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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.

This paper presents experimental results for two fuel-related topics in a diesel engine: (1) how fuel volatility affects the premixed burn and heat release rate, and (2) how ignition quality influences the soot formation. Fast evaporation of fuel may lead to more intense heat release if a higher percentage of the fuel is mixed with air to form a combustible mixture. However, if the evaporation of fuel is driven by mixing with high-temperature gases from the ambient, a high-volatility fuel will require less oxygen entrainment and mixing for complete vaporization and, consequently, may not have potential for significant heat release simply because it has vaporized. Fuel cetane number changes also cause uncertainty regarding soot formation because variable ignition delay will change levels of fuel-air mixing prior to combustion.

A full understanding and characterization of the near-field of diesel sprays is daunting because the dense spray region inhibits most diagnostics. While x-ray diagnostics permit quantification of fuel mass along a line of sight, most laboratories necessarily use simple lighting to characterize the spray spreading angle, using it as an input for CFD modeling, for example. Questions arise as to what is meant by the “boundary” of the spray since liquid fuel concentration is not easily quantified in optical imaging. In this study we seek to establish a relationship between spray boundary obtained via optical diffused backlighting and the fuel concentration derived from tomographic reconstruction of x-ray radiography. Measurements are repeated in different facilities at the same specified operating conditions on the “Spray A” fuel injector of the Engine Combustion Network, which has a nozzle diameter of 90 μm.

The major challenge of the post-processing of soot aggregates in transmission electron microscope (TEM) images is the detection of soot primary particles that have no clear boundaries, vary in size within the fractal aggregates, and often overlap with each other. In this study, we propose an automated detection code for primary particles implementing the Canny Edge Detection (CED) and Circular Hough Transform (CHT) on pre-processed TEM images for particle edge enhancement using unsharp filtering as well as image inversion and self-subtraction. The particle detection code is tested for soot TEM images obtained at various ambient and injection conditions, and from five different combustion facilities including three constant-volume combustion chambers and two diesel engines.

The 4th Workshop of the Engine Combustion Network (ECN) was held September 5-6, 2015 in Kyoto, Japan. This manuscript presents a summary of the progress in experiments and modeling among ECN contributors leading to a better understanding of soot formation under the ECN “Spray A” configuration and some parametric variants. Relevant published and unpublished work from prior ECN workshops is reviewed. Experiments measuring soot particle size and morphology, soot volume fraction (fv), and transient soot mass have been conducted at various international institutions providing target data for improvements to computational models. Multiple modeling contributions using both the Reynolds Averaged Navier-Stokes (RANS) Equations approach and the Large-Eddy Simulation (LES) approach have been submitted. Among these, various chemical mechanisms, soot models, and turbulence-chemistry interaction (TCI) methodologies have been considered.

Understanding and prediction of flash-boiling spray behavior in gasoline direct-injection (GDI) engines remains a challenge. In this study, computational fluid dynamics (CFD) simulations using the homogeneous relaxation model (HRM) for not only internal nozzle flow but also external spray were evaluated using CONVERGE software and compared to experimental data. High-speed extinction imaging experiments were carried out in a real-size axial-hole transparent nozzle installed at the tip of machined GDI injector fueled with n-pentane under various ambient pressure conditions (Pa/Ps = 0.07 - 1.39). The width of the spray during injection was assessed by means of projected liquid volume, but the structure and timing for boil-off of liquid within the sac of the injector were also assessed after the end of injection, including cases with different designed sac volumes.

Diesel spray mixture formation is investigated at target conditions using multiple diagnostics and laboratories. High-speed Particle Image Velocimetry (PIV) is used to measure the velocity field inside and outside the jet simultaneously with a new frame straddling synchronization scheme. The PIV measurements are carried out in the Engine Combustion Network Spray A target conditions, enabling direct comparisons with mixture fraction measurements previously performed in the same conditions, and forming a unique database at diesel conditions. A 1D spray model, based upon mass and momentum exchange between axial control volumes and near-Gaussian velocity and mixture fraction profiles is evaluated against the data.

Combustion issued from an eight-hole, direct-injection spray was experimentally studied in a constant-volume pre-burn combustion vessel using simultaneous high-speed diffused back-illumination extinction imaging (DBIEI) and OH* chemiluminescence. DBIEI has been employed to observe the liquid-phase of the spray and to quantitatively investigate the soot formation and oxidation taking place during combustion. The fuel-air mixture was ignited with a plasma induced by a single-shot Nd:YAG laser, permitting precise control of the ignition location in space and time. OH* chemiluminescence was used to track the high-temperature ignition and flame. The study showed that increasing the delay between the end of injection and ignition drastically reduces soot formation without necessarily compromising combustion efficiency. For long delays between the end of injection and ignition (1.9 ms) soot formation was eliminated in the main downstream charge of the fuel spray.

