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Optimization of the engine cold start is critical for gasoline direct injection (GDI) engines to meet increasingly stringent emission regulations, since the emissions during the first 20 seconds of the cold start constitute more than 80% of the hydrocarbon (HC) emissions for the entire EPA FTP75 drive cycle. However, Direct Injection Spark Ignition (DISI) engine cold start optimization is very challenging due to the rapidly changing engine speed, cold thermal environment and low cranking fuel pressure. One approach to reduce HC emissions for DISI engines is to adopt retarded spark so that engines generate high heat fluxes for faster catalyst light-off during the cold idle. This approach typically degrades the engine combustion stability and presents additional challenges to the engine cold start. This paper describes a CFD modeling based approach to address these challenges for the Ford 3.5L V6 EcoBoost engine cold start.

Ford Motor Company is introducing “EcoBoost” gasoline turbocharged direct injection (GTDI) engine technology in the 2010 Lincoln MKS. A logical enhancement of EcoBoost technology is the use of E85 for knock mitigation. The subject of this paper is the optimal use of E85 by using two fuel systems in the same EcoBoost engine: port fuel injection (PFI) of gasoline and direct injection (DI) of E85. Gasoline PFI is used for starting and light-medium load operation, while E85 DI is used only as required during high load operation to avoid knock. Direct injection of E85 (a commercially available blend of ∼85% ethanol and ∼15% gasoline) is extremely effective in suppressing knock, due to ethanol's high inherent octane and its high heat of vaporization, which results in substantial cooling of the charge. As a result, the compression ratio (CR) can be increased and higher boost levels can be used.

In order to detect degradation of engine oil lubricant, bench testing along with a number of diesel-powered Ford trucks were instruments and tested. The purpose of the bench testing was primarily to determine performance aspects such as repeatability, hysteresis effects and so on. Vehicle testing was conducted by designing and installing a separate oil reservoir along with a circulation system which was mounted in the vicinity of the oil pan. An innovative oil sensor was directly installed on the reservoir which can measure five (5) independent oil parameters (viscosity, density, permittivity, conductance, temperature). In addition, the concept is capable of detecting the oil level continuously during normal engine operation. The sensing system consists of an ultrasonic transducer for the oil level detection as well as a Tuning Fork mechanical resonator for the oil condition measurement.

The challenges of flex-fuel vehicle (FFV) emissions measurements have recently come to the forefront for the emissions testing community. The proliferation of ethanol blended gasoline in fractions as high as 85% has placed a new challenge in the path of accurate measures of NMHC and NMOG emissions. Test methods need modification to cope with excess amounts of water in the exhaust, assure transfer and capture of oxygenated compounds to integrated measurement systems (impinger and cartridge measurements) and provide modal emission rates of oxygenated species. Current test methods fall short of addressing these challenges. This presentation will discuss the challenges to FFV testing, modifications made to Ford Motor Company’s Vehicle Emissions Research Laboratory test cells, and demonstrate the improvements in recovery of oxygenated species from the vehicle exhaust system for both regulatory measurements and development measurements.

Quantitative planar laser-induced fluorescence (PLIF) of gaseous acetone as a fuel-tracer has been used in an optically accessible engine, fueled by direct hydrogen injection. The purpose of this article is to assess the accuracy and precision of the measurement and the associated data reduction procedures. A detailed description of the acetone seeding system is given as well. The key features of the experiment are a high-pressure bubbler saturating the hydrogen fuel with acetone vapor, direct injection into an optical engine, excitation of acetone fluorescence with an Nd:YAG laser at 266 nm, and detection of the resulting fluorescence by an unintensified camera. Key steps in the quantification of the single-shot imaging data are an in-situ calibration and a correction for the effect of local temperature on the fluorescence measurement.

The objective of this research is a detailed investigation of unburned hydrocarbon (UHC) in a highly-dilute diesel low temperature combustion (LTC) regime. This research concentrates on understanding the mechanisms that control the formation of UHC via experiments and simulations in a 0.48L signal-cylinder light duty engine operating at 2000 r/min and 5.5 bar IMEP with multiple injections. A multi-gas FTIR along with other gas and smoke emissions instruments are used to measure exhaust UHC species and other emissions. Controlled experiments in the single-cylinder engine are then combined with three computational tools, namely heat release analysis of measured cylinder pressure, analysis of spray trajectory with a phenomenological spray model using in-cylinder thermodynamics [1], and KIVA-3V Chemkin CFD computations recently tested at LTC conditions [2].

A systematic methodology has been employed to develop the Duratec 3.5L EcoBoost combustion system, with focus on the optimization of the combustion system including injector spray pattern, intake port design, piston geometry, cylinder head geometry. The development methodology was led by CFD (Computational Fluid Dynamics) modeling together with a testing program that uses optical, single-cylinder, and multi-cylinder engines. The current study shows the effect of several spray patterns on air-fuel mixing, in-cylinder flow development, surface wetting, and turbulence intensity. A few sets of injector spray patterns are studied; some that have a wide total cone angle, some that have a narrow cone angle and a couple of optimized injector spray patterns. The effect of the spray pattern at part load, full load and cold start operation was investigated and the methodology for choosing an optimized injector is presented.

