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Co-Optimization of Fuels and Engines initiative (Co-Optima) of the U.S Department of Energy started investigations on several candidates of biofuels and blends for internal combustion engines. At this stage, only a few biomass-derived fuel blendstocks (including ethanol) for advanced spark-ignition engines have been selected using enhanced screening criteria, which included boiling point, toxicity, research octane number, octane sensitivity, and economical distribution system, etc. Ethanol, of which this paper is focused on, is also an important fuel because of its high-octane number which in turn promotes advance ignition timing and higher thermal efficiencies in reciprocating engines. Measurements of laminar burning velocity (LBV) is a key metric to understand fuel performance and applicability in engines. Furthermore, in order to quantify more complicated, and practical, burning regimes such as turbulent combustion much of the underlying theory requires knowledge of LBV.

The biofuel and engine co-development framework was initiated at Sandia National Labs. Here, the synthetic biologists develop and engineer a new platform for drop-in fuel production from lignocellulosic biomass, using several endophytic fungi. Hence this process has the potential advantage that expensive pretreatment and fuel refining stages can be optimized thereby allowing scalability and cost reduction; two major considerations for widespread biofuel utilization. Large concentrations of ketones along with other volatile organic compounds were produced by fungi grown over switchgrass media. The combustion and emission properties of these new large ketones are poorly known.

The 2,4-dimethyl-3-pentanone (DIPK) is a promising biofuel candidate for automotive applications that is produced by the endophytic fungal conversion process which can be optimized for widespread utilization. There are some studies in the literature on combustion properties of DIPK, such as ignition delay times and laminar burning velocity (LBV) measurements. However, most studies are conducted one atmospheric (atm) pressure which are far away from the high-pressure conditions present inside reciprocating engines. Therefore, we present LBV measurements at high pressures up to 10 atm for this fuel using a spherical flame speed facility. It is known that the flame in a constant volume chamber develops cellular structure (hydrodynamic instability) as the initial pressure increases because of the reduction in flame thickness. In addition, the diffusional-thermal instability prevents experiments for rich mixtures because of the reduction of Lewis number (Le).

A gasoline engine with an electronically controlled fuel injection system has substantially better fuel economy and lower emissions than a carburetted engine. In general, the stability of engine operation is improved with fuel injector, but the stability of engine operation at idle is not improved compared with a carburetted gasoline engine. In addition, the increase in time that an engine is at idle due to traffic congestion has an effect on the engine stability and vehicle reliability. Therefore, in this research, we will study the influence of fuel injection timing, spark timing, dwell angle, and air-fuel ratio on engine stability at idle.

This paper reviews the literature which identifies the causes, consequences and cures for engine knock as it affects high performance engines. The physical events of normal and abnormal combustion are described. The observed variations in combustion phenomenon are explained through chemical kinetics. A mathematical model of combustion which can predict knock in an engine cylinder is summarized. Several mechanisms of knock induced damage are outlined. Design and operating considerations which affect an engine's propensity to knock are discussed. Terms that have become associated with combustion in general and the knocking phenomenon in particular are collected and examined

A power electronics module was equipped with an evaporative spray cooling nozzle assembly that served to remove waste heat from the silicon devices. The spray cooling nozzle assembly took the place of the standard heat sink, which uses single phase convection. The purpose of this work was to test the ability of spray cooling to enable higher power density in power electronics with high temperature coolant, and to be an effective and lightweight system level solution to the thermal management needs of aerospace vehicles. The spray cooling work done here was with 95 °C water, and this data is compared to 100 °C water/ propylene glycol spray cooling data from a previous paper so as to compare the spray cooling performance of a single component liquid to that of a binary liquid such as WPG. The module used during this work was a COTS module manufactured by Semikron, Inc., with a maximum DC power input of 180 kW (450 VDC and 400 A).

Calibrating the engine control unit to satisfy pollutant and performance objectives can be a challenging task. Due to the large number of variables and their interactive complexities, many firms apply design of experiment methods and modeling techniques to the acquired test data. This establishes a “black box” or “gray box” simulation model that predicts power and emissions as a function of the engine parameters. An offline optimization procedure on the fitted model(s) will identify the engine control strategy that best satisfies pollutant and performance objectives. A review of the literature reveals that the General Linear Modeling method and Neural Network modeling architectures are widely used in the development of “black box” or “gray box” simulation models. While Neural Network methods are “assumption free”, the General Linear Model method is limited to those problems in which the errors, ε, are normally distributed and have constant variance, σ2.

Effective thermal management and removal of the waste heat generated at diode arrays is critical to the development of high-power solid-state lasers. Thermal design must be considered in the packaging of these arrays. Two different packages with heat dissipation through spray cooling are evaluated experimentally and numerically. Their overall performance is compared with other packaging configurations using different heat removal approaches. A novel packaging design is proposed that can fulfill the requirements of low thermal resistance, temperature uniformity among emitters in the diode array, low coolant flow rate, simplicity and low assembly cost. The effect of temperature uniformity on the pumping efficiency for gain media is examined for our novel packaging design. The thermal stress induced by temperature variation within an emitter is also considered.

For aircraft electromechanical actuator (EMA) cooling applications using forced air produced by axial fans, the main objective in fan design is to generate high static pressure head, high volumetric flow rate, and high efficiency over a wide operating range of rotational speed (1x∼3x) and ambient pressure (0.2∼1 atm). In this paper, a fan design based on a fan diameter of 86 mm, fan depth (thickness) of 25.4 mm, and hub diameter of 48 mm is presented. The blade setting angle and the chord lengths at the leading and trailing edges are varied in their suitable ranges to determine the optimal blade profiles. The fan static pressure head, volumetric flow rate, and flow velocity are calculated at various ambient pressures and rotational speeds. The optimal blade design in terms of maximum total-to-total pressure ratio and efficiency at the design point is obtained via CFD simulation. A 5-blade configuration yields the best performance in terms of efficiency and total pressure ratio.

