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Comparisons have been made between dual-fuel (80% port-injection gasoline and 20% direct-injection diesel by mass) Highly Premixed Charge Combustion (HPCC) and blended-fuel (80% gasoline and 20% diesel) Low Temperature Combustion (LTC) modes on a 1-L single-cylinder test engine. In the HPCC mode, both early-injection (E-HPCC) and late-injection (L-HPCC) of diesel have been used. The comparisons have been conducted with a fixed fuel injection rate of 50 mg/cycle at 1500 rpm, and with the combustion phasing fixed (by adjusting the injection timing) so that the 50% heat release point (CA50) is at 8° ATDC. The rapid heat release process of LTC leads to the highest maximum pressure rise rate (MPRR). A two-peak heat release process is observed in L-HPCC, resulting in a lower MPRR. The heat release rate and MPRR values for the E-HPCC are comparable to the L-HPCC values. The EHPCC mode provides the lowest NOX emission. The soot emissions for all three modes are low.

A model has been developed to predict the performance of the Texaco Controlled Combustion, Stratified Charge Engine starting from engine geometry, fuel characteristics and the operating conditions. This performance model divides the engine cycle into the following phases: Intake, Compression, Rapid Combustion, Mixing-Dominated Expansion, Heat-Transfer Dominated Expansion and Exhaust. During the rapid combustion phase, the rate of heat release is assumed to be controlled by the rate of fuel injection and the air-to-fuel ratio. The burning rate in the mixing controlled stage appears to be dominated by the rate of entrainment of the surrounding gas by the plume of burning products and this rate is assumed to be controlled by the turbulent eddy entrainment velocity. A plume geometry model has been developed to obtain the surface area of the plume for entrainment during the mixing dominated phase.

This paper describes the use of a modified quasi-dimensional spark-ignition engine simulation code to predict the extent of cycle-to-cycle variations in combustion. The modifications primarily relate to the combustion model and include the following: 1. A flame kernel model was developed and implemented to avoid choosing the initial flame size and temperature arbitrarily. 2. Instead of the usual assumption of the flame being spherical, ellipsoidal flame shapes are permitted in the model when the gas velocity in the vicinity of the spark plug during kernel development is high. Changes in flame shape influence the flame front area and the interaction of the enflamed volume with the combustion chamber walls. 3. The flame center shifts due to convection by the gas flow in the cylinder. This influences the flame front area through the interaction between the enflamed volume and the combustion chamber walls. 4. Turbulence intensity is not uniform in cylinder, and varies cycle-to-cycle.

Cranking and startup fuel control has become increasingly important due to ever tightening emission requirements. Additionally, engine-off strategies during idle will require substantially more engine startup events with the associated need for very clean starts. Thus, knowledge of an engine's Air-Fuel Ratio (AFR) during its early cycles is necessary in order to optimize cranking and startup fueling. This paper examines and compares two methods of measuring an engine's AFR during engine startup (approximately the first second of operation); an in-cylinder technique using a Fast Flame Ionization Detector (FFID) and the conventional exhaust based Universal Exhaust Gas Oxygen (UEGO) sensor method. Engine starts using a Ford Zetec engine were performed at three different temperatures (0, 20 and 90 C) as well as different initial engine starting positions.

Gas-pressurized space suits are highly resistive to astronaut movement, and this resistance has been previously explained by volume and/or structural effects. This study proposed that an additional effect, pressure effects due to compressing/expanding the internal gas during joint articulation, also inhibits mobility. EMU elbow torque components were quantified through hypobaric testing. Structural effects dominated at low joint angles, and volume effects were found to be the primary torque component at higher angles. Pressure effects were found to be significant only at high joint angles (increased flexion), contributing up to 8.8% of the total torque. These effects are predicted to increase for larger, multi-axis joints. An active regulator system was developed to mitigate pressure effects, and was found to be capable of mitigating repeated pressure spikes caused by volume changes.

The purpose of this work was to develop an understanding of how liquid fuel transported into the cylinder of a port-fuel-injected gasoline-fueled SI engine contributes to hydrocarbon (HC) emissions. To simulate the liquid fuel flow from the valve seat region into the cylinder, a specially designed fuel probe was developed and used to inject controlled amounts of liquid fuel onto the port wall close to the valve seat. By operating the engine on pre-vaporized Indolene, and injecting a small amount of liquid fuel close to the valve seat while the intake valve was open, we examined the effects of liquid fuel entering the cylinder at different circumferential locations around the valve seat. Similar experiments were also carried out with closed valve injection of liquid fuel at the valve seat to assess the effects of residual blowback, and of evaporation from the intake valve and port surfaces.

