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The objectives of this paper are to describe the research efforts in diesel engine combustion at Sandia National Laboratories' Combustion Research Facility and to provide recent experimental results. We have four diesel engine experiments supported by the Department of Energy, Office of Heavy Vehicle Technologies: a one-cylinder version of a Cummins heavy-duty engine, a diesel simulation facility, a one-cylinder Caterpillar engine to evaluate combustion of alternative fuels, and a homogeneous-charge, compression-ignition (HCCI) engine. Recent experimental results of diesel combustion research will be discussed and a description will be given of our HCCI experimental program and of our HCCI modeling work.

One way to increase the load range in an HCCI engine is to increase boost pressure. In this modeling study, we investigate the effect of increased boost pressure on the fuel chemistry in an HCCI engine. Computed results of HCCI combustion are compared to experimental results in a HCCI engine. We examine the influence of boost pressure using a number of different detailed chemical kinetic models - representing both pure compounds (methylcyclohexane, cyclohexane, iso-octane and n-heptane) and multi-component models (primary reference fuel model and gasoline surrogate fuel model). We examine how the model predictions are altered by increased fueling, as well as reaction rate variation, and the inclusion of residuals in our calculations. In this study, we probe the low temperature chemistry (LTC) region and examine the chemistry responsible for the low-temperature heat release (LTHR) for wide ranges of intake boost pressure.

Laser excitation wavelengths for two-line planar laser-induced fluorescence (PLIF) of 3-pentanone have been optimized for simultaneous imaging of temperature and composition under engine-relevant conditions. Validation of the diagnostic was performed in a motored optical IC engine seeded homogeneously with 3-pentanone. PLIF measurements of the uniform mixture during the compression stroke were used to measure the average temperature and to access the random uncertainty in the measurements. To determine the accuracy of the temperature measurements, experimental average temperatures were compared to values computed assuming isentropic compression and to the output of a tuned 1-D engine simulation. The comparison indicated that the absolute accuracy of the temperature measurements is better than ±5%. Probability density functions (PDFs) calculated from the single-shot images were used to estimate the precision of the measurements.

The importance of new technologies to improve the performance and fuel economy of internal combustion engines is now widely recognized and is essential to achieve CO₂ emissions targets and energy security. Increased hybridization, combustion improvements, friction reduction and ancillary developments are all playing an important part in achieving these goals. Turbocharging technology is established in the diesel engine field and will become more prominent as gasoline engine downsizing is more widely introduced to achieve significant fuel economy improvements. The work presented here introduces, for the first time, a new technology that applies conventional turbomachinery hardware to depressurize the exhaust system of almost any internal combustion engine by novel routing of the exhaust gases. The exhaust stroke of the piston is exposed to this low pressure leading to reduced or even reversed pumping losses, offering ≻5% increased engine torque and up to 5% reduced fuel consumption.

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).

An accurate prediction of internal nozzle flow in fuel injector offers the potential to improve predictions of spray computational fluid dynamics (CFD) in an engine, providing a coupled internal-external calculation or by defining better rate of injection (ROI) profile and spray angle information for Lagrangian parcel computations. Previous research has addressed experiments and computations in transparent nozzles, but less is known about realistic multi-hole diesel injectors compared to single axial-hole fuel injectors. In this study, the transient injector opening and closing is characterized using a transparent multi-hole diesel injector, and compared to that of a single axial hole nozzle (ECN Spray D shape). A real-size five-hole acrylic transparent nozzle was mounted in a high-pressure, constant-flow chamber. Internal nozzle phenomena such as cavitation and gas exchange were visualized by high-speed long-distance microscopy.

EGR can be used beneficially to control combustion phasing in HCCI engines. To better understand the function of EGR, this study experimentally investigates the thermodynamic and chemical effects of real EGR, simulated EGR, dry EGR, and individual EGR constituents (N2, CO2, and H2O) on the autoignition processes. This was done for gasoline and various PRF blends. The data show that addition of real EGR retards the autoignition timing for all fuels. However, the amount of retard is dependent on the specific fuel type. This can be explained by identifying and quantifying the various underlying mechanisms, which are: 1) Thermodynamic cooling effect due to increased specific-heat capacity, 2) [O2] reduction effect, 3) Enhancement of autoignition due to the presence of H2O, 4) Enhancement or suppression of autoignition due to the presence of trace species such as unburned or partially-oxidized hydrocarbons.