This paper describes a CFD modeling based approach to address design challenges in GDI (gasoline direct injection) engine combustion system development. A Ford in-house developed CFD code MESIM (Multi-dimensional Engine Simulation) was applied to the study. Gasoline fuel is multi-component in nature and behaves very differently from the single component fuel representation under various operating conditions. A multi-component fuel model has been developed and is incorporated in MESIM code. To apply the model in engine simulations, a multi-component fuel recipe that represents the vaporization characteristics of gasoline is also developed using a numerical model that simulates the ASTM D86 fuel distillation experimental procedure. The effect of the multi-component model on the fuel air mixture preparations under different engine conditions is investigated. The modeling approach is applied to guide the GDI engine piston designs.

Diesel spray experimentation at controlled high-temperature and high-pressure conditions is intended to provide a more fundamental understanding of diesel combustion than can be achieved in engine experiments. This level of understanding is needed to develop the high-fidelity multi-scale CFD models that will be used to optimize future engine designs. Several spray chamber facilities capable of high-temperature, high-pressure conditions typical of engine combustion have been developed, but because of the uniqueness of each facility, there are uncertainties about their operation. For this paper, we describe results from comparative studies using constant-volume vessels at Sandia National Laboratories and IFP.

Long chain alcohols possess major advantages over the currently used ethanol as bio-components for gasoline, including higher energy content, better engine compatibility, and less water solubility. The rapid developments in biofuel technology have made it possible to produce C 4 -C 5 alcohols cost effectively. These higher alcohols could significantly expand the biofuel content and potentially substitute ethanol in future gasoline mixtures. This study characterizes some fundamental properties of a C 5 alcohol, isopentanol, as a fuel for HCCI engines. Wide ranges of engine speed, intake temperature, intake pressure, and equivalence ratio are investigated. Results are presented in comparison with gasoline or ethanol data previously reported. For a given combustion phasing, isopentanol requires lower intake temperatures than gasoline or ethanol at all tested speeds, indicating a higher HCCI reactivity.

Advanced High Strength Steels (AHSS) have been implemented in the automotive industry to balance the requirements for vehicle crash safety, emissions, and fuel economy. With lower ductility compared to conventional steels, the fracture behavior of AHSS components has to be considered in vehicle crash simulations to achieve a reliable crashworthiness prediction. Without considering the fracture behavior, component fracture cannot be predicted and subsequently the crash energy absorbed by the fractured component can be over-estimated. In full vehicle simulations, failure to predict component fracture sometimes leads to less predicted intrusion. In this paper, the feasibility of using computer simulations in predicting fracture during crash deformation is studied.

The effects of spray targeting on mixing, combustion, and pollutant formation under a low-load, late-injection, low-temperature combustion (LTC) diesel operating condition are investigated by optical engine measurements and multi-dimensional modeling. Three common spray-targeting strategies are examined: conventional piston-bowl-wall targeting (152° included angle); narrow-angle floor targeting (124° included angle); and wide-angle piston-bowl-lip targeting (160° included angle). Planar laser-induced fluorescence diagnostics in a heavy-duty direct-injection optical diesel engine provide two-dimensional images of fuel-vapor, low-temperature ignition (H2CO), high-temperature ignition (OH) and soot-formation species (PAH) to characterize the LTC combustion process.

Engine and flow reactor experiments were conducted to determine the impact of biodiesel relative to ultra-low-sulfur diesel (ULSD) on inhibition of the selective catalytic reduction (SCR) reaction over an Fe-zeolite catalyst. Fe-zeolite SCR catalysts have the ability to adsorb and store unburned hydrocarbons (HC) at temperatures below 300°C. These stored HCs inhibit or block NOx-ammonia reaction sites at low temperatures. Although biodiesel is not a hydrocarbon, similar effects are anticipated for unburned biodiesel and its organic combustion products. Flow reactor experiments indicate that in the absence of exposure to HC or B100, NOx conversion begins at between 100° and 200°C. When exposure to unburned fuel occurs at higher temperatures (250°-400°C), the catalyst is able to adsorb a greater mass of biodiesel than of ULSD. Experiments show that when the catalyst is masked with ULSD, NOx conversion is inhibited until it is heated to 400°C.

Fuel injection during negative valve overlap (NVO) can extend low-load gasoline HCCI operation through control of main combustion phasing. Reactions and heat release accompanying NVO fuel injection give rise to changes in temperature and composition of the charge prior to main combustion. The extent of reaction of injected NVO fuel and the relative importance of resulting thermal and chemical effects on main combustion are a current research topic. In this work, bulk temperature computations are used to quantify thermal conditions prior to main ignition for cases with and without NVO fueling. To separate measured thermal effects from chemical effects of NVO fuel reactions on the main combustion, cases without NVO fuel but with similar mixture temperatures and combustion phasing are compared. Effects of varying NVO fuel amount and injection timing on heat release, combustion phasing, bulk temperature evolution, and iso-octane ignition temperatures are analyzed.

