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The concentration of carbonaceous particulate matter in the exhaust of diesel engines depends on the rates of formation and oxidation of soot in the combustion chamber. Soot forms early in the combustion process when local fuel-rich areas exist, whereas soot oxidation occurs later when more air is entrained into the fuel spray. Based on this understanding, a phenomenological combustion model is established. In the model, the cylinder volume is divided into four zones: a rich fuel spray core, a premixed-burning/burned gas zone, a mixing controlled burning zone and a lean air zone. Soot formation takes place in the mixing controlled burning zone where the local C/O ratio is above the critical value. Soot oxidation occurs in the premixed-burning/burned gas zone as air is entrained. By using a quasi-global chemical reaction scheme, the oxidation of soot particles by different species can be investigated.

One of the main applications for aluminum extrusions in the automotive sector is crash structures including crash rails, crash cans, bumpers and structural body components. The objective is usually to optimize the energy absorption capability for a given structure weight. The ability to extrude thin wall multi-void extrusions contributes to this goal. However, the alloy used also plays a significant role in terms of the ability to produce the required geometry, strength - which to a large extent controls the energy absorption capability and the “ductility” or fracture behavior which controls the strain that can be applied locally during crush deformation before cracking. This paper describes results of a test program to examine the crush behavior of a range of alloys typically supplied for automotive applications as a function of processing parameters including artificial ageing and quench rate.

This paper presents the adhesion strength of ice on sanded and machine-finished aluminum test coupons as measured using the National Research Council of Canada (NRC) Altitude Icing Wind Tunnel (AIWT) spin rig. This rig is used to evaluate commercial and internally-developed coatings for low-adhesion properties, and the performance of ice on aluminum is required as a baseline to compare the coatings against. The tests are performed over a range of aerodynamic and icing cloud conditions, including variations in static air temperature and exposure time (and therefore accumulated ice mass). The data analysis includes an evaluation of the uncertainty in the results based on the measured ice mass repeatability and the measured shear stress repeatability.

The operation of S.I. engines on lean or diluents containing gaseous fuel-air mixtures is attractive in principle since it can provide improved fuel economy, reduced tendency to knock and low NOx emissions combined with a possible improvement to the operational life of the engine. However, the overall flame propagation rates then tend to drop sharply as the operational mixture is excessively leaned or diluted with CO2 or N2. The paper presents experimental data obtained in a single cylinder, variable compression ratio, S.I., CFR engine when operated on a number of gaseous fuels and some of their mixtures. A gradual leaning of the operating mixture can affect adversely in turn, emissions of CO and unburned fuel and cyclic variation. The extent of deterioration in these operating parameters is shown to correlate well with the corresponding values of the combustion period, a key combustion indicator. Similar effects were observed when adding diluents to stoichiometric CH4-air mixtures.

This paper presents the emission characteristics of a HCCI engine operation using n-heptane. The experiments were conducted in a single cylinder Co-operative Fuel Research (CFR) engine equipped with an air-assist port fuel injector. The effects of intake temperature, air/fuel ratio, compression ratio, turbo-charging, and EGR rate on exhaust emissions were explored. The analysis of the exhaust gases included oxides of nitrogen (NOx), nitrous oxide (N2O), carbon monoxide (CO), total hydrocarbon (THC), and soot. The hydrocarbon species present in exhaust gases and their concentrations at several operating conditions were also characterized. The strategies to obtain low HC, CO and NOx emissions are presented and discussed. The approaches to effectively retard HCCI combustion phase without deteriorating combustion efficiency are examined. It was found that HCCI combustion produces extremely low soot and NOx emissions.

In recent years, light weight components have been an area of significant importance in automotive design. This has led to the replacement of steel and cast iron with aluminum alloys for many automotive components. For instance, Al-Si alloys have successfully replaced nodular and gray cast iron in the production of large automotive components such as engine blocks. However, excessive residual strain along the cylinder bores of these engine blocks may result in cylinder distortion during engine operation. Therefore, in this study, neutron diffraction was used to evaluate residual strain along the aluminum cylinder bridge and the gray cast iron liners of distorted and undistorted engine blocks. The strains were measured in the hoop, radial, and axial orientations. The results suggest that the residual strain along the aluminum cylinder bridge of the distorted engine block was tensile for all three measured components.