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 dynamics of automotive differentials have been studied extensively to improve their efficiency and additionally, in recent years, generated noise and vibration. Various mathematical models have been proposed to describe the contact/impact of gear teeth pairs. However, the influence of vehicular cruising speed on the resisting torque has not been considered in sufficient detail. This can lead to unrealistic predictions with regards to loss of contact of teeth pair, a phenomenon which leads to NVH issues. The current work presents a torsional model of a hypoid gear pair. The resisting torque is a function of the traction force and aerodynamic drag, whilst the vehicle is cruising at nominally constant speed. The pinion input torque is derived through assumed instantaneous equilibrium conditions. In this approach, realistic excitation capturing the vehicle's driving conditions is imposed on the dynamics of the hypoid gear pair.

Prior studies have shown that fuel addition during negative valve overlap (NVO) can both increase temperature and alter composition of the charge carried over to main HCCI combustion. Late NVO fuel injection, i.e., near top dead center, can cause piston wetting and subsequent localized rich flames. Since acetylene is a product of rich combustion and is known to advance ignition, it is hypothesized that the species could play a chemical role in enhancing main combustion. The objective of this work is to quantify the effects of acetylene on HCCI combustion. While the research topic is specifically relevant to NVO-fueled HCCI operation, the experiments are conducted without NVO fueling to avoid uncertainties of NVO reforming reactions. Instead, a single post-NVO injection of iso-octane fuels the cycle, and acetylene is seeded into the intake flow at varying concentrations to simulate a reformed product of NVO.

Within the Engine Combustion Network (ECN) spray combustion research frame, simultaneous line-of-sight laser extinction measurements and laser-induced incandescence (LII) imaging were performed to derive the soot volume fraction (fv). Experiments are conducted at engine-relevant high-temperature and high-pressure conditions in a constant-volume pre-combustion type vessel. The target condition, called "Spray A," uses well-defined ambient (900 K, 60 bar, 22.8 kg/m₃, 15% oxygen) and injector conditions (common rail, 1500 bar, KS1.5/86 nozzle, 0.090 mm orifice diameter, n-dodecane, 363 K). Extinction measurements are used to calibrate LII images for quantitative soot distribution measurements at cross sections intersecting the spray axis. LII images are taken after the start of injection where quasi-stationary combustion is already established.

This work explores the potential of partial fuel stratification to smooth HCCI heat-release rates at high load. A combination of engine experiments and multi-zone chemical-kinetics modeling was used for this. The term “partial” is introduced to emphasize that care is taken to supply fuel to all parts of the in-cylinder charge, which is essential for reaching high power output. It was found that partial fuel stratification offers good potential to achieve a staged combustion event with reduced pressure-rise rates. Therefore, partial fuel stratification has the potential to increase the high-load limits for HCCI/SCCI operation. However, for the technique to be effective the crank-angle phasing of the “hot” ignition has to be sensitive to the local ϕ. Sufficient sensitivity was observed only for fuel blends that exhibit low-temperature heat release (like diesel fuel).

Ethanol and ethanol/gasoline blends are being widely considered as alternative fuels for light-duty automotive applications. At the same time, HCCI combustion has the potential to provide high efficiency and ultra-low exhaust emissions. However, the application of HCCI is typically limited to low and moderate loads because of unacceptably high heat-release rates (HRR) at higher fueling rates. This work investigates the potential of lowering the HCCI HRR at high loads by using partial fuel stratification to increase the in-cylinder thermal stratification. This strategy is based on ethanol's high heat of vaporization combined with its true single-stage ignition characteristics. Using partial fuel stratification, the strong fuel-vaporization cooling produces thermal stratification due to variations in the amount of fuel vaporization in different parts of the combustion chamber.

This study presents estimates for measurement uncertainties for a Homogenous Charge Compression Ignition (HCCI)/Low-Temperature Gasoline Combustion (LTGC) engine testing facility. A previously presented framework for quantifying those uncertainties developed uncertainty estimates based on the transducers manufacturers’ published tolerances. The present work utilizes the framework with improved uncertainty estimates in order to more accurately represent the actual uncertainties of the data acquired in the HCCI/LTGC laboratory, which ultimately results in a reduction in the uncertainty from 30 to less than 1 kPa during the intake and exhaust strokes. Details of laboratory calibration techniques and commissioning runs are used to constrain the sensitivities of the transducers relative to manufacturer supplied values.

