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Exhaust gas recirculation, fuel injection strategy and boost pressure are among the key enablers to attain low NOx and soot emissions simultaneously on modern diesel engines. In this work, the individual influence of these parameters on the emissions are investigated independently for engine loads up to 8 bar IMEP. A single-shot fuel injection strategy has been deployed to push the diesel cycle into low temperature combustion with EGR. The results indicated that NOx was a stronger respondent to injection pressure levels than to boost when the EGR ratio is relatively low. However, when the EGR level was sufficiently high, the NOx was virtually grounded and the effect of boost or injection pressure becomes irrelevant. Further tests indicated that a higher injection pressure lowered soot emissions across the EGR sweeps while the effect of boost on the soot reduction appeared significant only at higher soot levels.

Modern diesel engines employ a multitude of strategies for oxides of nitrogen (NOx) emission abatement, with exhaust gas recirculation (EGR) being one of the most effective technique. The need for a precise control on the intake charge dilution (as a result of EGR) is paramount since small fluctuations in the intake charge dilution at high EGR rates may cause larger than acceptable spikes in NOx/soot emissions or deterioration in the combustion efficiency, especially at low to mid-engine loads. The control problem becomes more pronounced during transient engine operation; currently the trend is to momentarily close the EGR valve during tip-in or tip-out events. Therefore, there is a need to understand the transient EGR behaviour and its impact on the intake charge development especially under unstable combustion regimes such as low temperature combustion.

Ferritic nitrocarburizing offers excellent wear, scuffing, corrosion and fatigue resistance by producing a thin compound layer and diffusion zone containing ε (Fe2-3(C, N)), γ′ (Fe4N), cementite (Fe3C) and various alloy carbides and nitrides on the material surface. It is a widely accepted surface treatment process that results in smaller distortion than carburizing and carbonitriding processes. However this smaller distortion has to be further reduced to prevent the performance issues, out of tolerance distortion and post grinding work hours/cost in an automotive component. A numerical model has been developed to calculate the nitrogen and carbon composition profiles of SAE 1010 torque converter pistons during nitrocarburizing treatment. The nitrogen composition profiles are modeled against the part thickness to predict distortion.

The increased availability of natural gas (NG) in the U.S. has renewed interest in the application to heavy-duty (HD) diesel engines in order to realize fuel cost savings and reduce pollutant emissions, while increasing fuel economy. Reactivity controlled compression ignition (RCCI) combustion employs two fuels with a large difference in auto-ignition properties to generate a spatial gradient of fuel-air mixtures and reactivity. Typically, a high octane fuel is premixed by means of port-injection, followed by direct injection of a high cetane fuel late in the compression stroke. Previous work by the authors has shown that NG and diesel RCCI offers improved fuel efficiency and lower oxides of nitrogen (NOx) and soot emissions when compared to conventional diesel diffusion combustion. The work concluded that NG and diesel RCCI engines are load limited by high rates of pressure rise (RoPR) (>15 bar/deg) and high peak cylinder pressure (PCP) (>200 bar).

This study investigated neat n-butanol combustion, emissions and thermal efficiency characteristics in a compression ignition (CI) engine by using two fuelling techniques - port fuel injection (PFI) and direct injection (DI). Diesel fuel was used in this research for reference. The engine tests were conducted on a single-cylinder four-stroke DI diesel engine with a compression ratio of 18.2 : 1. An n-Butanol PFI system was installed to study the combustion characteristics of Homogeneous Charge Compression Ignition (HCCI). A common-rail fuel injection system was used to conduct the DI tests with n-butanol and diesel. 90 MPa injection pressure was used for the DI tests. The engine was run at 1500 rpm. The intake boost pressure, engine load, exhaust gas recirculation (EGR) ratio, and DI timing were independently controlled to investigate the engine performance.

The ever-stringent emission regulations are major challenges for the diesel fueled engines in automotive industry. The applications of advanced after-treatment technologies as well as alternative fuels [1] are considered as promising methodology to reduce exhaust emission from compression ignition (CI) engines. Using dimethyl ether (DME) as an alternative fuel has been extensively studied by many researchers and automotive manufactures since DME has demonstrated enormous potential in terms of emission reduction, such as low CO emission, and soot and sulfur free. However, the effect of employing DME in a lean NOX trap (LNT) based after-treatment system has not been fully addressed yet. In this work, investigations of the long breathing LNT system using DME as a reductant were performed on a heated after-treatment flow bench with simulated engine exhaust condition.

In this study, impacts of neat n-butanol fuel injection parameters on direct injection (DI) compression ignition (CI) engine performance were investigated to gain knowledge for understanding the fuel injection strategies for n-butanol. The engine tests were conducted on a four-stroke single-cylinder DI CI engine with a compression ratio of 18.2:1. The effects of fuel injection pressure (40, 60 and 90 MPa) and injection timing in a single injection strategy were investigated. The results showed that an increase in injection pressure significantly reduced nitrogen oxides (NOx) emissions which is the opposite trend seen in conventional diesel combustion. The parallel use of a higher injection pressure and retarded injection timing was a proposed method to reduce NOx and cylinder pressure rise rate simultaneously. NOx was further reduced by using exhaust gas recirculation (EGR) while keeping near zero soot emissions.

