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EGR coolers are effective to reduce NOx emissions from diesel engines due to lower intake charge temperature. EGR cooler fouling reduces heat transfer capacity of the cooler significantly and increases pressure drop across the cooler. Engine coolant provided at 40–90 C is used to cool EGR coolers. The presence of a cold surface in the cooler causes particulate soot deposition and hydrocarbon condensation. The experimental data also indicates that the fouling is mainly caused by soot and hydrocarbons. In this study, a 1-D model is extended to simulate particulate soot and hydrocarbon deposition on a concentric tube EGR cooler with a constant wall temperature. The soot deposition caused by thermophoresis phenomena is taken into account the model. Condensation of a wide range of hydrocarbon molecules are also modeled but the results show condensation of only heavy molecules at coolant temperature.

Direct injection spark-ignition (DISI) gasoline engines can offer better fuel economy and higher performance over their port fuel-injected counterparts, and are now appearing increasingly in more U.S. vehicles. Small displacement, turbocharged DISI engines are likely to be used in lieu of large displacement engines, particularly in light-duty trucks and sport utility vehicles, to meet fuel economy standards for 2016. In addition to changes in gasoline engine technology, fuel composition may increase in ethanol content beyond the 10% allowed by current law due to the Renewable Fuels Standard passed as part of the 2007 Energy Independence and Security Act (EISA). In this study, we present the results of an emissions analysis of a U.S.-legal stoichiometric, turbocharged DISI vehicle, operating on ethanol blends, with an emphasis on detailed particulate matter (PM) characterization.

Neutron diffraction is a powerful tool that can be used to identify the phases present and to measure the spacing of the atomic planes in a material. Thus, the residual stresses can be determined within a component and/or the phases present. New intercritically austempered irons rely on the unique properties of the austenite phase present in their microstructures. If these materials are to see widespread use, methods to verify the quality (behavior consistency) of these materials and to provide guidance for further optimization will be needed. Neutron diffraction studies were performed at the second generation neutron residual stress facility (NRSF2) at the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory on a variety of intercritically austempered irons. For similar materials, such as TRIP steels, the strengthening mechanism involves the transformation of metastable austenite to martensite during deformation.

Ash, primarily derived from diesel engine lubricants, accumulates in diesel particulate filters directly affecting the filter's pressure drop sensitivity to soot accumulation, thus impacting regeneration frequency and fuel economy. After approximately 33,000 miles of equivalent on-road aging, ash comprises more than half of the material accumulated in a typical cordierite filter. Ash accumulation reduces the effective filtration area, resulting in higher local soot loads toward the front of the filter. At a typical ash cleaning interval of 150,000 miles, ash more than doubles the filter's pressure drop sensitivity to soot, in addition to raising the pressure drop level itself. In order to evaluate the effects of lubricant-derived ash on DPF pressure drop performance, a novel accelerated ash loading system was employed to generate the ash and load the DPFs under carefully-controlled exhaust conditions.

One of the issues in stamping of advanced high strength steels (AHSS) is the stretch bending fracture on a sharp radius (commonly referred to as shear fracture). Shear fracture typically occurs at a strain level below the conventional forming limit curve (FLC). Therefore it is difficult to predict in computer simulations using the FLC as the failure criterion. A modified Mohr-Coulomb (M-C) fracture criterion has been developed to predict shear fracture. The model parameters for several AHSS have been calibrated using various tests including the butter-fly shaped shear test. In this paper, validation simulations are conducted using the modified (M-C) fracture criterion for a dual phase (DP) 780 steel to predict fracture in the stretch forming simulator (SFS) test and the bending under tension (BUT) test. Various deformation fracture modes are analyzed, and the range of usability of the criterion is identified.

Plug-in hybrid electric vehicle (PHEV) technologies have the potential for considerable petroleum consumption reductions, possibly at the expense of increased tailpipe emissions due to multiple “cold” start events and improper use of the engine for PHEV specific operation. PHEVs operate predominantly as electric vehicles (EVs) with intermittent assist from the engine during high power demands. As a consequence, the engine can be subjected to multiple cold start events. These cold start events may have a significant impact on the tailpipe emissions due to degraded catalyst performance and starting the engine under less than ideal conditions. On current hybrid electric vehicles (HEVs), the first cold start of the engine dictates whether or not the vehicle will pass federal emissions tests. PHEV operation compounds this problem due to infrequent, multiple engine cold starts.