The characteristics of the early development of fuel sprays from pressure swirl atomizer injectors of the type used in direct injection gasoline engines is investigated. Planar laser-induced fluorescence (PLIF) was used to visualize the fuel distribution inside a firing optical engine. The early spray development of three different injectors at three different fuel pressures (3, 5, and 7 MPa) was followed as a function of time in 30 μsec intervals. Four phases could be identified: 1) A delay phase between the rising edge of the injection pulse and the first occurrence of fuel in the combustion chamber, 2) A solid jet or pre-spray phase, in which a poorly atomized stream of liquid fuel during the first 150 μsec of the injection. 3) A wide hollow cone phase, separation of the liquid jet into a hollow cone spray once sufficient tangential velocity has been established and 4) A fully developed spray, in which the spray cone angle is narrowed due to a low pressure zone at the center.

A one-dimensional model for crevice HC post-flame oxidation is used to calculate and understand the effect of operating parameters and fuel type (propane and isooctane) on the extent of crevice hydrocarbon and the product distribution in the post flame environment. The calculations show that the main parameters controlling oxidation are: bulk burned gas temperatures, wall temperatures, turbulent diffusivity, and fuel oxidation rates. Calculated extents of oxidation agree well with experimental values, and the sensitivities to operating conditions (wall temperatures, equivalence ratio, fuel type) are reasonably well captured. Whereas the bulk gas temperatures largely determine the extent of oxidation, the hydrocarbon product distribution is not very much affected by the burned gas temperatures, but mostly by diffusion rates. Uncertainties in both turbulent diffusion rates as well as in mechanisms are an important factor limiting the predictive capabilities of the model.

The NOx emission and knock characteristics of a PFI engine operating on ethanol/gasoline mixtures were assessed at 1500 and 2000 rpm with λ =1 under Wide-Open-Throttle condition. There was no significant charge cooling due to fuel evaporation. The decrease in NOx emission and exhaust temperature could be explained by the change in adiabatic flame temperature of the mixture. The fuel knock resistance improved significantly with the gasohol so that ignition could be timed at a value much closer or at MBT timing. Changing from 0% to 100% ethanol in the fuel, this combustion phasing improvement led to a 20% increase in NIMEP and 8 percentage points in fuel conversion efficiency at 1500 rpm. At 2000 rpm, where knocking was less severe, the improvement was about half (10% increase in NIMEP and 4 percentage points in fuel conversion efficiency).

Optimal design of modern direct injection spark-ignition engines depends heavily on the characteristics and distribution of the fuel spray. This study was designed to investigate changes in the spray properties due to fuel volatility and operating conditions using a firing optically-accessible engine with planar laser-induced fluorescence (PLIF) imaging. The results show that the spray structure changes not only with ambient gas density, which is often measured, but also with fuel temperature and volatility. As ambient pressure decreases and fuel temperature increases, the volatile ends of multi-component fuels evaporate quickly, disrupting the spray structure and producing a vapor core along the axis of the spray. Beyond a certain point, evaporation is rapid enough to expand the initial cone angle of the spray while causing a decrease in the overall spray width.

Optimal design of modern direct injection spark-ignition engines depends heavily on the characteristics and distribution of the fuel spray. This study was designed to compliment imaging experiments of changes in the spray structure due to fuel volatility and operating conditions. Use of phase-Doppler particle analysis (PDPA) allows quantitative point measurements of droplet diameter and velocity. In agreement with imaging experiments, the results show that the spray structure changes not only with ambient gas density, which is often measured, but also with fuel temperature and volatility. The mean droplet diameter was found to decrease substantially with increasing fuel temperature and decreasing ambient density. Under conditions of low potential for vaporization, the observed trends in mean droplet sizes agree with published correlations for pressure-swirl atomizers.

The fuel effects on HCCI operation in a spark assisted direct injection gasoline engine are assessed. The low load limit has been extended with a pilot fuel injection during the negative valve overlap (NVO) period. The fuel matrix consists of hydrocarbon fuels and various ethanol blends and a butanol blend, plus fuels with added ignition improvers. The hydrocarbon fuels and the butanol blend do not significantly alter the high or the low limits of operation. The HCCI operation appears to be controlled more by the thermal environment than by the fuel properties. For E85, the engine behavior depends on the extent that the heat release from the pilot injected fuel in the NVO period compensates for the evaporative cooling of the fuel.

The influence of charge motion and fuel injection characteristics on diesel combustion was studied in a rapid compression machine (RCM), a research apparatus that simulates the direct-injection diesel in-cylinder environment. An experimental data base was generated in which inlet air flow conditions (temperature, velocity, swirl level) and fuel injection pressure were independently varied. High-speed movies using both direct and shadowgraph photography were taken at selected operating conditions. Cylinder pressure data were analyzed using a one-zone heat release model to calculate ignition delay times, premixed and diffusion burning rates, and cumulative heat release profiles. The photographic analysis provided data on the liquid and vapor penetration rates, fuel-air mixing, ignition characteristics, and flame spreading rates.