The liquid and vapor-phase spray penetrations of #2 diesel and neat (100%) soybean-derived biodiesel have been studied at late expansion-cycle conditions in a constant-volume optical chamber. In modern diesel engines, late-cycle staged injections may be used to assist in the operation of exhaust stream aftertreatment devices. These late-cycle injections occur well after top-dead-center (TDC), when post-combustion temperatures are relatively high and densities are low. The behavior of diesel sprays under these conditions has not been well-established in the literature. In the current work, high-speed Mie-scatter and schlieren imaging are employed in an optically accessible chamber to characterize the transient and quasi-steady liquid penetration behavior of diesel sprays under conditions relevant for late-cycle post injections, with very low densities (1.2 - 3 kg/m 3 ) and moderately high temperatures (800 - 1400 K).

The influence of soy- and palm-based biofuels on the in-cylinder sources of unburned hydrocarbons (UHC) and carbon monoxide (CO) was investigated in an optically accessible research engine operating in a partially premixed, low-temperature combustion regime. The biofuels were blended with an emissions certification grade diesel fuel and the soy-based biofuel was also tested neat. Cylinder pressure and emissions of UHC, CO, soot, and NOx were obtained to characterize global fuel effects on combustion and emissions. Planar laser-induced fluorescence was used to capture the spatial distribution of fuel and partial oxidation products within the clearance and bowl volumes of the combustion chamber. In addition, late-cycle (30° and 50° aTDC) semi-quantitative CO distributions were measured above the piston within the clearance volume using a deep-UV LIF technique.

The characteristics of ethanol autoignition and the associated HCCI performance are examined in this work. The experiments were conducted over wide ranges of engine speed, load and intake boost pressure (Piⁿ) in a single-cylinder HCCI research engine (0.98 liters) with a CR = 14 piston. The data show that pure ethanol is a true single-stage ignition fuel. It does not exhibit low-temperature heat release (LTHR), not even for boosted operation. This makes ethanol uniquely different from conventional distillate fuels and offers several benefits: a) The intake temperature (Tiⁿ) does not have to be adjusted much with changes of engine speed, load and intake boost pressure. b) High Piⁿ can be tolerated without running out of control authority because of an excessively low Tiⁿ requirement. However, by maintaining true single-stage ignition characteristics, ethanol also shows a relatively low temperature-rise rate just prior to its hot ignition point.

Fuel injection during negative valve overlap offers a promising method of controlling HCCI combustion, but sorting out the thermal and chemical effects of NVO fueling requires knowledge of temperatures throughout the cycle. Computing bulk temperatures throughout closed portions of the cycle is relatively straightforward using an equation of state, once a temperature at one crank angle is established. Unfortunately, computing charge temperatures at intake valve closing for NVO operation is complicated by a large, unknown fraction of residual gases at unknown temperature. To address the problem, we model blowdown and recompression during exhaust valve opening and closing events, allowing us to estimate in-cylinder charge temperatures based on exhaust-port measurements. This algorithm permits subsequent calculation of crank-angle-resolved bulk temperatures and residual gas fraction over a wide range of NVO operation.

This paper examines the interaction of bulk flow and jet-induced fuel convection in an optically accessible hydrogen-fueled engine with direct injection. Planar laser-induced fluorescence (PLIF) of gaseous acetone as a fuel tracer was performed to obtain quantitative images of the hydrogen mole-fraction in the operating engine. With the engine motored, fuel was injected into inert bulk gas from a centrally located injector during the compression stroke. The injector had a single-hole nozzle with the jet angled at 50 degrees with respect to the vertical injector axis. Two parameters were varied in the experiments, injector orientation and tumble intensity, and for each of these, the injection timing was varied. Image series of the mean fuel mole-fraction between injection and near-TDC crank angles capture the mixture-formation process for each configuration and injection timing.

The behavior of the engine-out UHC and CO emissions from a light-duty diesel optical engine operating at two PPCI conditions was investigated for fifteen different fuels, including diesel fuels, biofuel blends, n-heptane-iso-octane mixtures, and n-cetane-HMN mixtures. The two highly dilute (9-10% O₂) early direct injection PPCI conditions included a low speed (1500 RPM) and load (3.0 bar IMEP) case~where the UHC and CO have been found to stem from overly-lean fuel-air mixtures~and a condition with a relatively higher speed (2000 RPM) and load (6.0 bar IMEP)~where globally richer mixtures may lead to different sources of UHC and CO. The main objectives of this work were to explore the general behavior of the UHC and CO emissions from early-injection PPCI combustion and to gain an understanding of how fuel properties and engine load affect the engine-out emissions.