Turbochargers are progressively used in modern automotive engines to enhance engine performance and reduce energy loss and adverse emissions. Use of turbochargers along with other modern technologies has enabled development of significantly downsized internal combustion engines. However, turbochargers are major sources of acoustic emissions in modern automobiles. Their acoustics has a distinctive signature, originating from fluid-structure interactions. The bearing systems of turbochargers also constitute an important noise source. In this case, the acoustic emissions can mainly be attributed to hydrodynamic pressure fluctuations of the lubricant film. The developed analytical model determines the lubricant pressure distribution in the floating journal bearings used mainly in the modern turbocharges. This allows for an estimation of acoustic emissions.

Our previous work applied LIF measurements of in-cylinder fuel distribution to predict CO2, CO, and HC emissions from an HCCI engine under low-load stratified-charge conditions. The prediction method is based on the premise that local fuel-air packets at a given equivalence ratio (characterized using LIF imaging) burn as if in a homogeneous charge at the same equivalence ratio. Thus, emissions measured during homogeneous operation provide an emission-versus- equivalence-ratio look-up table for predicting stratified-charge emissions. The present paper extends the technique to predict engine-out NOX emissions. Because of operating-range limitations, NOX look-up data for homogeneous operation cannot adequately be determined by experiment. Instead, a CHEMKIN-based model provides this look-up table data instead.

This paper proposes a method for quantitatively predicting emissions from a homogeneous-charge compression-ignition (HCCI) engine using laser-induced fluorescence (LIF) imaging of the in-cylinder fuel distribution. The prediction scheme, which is applied to stratified operation, is based on the premise that local fuel-air packets at a given equivalence ratio burn as if in an isolated homogeneous mixture at the same equivalence ratio. Insofar as the premise holds true, the emissions produced by each packet can be predicted using a look-up table of exhaust emission values measured during homogeneous operation. LIF images of fuel distribution during stratified operation are reduced to probability density functions (PDF) that, together with the look-up tables, allow prediction of engine-out emissions. Despite the simplifications associated with the prediction scheme, predicted values of CO2, CO and HC emissions each agree to within 15% of total fuel carbon for low-load operation.

This work investigates the potential of in-cylinder thermal stratification for reducing the pressure-rise rate in HCCI engines, and the coupling between thermal stratification and combustion-phasing retard. A combination of computational and experimental results is employed. The computations were conducted using both a custom multi-zone version and the standard single-zone version of the Senkin application of the CHEMKIN III kinetics-rate code, and kinetic mechanisms for iso-octane. This study shows that the potential for extending the high-load operating limit by adjusting the thermal stratification is very large. With appropriate stratification, even a stoichiometric charge can be combusted with low pressure-rise rates, giving an output of 16 bar IMEPg for naturally aspirated operation. For more typical HCCI fueling rates (ϕ = 0.38 - 0.45), the optimal charge-temperature distribution is found to depend on both the amount of fuel and the combustion phasing.

This work investigates the effects of cavitation on spray characteristics by comparing measurements of liquid and vapor penetration as well as ignition delay and lift-off length. A smoothed-inlet, converging nozzle (nominal KS1.5) was compared to a sharp-edged nozzle (nominal K0) in a constant-volume combustion vessel under thermodynamic conditions consistent with modern compression ignition engines. Within the near-nozzle region, the K0 nozzle displayed larger radial dispersion of the liquid as compared to the KS1.5 nozzle, and shorter axial liquid penetration. Moving downstream, the KS1.5 jet growth rate increased, eventually reaching a growth rate similar to the K0 nozzle while maintaining a smaller radial width. The increasing spreading angle in the far field creates a virtual origin, or mixing offset, several millimeters downstream for the KS1.5 nozzle.

This paper investigates flow and combustion in a full-cycle simulation of a four-stroke, three-valve HCCI engine by visualizing the flow with pathlines. Pathlines trace massless particles in a transient flow field. In addition to visualization, pathlines are used here to trace the history, or evolution, of flow fields and species. In this study evolution is followed from the intake port through combustion. Pathline analysis follows packets of intake charge in time and space from induction through combustion. The local scalar fields traversed by the individual packets in terms of velocity magnitude, turbulence, species concentration and temperatures are extracted from the simulation results. The results show how the intake event establishes local chemical and thermal environments in-cylinder and how the species respond (chemically react) to the local field.