The effects of spray/wall interaction on diesel combustion and soot formation in a two-dimensional piston cavity were studied with a high speed color video camera in a constant volume combustion vessel. The two-dimensional piston cavity was applied to generate the impinging spray flame. In the cavity, the flat surface which plays a role as the cylinder head has a 13.5 degree angle with the injector axis and the impinging point was located 30 mm away from the nozzle tip. Three injection pressures of 100, 150, and 200 MPa and a single hole diesel injector (hole diameter: 0.133mm) were selected. The flame structure and combustion process were examined by using the color luminosity images. Two-color pyrometry was used to measure the line-of sight soot temperature and concentration by using the R and B channels of the color images. The soot mass generated by impinging spray flame is higher than that of the free spray flame.

We present simulated fuel economy and emissions of city transit buses powered by conventional diesel engines and diesel-hybrid electric powertrains of varying size. Six representative city drive cycles were included in the study. In addition, we included previously published aftertreatment device models for control of CO, HC, NOx, and particulate matter (PM) emissions. Our results reveal that bus hybridization can significantly enhance fuel economy by reducing engine idling time, reducing demands for accessory loads, exploiting regenerative braking, and shifting engine operation to speeds and loads with higher fuel efficiency. Increased hybridization also tends to monotonically reduce engine-out emissions, but tailpipe (post-aftertreatment) emissions are affected by complex interactions between engine load and the transient catalyst temperatures, and the emissions results were found to depend significantly on motor size and details of each drive cycle.

Two hybrid powertrain configurations, including parallel and series hybrids, were simulated for fuel economy, component energy loss, and emissions control in Class 8 trucks over both city and highway driving conditions. A comprehensive set of component models describing engine fuel consumption, emissions control, battery energy, and accessory power demand interactions was developed and integrated with the simulated hybrid trucks to identify heavy-duty (HD) hybrid technology barriers. The results show that series hybrid is absolutely negative for fuel-economy improvement of long-haul trucks due to an efficiency penalty associated with the dual-step conversions of energy (i.e. mechanical to electric to mechanical).

This study simulates soot formation processes in diesel combustion using a large eddy simulation (LES) model, based on a one-equation subgrid turbulent kinetic energy model. This approach was implemented in the KIVA4 code, and used to model diesel spray combustion within a constant volume chamber. The combustion model uses a direct integration approach with a fast explicit ordinary differential equation (ODE) solver, and is additionally parallelized using OpenMP. The soot mass production within each computation cell was determined using a phenomenological soot formation model developed by Waseda University. This model was combined with the LES code mentioned above, and included the following important steps: particle inception during which acenaphthylene (A2R5) grows irreversibly to form soot; surface growth with driven by reactions with C2H2; surface oxidation by OH radical and O2 attack; and particle coagulation.

As the piston pin works under significant mechanical load, it is susceptible to wear, seizure, and structural failure, especially in heavy duty internal combustion engines. It has been found that the friction loss associated with the pin is comparable to that of the piston, and can be reduced when the interface geometry is properly modified. However, the mechanism that leads to such friction reduction, as well as the approaches towards further improvement, remain unknown. This work develops a piston pin lubrication model capable of simulating the interaction between the pin, the piston, and the connecting rod. The model integrates dynamics, solid contact, oil transport, and lubrication theory, and applies an efficient numerical scheme with second order accuracy to solve the highly stiff equations. As a first approach, the current model assumes every component to be rigid.

This article is concerned with identification of true stress-strain curve under biaxial tension of thermoplastic polymers. A new type of biaxial tension attachment was embedded first in a universal material test machine, which is able to transform unidirectional loading of the test machine to biaxial loading on the specimen with constant velocity. Cruciform specimen geometry was optimized via FE modeling. Three methods of calculating true stress in biaxial tension tests were compared, based on incompressibility assumption, linear elastic theory and inverse engineering method, respectively. The inverse engineering method is more appropriate for thermoplastic polymers since it considers the practical volume change of the material during biaxial tension deformation. The strategy of data processing was established to obtain biaxial tension true stress-strain curves of different thermoplastic polymers.

This work examines the effect of valve timing during cold crank-start and cold fast-idle (1200 rpm, 2 bar NIMEP) on the emissions of hydrocarbons (HC) and particulate mass and number (PM/PN). Four different cam-phaser configurations are studied in detail: 1. Baseline stock valve timing. 2. Late intake opening/closing. 3. Early exhaust opening/closing. 4. Late intake phasing combined with early exhaust phasing. Delaying the intake valve opening improves the mixture formation process and results in more than 25% reduction of the HC and of the PM/PN emissions during cold crank-start. Early exhaust valve phasing results in a deterioration of the HC and PM/PN emissions performance during cold crank-start. Nevertheless, early exhaust valve phasing slightly improves the HC emissions and substantially reduces the particulate emissions at cold fast-idle.

