. The extent of the effect that lubricant phosphorus and sulfur have on DOCs remains unclear, however, it appears to be minor.

A rapid compression machine for chemical kinetic studies has been developed. The design objectives of the machine were to obtain: 1)uniform well-defined core gas; 2) laminar flow condition; 3) maximum ratio of cooling to compression time; 4) side wall vortex containment; and, 5) minimum mechanical vibration. A piston crevice volume was incorporated to achieve the side wall vortex containment. Tests with inert gases showed the post-compression pressure matched with the calculated laminar pressure indicating that the machine achieved these design objectives. Measurements of ignition delays for homogeneous PRF/O2/N2/Ar mixture in the rapid compression machine have been made with five primary reference fuels (ON 100, 90, 75, 50, and 0) at an equivalence ratio of 1, a diluent (s)/oxygen ratio of 3.77, and two initial pressures of 500 Torr and 1000 Torr. Post-compression temperatures were varied by blending Ar and N2 in different ratios.

A novel engine management strategy for achieving fast catalyst light-off without the use of an exhaust air pump in a port-fuel-injected, spark ignition engine was developed. A conventional 4-cylinder engine was operated with three cylinders running rich and the fourth one as an air pump to supply air to the exhaust manifold. Under steady-state cold coolant conditions, this strategy achieved near total oxidation of CO and HC with sufficiently retarded spark timing, resulting in a 400% increase in feedgas enthalpy flow and a 90% reduction in feedgas HC emissions compared to conventional operation. The strategy was also evaluated for crank starts. Using the existing engine hardware, implementing the strategy resulted in a reduction in catalyst light-off time from 28.0 seconds under conventional operation to 9.1 seconds.

Measurements of particulate matter (PM) from spark ignition (SI) engine exhaust using dilution tunnels will become more prevalent as emission standards are tightened. Hence, a study of the dilution process was undertaken in order to understand how various dilution related parameters affect the accuracy with which PM sizes and concentrations can be determined. A SI and a compression ignition (CI) engine were separately used to examine parameters of the dilution process; the present work discusses the results in the context of SI exhaust dilution. A Scanning Mobility Particle Sizer (SMPS) was used to measure the size distribution, number density, and volume fraction of PM. Temperature measurements in the exhaust pipe and dilution tunnel reveal the degree of mixing between exhaust and dilution air, the effect of flowrate on heat transfer from undiluted and diluted exhaust to the environment, and the minimum permissible dilution ratio for a maximum sample temperature of 52°C.

The prediction of knock onset in spark-ignition engines requires a chemical model for the autoignition of the hydrocarbon fuel-air mixture, and a description of the unburned end-gas thermal state. Previous studies have shown that a reduced chemistry model developed by Keck et al. adequately predicts the initiation of autoignition. However, the combined effects of heat transfer and compression on the state of the end gas have not been thoroughly investigated. The importance of end-gas heat transfer was studied with the objective of improving the ability of our knock model to predict knock onset over a wide range of engine conditions. This was achieved through changing the thermal environment of the end gas by either varying the inlet air temperature or the coolant temperature. Results show that there is significant heating of the in-cylinder charge during intake and a substantial part of the compression process.

The paper describes the design and construction of a two cylinder apparatus to measure heat transfer under conditions of oscillating pressure and oscillating flow such as found in Stirling-cycle machines. The apparatus consists of two large single stage air compressors joined by a rigid drive shaft between the two crank shafts. The compressors are 27.94 cm (11-in) diameter by 22.86 cm (9-in) stroke. The apparatus is powered by a 25 HP variable speed DC motor. Belts and a jack shaft provide wide speed ranges. The test section, which is connected between the compressor cylinders, is a 44.45 mm (1.75-in) diameter tube and about 254 cm (100-in) long. The test section is configured for measuring wall heat flux, and gas pressure as a function of time. An LDV system is being installed for measurement of gas velocity as a function of time and position. A fast response micro thermocouple measures gas temperature as a function of time and position.