The aircraft electromechanical actuator (EMA) cooling fan is a critical component because an EMA failure caused by overheating could lead to a catastrophic failure in aircraft. Fault tree analysis (FTA) is used to access the failure probability of EMA fans with the goal of improving their mean time to failure (MTTF) from ∼O(5×104) to ∼ O(2.5×109) hours without incurring heavy weight penalty and high cost. The dual-winding and dual-bearing approaches are analyzed and a contra rotating dual-fan design is proposed. Fan motors are assumed to be brushless direct current (BLDC) motors. To have a full understanding of fan reliability, all possible failure mechanisms and failure modes are taken into account. After summarizing the possible failure causes and failure modes of BLDC fans by focusing on each failure mechanism, the life expectancy of fan ball bearings based on a major failure mechanism of lubricant deterioration is calculated and compared to that provided in the literature.

Peak pressure, crank angle and induction pressure were measured in cylinder number one of a Ford 4.6 liter Modular engine. Chaos analysis was conducted on these measurements and the phase, waveform, Poincare, and FFT plots are presented. These plots show conclusively that the pressure fluctuation inside a cylinder is a broadband chaos.

Engine dynamometer testing of homogeneous charge, spark ignition lean burn engines fueled by natural gas, hydrogen/natural gas blends and neat hydrogen was conducted to determine if NOx emissions from blended fuel operation can be reduced below those generated from natural gas operation, approaching those due to a 100% hydrogen fueled engine. The preliminary tests were conducted at the University of Central Florida/Florida Solar Energy Center on an eight cylinder automotive engine. The results indicate that the hydrogen/natural gas fuel has the potential of meeting highly restrictive NOx levels. Sandia National Laboratories conducted follow-on, comparative tests using a single cylinder research engine. The Sandia results indicate that the proposed CARB EZEV standard for NOx can be met without exhaust gas aftertreatment using a 30% hydrogen (by volume) / 70% natural gas blend fuel in a constant speed/power, hybrid vehicle application which achieves 60 MPG gasoline equivalent efficiency.

Optimizing IC engine performance currently requires an exhaustive experimental search to determine the combination of internal components that maximizes torque or power. An alternate and more structured approach using Response Surface Methods will lead the experimenter to the optimum combination with the least number of trials. Using simulation software to evaluate IC engine configurations, this method improved the estimated power from 439 to 516 KW. Results of the study indicate that Response Surface Methods are a viable and robust method of converging to an IC engine configuration which achieves optimum performance.

In this paper, we address the thermal management issues which limit the lifespan, specific power and overall efficiency of an air-cooled rotary Wankel engine used in Unmanned Air Vehicles (UAVs). Our goal is to eliminate the hot spots and reduce the temperature gradients in the engine housing and side plates by aggressive heat spreading using heat pipes. We demonstrate by simulation that, for a specific power requirement, with heat spreading and more effective heat dissipation, thermal stress and distortion can be significantly reduced, even with air cooling. The maximum temperature drop was substantial, from 231°C to 129°C. The temperature difference (measure of temperature uniformity) decreased by 8.8 times (from 159°C to 18°C) for a typical UAV engine. Our heat spreaders would not change the frontal area of the engine and should have a negligible impact on the installed weight of the propulsion assembly.

The scaling laws of fans express basic relationships among the variables of fan static pressure head, volume flow rate, air density, rotational speed, fan diameter, and power. These relationships make it possible to compare the performance of geometrically similar fans in dissimilar conditions. The fan laws were derived from dimensionless analysis of the equations for volumetric flow rate, static pressure head, and power as a function of fan diameter, air density and rotational speed. The purpose of this study is to characterize a fan's performance characteristics at various rotational speeds and ambient pressures. The experimental results are compared to the fan scaling laws.

Laminar burning velocity (LBV) measurements are reported for promising high-performance fuels selected as drop-in transportation fuels to automotive grade gasoline as part of the United States Department of Energy’s Co-Optimization of Fuels and Engines Initiative (Co-Optima). LBV measurements were conducted for ethanol, methyl acetate, and 2-methylfuran with synthetic air (79.0 % N2 and 21.0 % O2 by volume) within a constant-volume spherical combustion rig. Mixture initial temperature was fixed at 428±4 K, with the corresponding initial pressure of 1.00±0.02 atm. Current LBV of ethanol is in good agreement with literature data. LBV of ethanol and 2-methylfuran showed similar values over the range of equivalence ratios, while methyl acetate exhibited an LBV significantly lower over the range of tested equivalence ratios. The maximum laminar burning velocity occurred at slightly richer equivalence ratio from the stoichiometric value for all fuels tested.

The blend of dimethyl ether (DME, CH3OCH3) and propane (C3H8) is a potentially renewable fuel mixture that has the potential to replace diesel in compression ignition engines. The combination can potentially reduce particulate and greenhouse gas emissions compared to a conventional diesel engine operating under similar conditions. However, detailed conceptual and simulation studies must be conducted before adopting a new fuel on a compression ignition engine. For these simulations, accurate chemical kinetic models are necessary. However, the validity of chemical kinetic mechanisms in the literature is unknown for mixing controlled compression ignition (MCCI) engine operating conditions. Hence, in this work, we studied the ignition of dimethyl ether (DME) and propane blends in a shock tube at MCCI engine conditions. Ignition delay time (IDT) data was collected behind the reflected shock for DME-propane mixtures for heavy-duty compression ignition (CI) engine parameters.