For logistical reasons, the military requires that jet fuel (JP-8, F-34) be used in both jet engines and diesel engines. While JP-8-fueled diesel engines appear to operate successfully in many cases, negative impacts, including engine failures, are occasionally reported. As diesel combustion with JP-8 has not been explored in great detail, fundamental information about JP-8 fuel spray combustion is needed. In this study, we report measurements of liquid-phase penetration length, vapor penetration, and ignition delay made in an optically-accessible combustion vessel over a range of high-temperature, high-pressure operating conditions applicable to a diesel engine. Results show that the liquid-phase penetration of JP-8 is less than that of diesel, owing to the lower boiling point temperatures of JP-8. Despite the more rapid vaporization, the vapor penetration rate of JP-8 matches that of diesel and ignition does not advance.

Shadowgraph/schlieren imaging techniques have often been used for flow visualization of reacting and non-reacting systems. In this paper we show that high-speed shadowgraph visualization in a high-pressure chamber can also be used to identify cool-flame and high-temperature combustion regions of diesel sprays, thereby providing insight into the time sequence of diesel ignition and combustion. When coupled to simultaneous high-speed Mie-scatter imaging, chemiluminescence imaging, pressure measurement, and spatially-integrated jet luminosity measurements by photodiode, the shadowgraph visualization provides further information about spray penetration after vaporization, spatial location of ignition and high-temperature combustion, and inactive combustion regions where problematic unburned hydrocarbons exist. Examples of the joint application of high-speed diagnostics include transient non-reacting and reacting injections, as well as multiple injections.

Diesel low-temperature combustion strategies often rely on early injection timing to allow sufficient fuel-ambient mixing to avoid NOx and soot-forming combustion. However, these early injection timings permit the spray to penetrate into a low ambient temperature and density environment where vaporization is poor and liquid impingement upon the cylinder liner and piston bowl are more likely to occur. The objective of this study is to measure the transient liquid and vapor penetration at early-injection conditions. High-speed Mie-scatter and shadowgraph imaging are employed in an optically accessible chamber with a free path of 100 mm prior to wall impingement and using a single-spray injector. The ambient temperature and density within the chamber are well-controlled (uniform) and selected to simulate in-cylinder conditions when injection occurs at -40 crank-angle degrees (CAD) or fewer before top-dead center (TDC).

Future fuels will come from a variety of feed stocks and refinement processes. Understanding the fundamentals of combustion and pollutants formation of these fuels will help clear hurdles in developing flex-fuel combustors. To this end, we investigated the combustion, soot formation, and soot oxidation processes for various classes of fuels, each with distinct physical properties and molecular structures. The fuels considered include: conventional No. 2 diesel (D2), low-aromatics jet fuel (JC), world-average jet fuel (JW), Fischer-Tropsch synthetic fuel (JS), coal-derived fuel (JP), and a two-component surrogate fuel (SR). Fuel sprays were injected into high-temperature, high-pressure ambient conditions that were representative of a practical diesel engine. Simultaneous laser extinction measurement and planar laser-induced incandescence imaging were performed to derive the in-situ soot volume fraction.

In-flame soot sampling based on the thermophoresis of particles and subsequent transmission electron microscope (TEM) imaging has been conducted in a diesel engine to study size, shape and structure of soot particles within the reacting diesel jet. A direct TEM sampling is pursued, as opposed to exhaust sampling, to gain fundamental insight about the structure of soot during key formation and oxidation stages. The size and shape of soot particles aggregate structure with stretched chains of spherical-like primary particles is currently an unknown for engine soot modelling approaches. However, the in-flame sampling of soot particles in the engine poses significant challenges in order to extract meaningful data. In this paper, the engine modification to address the challenges of high-pressure sealing and avoiding interference with moving valves and piston are discussed in detail.

This paper details the development and application of a Rayleigh imaging technique for quantitative mixing measurements in a vaporizing diesel spray under engine conditions. Experiments were performed in an optically accessible constant-volume combustion vessel that simulated the ambient conditions in a diesel engine. Two-dimensional imaging of Rayleigh scattering from a diesel spray of n-heptane and well-characterized ambient was accomplished by using a 532 nm Nd:YAG laser sheet and a low-noise back-illuminated CCD camera. Methods to minimize interference from unwanted elastic scattering sources (e.g. windows, particles) were investigated and are discussed in detail. The simultaneous measurement of Rayleigh scattering signal from the ambient and from the diesel spray provides important benefits towards making the technique quantitative and accurate.