In this work, empirical investigations of the diesel-ethanol Premixed Pilot-Assisted Combustion (PPAC) are carried out on a high compression ratio (18.2:1) single-cylinder diesel engine. The tests focus on determining the minimum ethanol fraction for ultra-low NOx & soot emissions, effect of single-pilot vs. twin-pilot strategies on emissions and ignition controllability, reducing the EGR requirements, enabling clean combustion across the load range and achieving high efficiency full-load operation. The results show that both low NOx and almost zero soot emissions can be achieved but at the expense of higher unburned hydrocarbons. Compared to a single-pilot injection, a twin-pilot strategy reduces the soot emissions significantly and also lowers the NOx emissions, thereby reducing the requirements for EGR. The near-TDC pilot provides excellent control over the combustion phasing, further reducing the need of a higher EGR quantity for phasing control.

Increasingly stringent emission standards have promoted the interest in alternate fuel sources. Because of the comparable energy density to the existing fossil fuels and renewable production, alcohol fuels may be a suitable replacement, or an additive to the gasoline/diesel fuels to meet the future emission standards with minimal modification to current engine geometry. In this research, the combustion characteristics of neat n-butanol are analyzed under spark ignition operation using a single cylinder SI engine. The fuel is injected into the intake manifold using a port-fuel injector. Two modes of charge dilution were used in this investigation to test the limits of stable engine operation, namely lean burn using excess fresh air and exhaust gas recirculation (EGR). The in-cylinder pressure measurement and subsequently, heat release analysis are used to investigate the combustion characteristics of the fuel under low load SI engine operation.

Experimental and numerical studies have been completed on the deformation behaviour of round AA6061-T6 aluminum extrusions during an axial cutting deformation mode employing both curved and straight deflectors to control the bending deformation of petalled side walls. Round extrusions of length 200 mm with a nominal wall thickness of 3.175 mm and an external diameter of 50.8 mm were considered. A heat treated 4140 steel alloy cutter and deflectors, both straight and curved, were designed and manufactured for the testing considered. The four blades of the cutter had an approximate average thickness of 1.00 mm which were designed to penetrate through the round AA6061-T6 extrusions. Experimental observations illustrated high crush force efficiencies of 0.82 for the extrusions which experienced the cutting deformation mode with the deflectors. Total energy absorption during the cutting process was approximately 5.48 kJ.

Empirical results indicated that the engine emission and fuel efficiency of low-temperature combustion (LTC) cycles can be optimized by adjusting the fuel-injection scheduling in order to obtain appropriate combustion energy release or heat-release rate patterns. Based on these empirical results the heat-release characteristics were correlated with the regulated emissions such as soot, hydrocarbon and oxides of nitrogen. The transition from conventional combustion to LTC with the desired set of heat-release rate has been implemented. This transition was facilitated with the simplified heat-release characterization wherein each of the consecutive engine cycles was analyzed with a real-time controller embedded with an FPGA (field programmable gate array) device. The analyzed results served as the primary feedback control signals to adjust fuel injection scheduling. The experimental efforts included the boost/backpressure, exhaust gas recirculation, and load transients in the LTC region.

Simultaneous low NOx (< 0.15 g/kWh) & soot (< 0.01 g/kWh) are attainable for enhanced premixed combustion that may lead to higher levels of hydrocarbons and carbon monoxide emissions as the engine cycles move to low temperature combustion, which is a departure from the ultra low hydrocarbon and carbon monoxide emissions, typical of the high compression ratio diesel engines. As a result, the fuel efficiency of such modes of combustion is also compromised (up to 5%). In this paper, advanced strategies for fuel injection are devised on a modern 4-cylinder common rail diesel engine modified for single cylinder research. Thermal efficiency comparisons are made between the low temperature combustion and the conventional diesel cycles. The fuel injection strategies include single injection with heavy EGR, and early multi-pulse fuel injection under low or medium engine loads respectively.

Extensive empirical work indicates that the exhaust emission and fuel efficiency of modern common-rail diesel engines characterise strong resilience to biodiesel fuels when the engines are operating in conventional high temperature combustion cycles. However, as the engine cycles approach the low temperature combustion (LTC) mode, which could be implemented by the heavy use of exhaust gas recirculation (EGR) or the homogeneous charge compression ignition (HCCI) type of combustion, the engine performance start to differ between the use of conventional and biodiesel fuels. Therefore, a set of fuel injection strategies were compared empirically under independently controlled EGR, intake boost, and exhaust backpressure in order to improve the neat biodiesel engine cycles.