The increasing use of gasoline direct injection (GDI) engines coupled with the implementation of new particulate matter (PM) and particle number (PN) emissions regulations requires new emissions control strategies. Gasoline particulate filters (GPFs) present one approach to reduce particle emissions. Although primarily composed of combustible material which may be removed through oxidation, particle also contains incombustible components or ash. Over the service life of the filter the accumulation of ash causes an increase in exhaust backpressure, and limits the useful life of the GPF. This study utilized an accelerated aging system to generate elevated ash levels by injecting lubricant oil with the gasoline fuel into a burner system. GPFs were aged to a series of levels representing filter life up to 150,000 miles (240,000 km). The impact of ash on the filter pressure drop and on its sensitivity to soot accumulation was investigated at specific ash levels.

Electric drives, whether in battery electric vehicles (BEVs) or various other applications, are an important part of modern transportation. Traditionally, physics-based models based on steady-state mapping of electric drives have been used to evaluate their behavior under transient conditions. Hardware-in-the-Loop (HIL) testing seeks to provide a more accurate representation of a component’s behavior under transient load conditions that are more representative of real world conditions it will operate under, without requiring a full vehicle installation. Oak Ridge National Laboratory (ORNL) developed such a HIL test platform capable of subjecting electric drives to both conventional steady-state test procedures as well as transient experiments such as vehicle drive cycles.

The gasoline direct injection (GDI) engine particulate emission sources are assessed under cold start conditions: the fast idle and speed/load combinations representative of the 1st acceleration in the US FTP. The focus is on the accumulation mode particle number (PN) emission. The sources are non-fuel, combustion of the premixed charge, and liquid fuel film. The non-fuel emissions are measured by operating the engine with premixed methane/air or hydrogen/air. Then the PN level is substantially lower than what is obtained with normal GDI operation; thus non-fuel contribution to PN is small. When operating with stoichiometric premixed gasoline/air, the PN level is comparable to the non-fuel level; thus premixed-stoichiometric mixture combustion does not significantly generate particulates. For fuel rich premixed gasoline/air, PN increases dramatically when lambda is less than 0.7 to 0.8.

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.

The increasing use of diesel and gasoline particulate filters requires advanced on-board diagnostics (OBD) to prevent and detect filter failures and malfunctions. Early detection of upstream (engine-out) malfunctions is paramount to preventing irreversible damage to downstream aftertreatment system components. Such early detection can mitigate the failure of the particulate filter resulting in the escape of emissions exceeding permissible limits and extend the component life. However, despite best efforts at early detection and filter failure prevention, the OBD system must also be able to detect filter failures when they occur. In this study, radio frequency (RF) sensors were used to directly monitor the particulate filter state of health for both gasoline particulate filter (GPF) and diesel particulate filter (DPF) applications.

A new analytical method to aid in the understanding of the organic carbon (OC) phase of particulate matter (PM) from advanced compression ignition (ACI) operating modes, is presented. The presence of NO2 and unburned fuel aromatics in ACI emissions, and the low exhaust temperatures that result from this low temperature combustion strategy, provide the right conditions for the formation of carboxylic acids and nitroaromatic compounds. These polar compounds contribute to OC in the PM and are not typically measured using nonpolar solvent extraction methods such as the soluble organic fraction (SOF) method. The new extraction and detection method employs capillary electrophoresis with electrospray ionization mass spectrometry (CE-ESI MS) and was specifically developed to determine polar organic compounds in the ACI PM emissions. The new method identified both nitrophenols and aromatic carboxylic acids in the ACI PM.

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible spark ignition (SI). A high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio (rc) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. To achieve efficiency improvements, engine experiments were coupled with computational fluid dynamics simulations to guide and explain experimental trends between the original engine and the high stroke-to-bore ratio design (1.5:1). The effects of EGR and late intake valve closing (IVC) and fuel characteristics are investigated through their effects on knock mitigation. Direct injection of 91 RON E10 gasoline, 99 RON E0 gasoline, and liquified petroleum gas (i.e., propane/autogas) were evaluated with geometric rc ranging from 13.3:1 to 16.8:1.