The effects of fuel composition on soot processes in diesel fuel jets were studied in an optically-accessible constant-volume combustion vessel at experimental conditions typical of a DI diesel. Four fuel blends used in recent engine studies were investigated, including three oxygenates and one diesel reference fuel: (1) T70, a fuel blend containing the oxygenate tetraethoxy-propane; (2) BM88, a fuel blend containing the oxygenate dibutyl-maleate; (3) GE80, a fuel blend containing the oxygenate tri-propylene-glycol-methyl-ether and (4) CN80, a diesel reference fuel composed of an n-hexadecane and heptamethyl-nonane mixture. Measurements of the soot distribution along the axis of quasi-steady fuel jets were performed using laser extinction and planar laser-induced incandescence (PLII) and were compared to previous results using a #2 diesel fuel (D2).

Methods of producing non-sooting, low flame temperature diesel combustion were investigated in an optically-accessible, quiescent constant-volume combustion vessel. Combustion and soot formation processes of single, isolated fuel jets were studied after autoignition and transient premixed combustion and while the injector needle was fully open (i.e., during the quasi-steady mixing-controlled phase of heat-release for diesel combustion).The investigation showed that fuel jets that do not undergo soot formation in any region of the reacting jet and that also have a low flame temperature could be produced in at least three different ways during mixing-controlled combustion: First, using a #2 diesel fuel and an injector tip with a 50 micron orifice, a fuel jet was non-sooting in ambient oxygen concentrations as low as 10% (simulating the use of EGR) for typical diesel ambient temperatures (1000 K) and densities.

This paper explores soot and soot-precursor formation characteristics of oxygenated fuels using experiments and numerical simulations under direct-injection diesel engine conditions. The paper strives to achieve four goals: 1)to introduce the “oxygen ratio” for accurate quantification of reactant-mixture stoichiometry for both oxygenated and non-oxygenated fuels; 2) to provide experimental results demonstrating that some oxygenates are more effective at reducing diesel soot than others; 3) to present results of numerical simulations showing that detailed chemical-kinetic models without complex fluid mechanics can capture some of the observed trends in the sooting tendencies of different oxygenated fuels; and 4) to provide further insight into the underlying mechanisms by which oxygenate structure and in-cylinder processes can affect soot formation in DI diesel engines. The oxygenates that were studied are di-butyl maleate (DBM) and tri-propylene glycol methyl ether (TPGME).

Laser plasma ignition has been pursued by engine researchers as an alternative to electric spark-ignition systems, potentially offering benefits by avoiding quenching surfaces and extending breakdown limits at higher boost pressure and lower equivalence ratio. For this study, we demonstrate another potential benefit: the ability to control the timing of ignition with short, nanosecond pulses, thereby optimizing the type of mixture that burns in rapidly changing, stratified fuel-air mixtures. We study laser ignition at various timings during single and double injections at simulated gasoline engine conditions within a controlled, high-temperature, high-pressure vessel. Laser ignition is accomplished with a single low-energy (10 mJ), short duration (8 ns) Nd:YAG laser beam that is tightly focused (0.015 mm average measured 1/e₂ diameter) at a typical GDI spark plug location.

Transients in the rate of injection (ROI) with respect to time are ever-present in direct-injection engines, even with common-rail fueling. The shape of the injection ramp-up and ramp-down affects spray penetration and mixing, particularly with multiple-injection schedules currently in practice. Ultimately, the accuracy of CFD model predictions used to optimize the combustion process depends upon the accuracy of the ROI utilized as fuel input boundary conditions. But experimental difficulties in the measurement of ROI, as well as real-world affects that change the ROI from the bench to the engine, add uncertainty that may be mistaken for weaknesses in spray modeling instead of errors in boundary conditions. In this work we use detailed, time-resolved measurements of penetration at the Spray A conditions of the Engine Combustion Network to rigorously guide the necessary ROI shape required to match penetration in jet models that allow variable rate of injection.

Formaldehyde (HCHO) near the lift-off location in a reacting diesel jet was visualized using planar laser-induced fluorescence (PLIF). Simultaneous imaging of OH chemiluminescence identified the high-temperature combustion region (lift-off). Experiments were performed in a constant-volume combustion vessel at ambient gas conditions (temperature and oxygen concentration) that generate no-soot, low-soot and moderate-soot diesel jets during mixing-controlled combustion. For no-soot conditions, results show that HCHO is formed upstream of the lift-off location and is consumed downstream of the lift-off length in fuel-rich premixed reaction zones at the jet center. Despite the fuel-rich combustion, and downstream regions that are surrounded by a high-temperature diffusion flame, there is no detectable PAH formation in the no-soot condition.