Low temperature combustion (LTC), though effective to reduce soot and oxides of nitrogen (NOx) simultaneously from diesel engines, operates in narrowly close to unstable regions. Adaptive control strategies are developed to expand the stable operations and to improve the fuel efficiency that was commonly compromised by LTC. Engine cycle simulations were performed to better design the combustion control models. The research platform consists of an advanced common-rail diesel engine modified for the intensified single cylinder research and a set of embedded real-time (RT) controllers, field programmable gate array (FPGA) devices, and a synchronized personal computer (PC) control and measurement system.

Extensive empirical work indicates that exhaust gas recirculation (EGR) is effective to lower the flame temperature and thus the oxides of nitrogen (NOx) production in-cylinder in diesel engines. Soot emissions are reduced in-cylinder by improved fuel/air mixing. As engine load increases, higher levels of intake boost and fuel injection pressure are required to suppress soot production. The high EGR and improved fuel/air mixing is then critical to enable low temperature combustion (LTC) processes. The paper explores the properties of the Fuels for Advanced Combustion Engines (FACE) Diesel, which are statistically designed to examine fuel effects, on a 0.75L single cylinder engine across the full range of load, spanning up to 15 bar IMEP. The lower cetane number (CN) of the diesel fuel improved the mixing process by prolonging the ignition delay and the mixing duration leading to substantial reduction of soot at low to medium loads, improving the trade-off between NOx and soot.

In this work, engine tests were performed to realize EGR-enabled LTC on a single-cylinder common-rail diesel engine with three different compression ratios (17.5, 15 and 13:1). The engine performance was first investigated at 17.5:1 compression ratio to provide baseline results, against which all further testing was referenced. The intake boost and injection pressure were progressively increased to ascertain the limiting load conditions for the compression ratio. To extend the engine load range, the compression ratio was then lowered and EGR sweep tests were again carried out. The strength and homogeneity of the cylinder charge were enhanced by using intake boost up to 3 bar absolute and injection pressure up to 180 MPa. The combustion phasing was locked in a narrow crank angle window (5~10° ATDC), during all the tests.

Carburized parts often see use in powertrain components for the automotive industry. These parts are commonly quenched and tempered after the carburizing process. The present study compared the austempering heat treatment to the traditional quench-and-temper process for carburized parts. Samples were produced from SAE 8620, 4320, and 8822 steels and heat treated across a range of conditions for austempering and for quench-and-tempering. Distortion was examined through the use of Navy C-Ring samples. Microstructure, hardness, and Charpy toughness were also examined. X-ray diffraction was used to compare the residual stress found in the case of the components after the quench-and-temper and the austempering heat treatments. Austempering samples showed less distortion and higher compressive residual stresses, while maintaining comparable hardness values in both case and core. Toughness measurements were also comparable between both processes.

Gray cast iron brake rotor experiences substantial wear during braking and contributes largely to the wear debris emissions. Surface coating on the gray cast iron rotor represents a trending approach dealing with the problems. In this research, a new plasma electrolytic aluminating (PEA) process was used for preparing an alumina-based ceramic coating with metallurgical bonding to the gray cast iron. Three different types of brake pads (ceramic, semi-metallic and non asbestos organic (NAO)) were used for tribotests. Performances of PEA coatings vs. different brake pad materials were comparatively investigated with respect to their coefficients of friction (COFs) and wear. The PEA-coated brake rotor has a dimple-like surface which promotes the formation of a thin transferred film to protect the rotor from wear. The transferred film materials come from the wear debris of the pads. The secondary plateaus are regenerated on the brake pads through compacting wear debris of the pads.

Engine performance and emission comparisons were made between the use of 100% soy, Canola and yellow grease derived biodiesel fuels and an ultra-low sulphur diesel fuel in the oxygen deficient regions, i.e. full or high load engine operations. Exhaust gas recirculation (EGR) was extensively applied to initiate low temperature combustion. An intake throttling valve was implemented to increase the differential pressure between the intake and exhaust in order to increase and enhance the EGR. The intake temperature, pressure, and EGR levels were modulated to improve the engine fuel efficiency and exhaust emissions. Furthermore, a preliminary ignition delay correlation under the influence of EGR was developed. Preliminary low temperature combustion modelling of the biodiesel and diesel fuels was also conducted. The research intends to achieve simultaneous reductions of nitrogen oxides and soot emissions in modern production diesel engines when biodiesel is applied.

Heat-release and cylinder pressure based adaptive fuel-injection control tests were performed on a modern common-rail diesel engine to improve the engine operation in the low-temperature combustion (LTC) region. A single shot injection strategy with heavy amount of exhaust gas recirculation (EGR) was used to modulate the in-cylinder charge conditions to achieve the low-temperature combustion. Adaptive fuel-injection techniques were used to anchor the cylinder pressure characteristics in the desired crank angle window and thereby stabilize the engine operation. The response of the adaptive control to boost, fueling, and engine speed variations was also tested. A combination of adaptive fuel-injection and automatic boost/back-pressure controls had helped to make the transient emissions comparable to the steady-state LTC emissions.