The heat transfer characteristics of impinging diesel sprays were studied in a Rapid Compression Machine. The temporal and spatial distributions of the heat transfer around the impingement point -were measured by an array of high frequency response surface thermocouples. Simultaneously, the flow field of the combusting spray was photographed with high speed movie through the transparent head of the apparatus. The results for the auto-ignited fuel sprays were compared to those of non-combusting sprays which were carried out in nitrogen. The values of the heat flux from the combusting sprays were found to be substantially different from those of the non-combusting sprays. The difference was attribute to the radiative heat transfer and the combustion generated bulk, motion and small scale turbulence.

A new monitoring system predicts the progression of welding temperature fields during resistance spot welding. The system captures welding voltages and currents to predict contact diameters and simulate temperature fields. The system accurately predicts fusion lines and heat-affected zones. Accuracy holds even for electrode tips used for a few thousand welds of zinc coated steels.

The presence of liquid fuel inside the engine cylinder is believed to be a strong contributor to the high levels of hydrocarbon emissions from spark ignition (SI) engines during the warm-up period. Quantifying and determining the fate of the liquid fuel that enters the cylinder is the first step in understanding the process of emissions formation. This work uses planar laser induced fluorescence (PLIF) to visualize the liquid fuel present in the cylinder. The fluorescing compounds in indolene, and mixtures of iso-octane with dopants of different boiling points (acetone and 3-pentanone) were used to trace the behavior of different volatility components. Images were taken of three different planes through the engine intersecting the intake valve region. A closed valve fuel injection strategy was used, as this is the strategy most commonly used in practice. Background subtraction and masking were both performed to reduce the effect of any spurious fluorescence.

The in-cylinder hydrocarbon (HC) mole fraction was measured on a cycle-resolved basis during simulated starting and warm-up of a port-injected single-cylinder SI research engine on a dynamometer. The measurements were made with a fast-response flame ionization detector with a heated sample line. The primary parameters that influence how rapidly a combustible mixture builds up in the cylinder are the inlet pressure and the amount of fuel injected; engine speed and fuel injection schedule have smaller effects. When a significant amount of liquid fuel is present at the intake port in the starting process, the first substantial firing cycle is often preceded by a cycle with abnormally high in-cylinder HC and low compression pressure. An energy balance analysis suggests that a large amount of liquid vaporization occurs within the cylinder in this cycle.

In internal combustion engines, a portion of liquid fuel spray may directly land on the liner and mix with oil (lubricant), forming a fuel-oil film (~10μm) that is much thicker than the original oil film (~0.1μm). When the piston retracts in the compression stroke, the fuel-oil mixture may have not been fully vaporized and can be scraped by the top ring into the 1st land crevice and eventually enter the combustion chamber in the format of droplets. Studies have shown that this mechanism is possibly a leading cause for low-speed pre-ignition (LSPI) as the droplets contain oil that has a much lower self-ignition temperature than pure fuel. In this interest, this work aims to study the oil-fuel interactions on the liner during an engine cycle, addressing molecular diffusion (in the liquid film) and vaporization (at the liquid-gas interface) to quantify the amount of fuel and oil that are subject to scraping by the top ring, thereby exploring their implications on LSPI and friction.

Numerical calculations of the fuel spray structure from a high-pressure swirl injector were used to enable the interpretation of experimental observations obtained in hot, hollow-cone fuel sprays issued into sub-atmospheric-pressure environments. The experiments show that the spray becomes narrower, more compact, but with a relatively long penetration depth. Model input parameters, including the droplet size distribution, early vapor production, and initial cone angle, were modified to determine which spray characteristics are important in recreating observed spray structures. A very small mean droplet diameter is needed to recreate the experimentally observed structure of the high-temperature, low-pressure sprays. Vapor addition to the emerging spray is then required to increase the axial penetration and provide the observed vapor core.

Particulate emissions from a production gasoline direct injection spark ignition engine were studied under a typical cold-fast-idle condition (1200 rpm, 2 bar NIMEP). The particle number (PN) density in the 22 to 365 nm range was measured as a function of the injection timing with single pulse injection and with split injection. Very low PN emissions were observed when injection took place in the mid intake stroke because of the fast fuel evaporation and mixing processes which were facilitated by the high turbulent kinetic energy created by the intake charge motion. Under these conditions, substantial liquid fuel film formation on the combustion chamber surfaces was avoided. PN emissions increased when injection took place in the compression stroke, and increased substantially when the fuel spray hit the piston.