A single-zone burn-rate analysis based on measured cylinder pressure data proposed by Gatowski et al. in 1984 was evaluated over the full load and speed range of a spark-ignition engine. The analysis, which determines the fuel mass burning rate based on the First Law of Thermodynamics, includes sub-models for the effects of residual fraction, heat transfer, and crevices. Each of these sub-models was assessed and calibrated. Cylinder pressure data over the full engine operating range obtained from two different engines were used to examine the robustness of the analysis. The sensitivity of predictions to the parameters wall temperature, heat transfer model coefficients and exponent, swirl ratio, motoring polytropic constant, in-cylinder mass, and to uncertainty in pressure data was evaluated.

This paper investigates theoretically the effects of heat transfer characteristics, such as crank-angle phasing and wall temperature swings, on the thermodynamic efficiency of an IC engine. The objective is to illustrate the fundamental physical basis of applying thin thermal barrier coatings to improve the performance of military and commercial IC engines. A simple model illustrates how the thermal impedance and thickness of coatings can be manipulated to control heat transfer and limit the high temperatures in engine components. A friction model is also included to estimate the overall improvement in engine efficiency by the proper selection of coating thickness and material.

A model has been developed to predict the performance of the Texaco Controlled Combustion, Stratified Charge Engine starting from engine geometry, fuel characteristics and the operating conditions. This performance model divides the engine cycle into the following phases: Intake, Compression, Rapid Combustion, Mixing-Dominated Expansion, Heat-Transfer Dominated Expansion and Exhaust. During the rapid combustion phase, the rate of heat release is assumed to be controlled by the rate of fuel injection and the air-to-fuel ratio. The burning rate in the mixing controlled stage appears to be dominated by the rate of entrainment of the surrounding gas by the plume of burning products and this rate is assumed to be controlled by the turbulent eddy entrainment velocity. A plume geometry model has been developed to obtain the surface area of the plume for entrainment during the mixing dominated phase.

The heat transfer characteristics of impinging diesel sprays were studied in a Rapid Compression Machine. The temporal and spatial distributions of the heat transfer around the impingement point -were measured by an array of high frequency response surface thermocouples. Simultaneously, the flow field of the combusting spray was photographed with high speed movie through the transparent head of the apparatus. The results for the auto-ignited fuel sprays were compared to those of non-combusting sprays which were carried out in nitrogen. The values of the heat flux from the combusting sprays were found to be substantially different from those of the non-combusting sprays. The difference was attribute to the radiative heat transfer and the combustion generated bulk, motion and small scale turbulence.

A one-dimensional model has been developed for the species and energy transfer over a thin (0.1-0.5 mm) layer of liquid fuel present on the wall of a spark-ignition engine. Time-varying boundary conditions during compression and flame passage were used to determine the rate of methanol vaporization and oxidation over a mid-speed, mid-load cycle, as a function of wall temperature. The heat of vaporization and the boiling point of the fuel were varied about a baseline to determine the effect of these characteristics, at a fixed operating point and lean conditions (ϕ = 0.9). The calculations show that the evaporation of fuels from layers on cold walls starts during flame passage, peaking a few milliseconds later, and continuing through the exhaust phase.

The Cu-zeolite (CuZ) SCR catalyst enables higher NOx conversion efficiency in part because it can store a significant amount of NH3. “NH3 storage control”, where diesel exhaust fluid (DEF) is dosed in accord with a target NH3 loading, is widely used with CuZ catalysts to achieve very high efficiency. The NH3 loading actually achieved on the catalyst is currently estimated through a stoichiometric calculation. With future high-capacity CuZ catalyst designs, it is likely that the accuracy of this NH3 loading estimate will become limiting for NOx conversion efficiency. Therefore, a direct measurement of NH3 loading is needed; RF sensing enables this. Relative to RF sensing of soot in a DPF (which is in commercial production), RF sensing of NH3 adsorbed on CuZ is more challenging. Therefore, more attention must be paid to the “microwave resonance cavity” created within the SCR assembly. The objective of this study was to develop design guidelines to enable and enhance RF sensing.