Continuous efforts to develop a lightweight alloy suitable for the most demanding applications in automotive industry resulted in a number of advanced aluminum (Al) and magnesium alloys and manufacturing routes. One example of this is the application of 319 Al alloy for production of 3.6L V6 gasoline engine blocks. Aluminum is sand cast around Fe-liner cylinder inserts, prior to undergoing the T7 heat treatment process. One of the critical factors determining the quality of the final product is the type, level, and profile of residual stresses along the Fe liners (or extent of liner distortion) that are always present in a cast component. In this study, neutron diffraction was used to characterize residual stresses along the Al and the Fe liners in the web region of the cast engine block. The strains were measured both in Al and Fe in hoop, radial, and axial orientations. The stresses were subsequently determined using generalized Hooke's law.

This paper examines issues related to planning, programming and execution of machining operations by a robot in the context of machining large parts with complex geometries by a gantry-mounted robotic system. Parts were created from surface data in a CAD/CAM environment. The same environment was used to generate tool paths using a conventional machine tool approach. These paths were converted to robot trajectories and validated using mathematical kinematic models of the robotic system. Validation was performed according to various criteria related to process performance. Associated robot programs were then automatically generated. The manufacturing cell was progressively integrated according to requirements resulting from iterative process characterization. A metrology-based calibration procedure was designed that considerably improved the system's positioning precision.

The use of carbon fiber reinforced thermoset composites has doubled in the last decade raising questions about the waste generated from manufacturing and at end-of-life, especially in the aircraft industry. In this study, 2.5 cm long carbon fibers were recovered from thermoset composite waste using a commercial scale pyrolysis process. Scanning electron microscopy, density measurements, single filament tensile testing as well as micro-droplet testing were performed to characterize the morphology, mechanical properties, and surface adhesion of the fibers. The recycled fibers appeared to be mostly undamaged and clean, exhibiting comparable mechanical properties to virgin carbon fibers. A carding process followed by an ultrasound treatment produced randomly aligned recycled fiber mats. These mats were used to fabricate composite plates, with fiber volume fractions up to 40 %, by infusion / compression molding.

Controlling the forming of large thermoplastic parts from a simulation requires very precise predictions of the pressure and volume profile evolution. Present pressure profile based simulations adequately predict the thickness distribution of a part, but the forming pressure and volume profile development lack the precision required for process control. However new simulations based on the amount of power required to form the material can accurately predict these pressure and volume profiles. In addition online monitoring of the forming power on existing machines can be easily implemented by installing a flow rate and pressure meter at the gas entrance, and if necessary, exits of the part. An important additional benefit is that a machine thus equipped can function as an online rheometer that can characterize the viscosity of the material at the operating point by tuning the simulation to the online measurements.

In 2017 the National Research Council of Canada developed an evaporation model for controlling engine icing tunnels in real time. The model included simplifications to allow it to update the control system once per second, including the assumption of sea level pressure in some calculations. Recently the engine icing system was required in an altitude facility requiring operation down to static temperatures of -40°C, and up to an altitude of 9.1 km (30 kft) or 30 kPa. To accommodate the larger temperature and pressure range the model was modified by removing the assumption of sea level operation and expanding the temperature range. In addition, due to the higher concentration of water vapor that can be held by the atmosphere at lower pressures, the significance of the effect of humidity on the air properties and the effect on the model was investigated.

A widely held belief in the combustion community is that the chemical and hydrodynamic structure of a stretched laminar premixed flame can be preserved in a turbulent flow field over a range of conditions collectively known as the flamelet regime, and the homogeneous charge spark-ignition engine combustion falls within the domain of this regime. The major assumption in the laminar flamelet concept as applied to the turbulent premixed flames is that the flame front behaves as a constant-property passive scalar surface, and an increase in the wrinkled flame surface area with increasing turbulence intensity is the dominant mechanism for the observed flame velocity enhancement. The two approaches that have been recently used for estimating a measure of the wrinkled flame surface area in spark-ignition engines and other premixed flames are the flame surface density concept and fractal geometry.

The demand for light weight vehicles continues to stimulate extensive research into the development of light weight casting alloys and optimization of their manufacturing processes. Of primary relevance are Aluminum (Al) and Magnesium (Mg) based alloys, which have successfully replaced selected iron based castings in automobiles. However, optimization of as-cast microstructure, processing and performance remains a challenge for some Al-based alloys. In this context, placement of chills in castings has been frequently used to locally manipulate the solidification conditions and microstructure of a casting. In this work, the effect of using an active copper chill on the residual strain profile of a sand-cast B319 aluminum alloy was investigated. Wedge-shaped castings were produced with three different cooling conditions: copper plate chill, copper pipe with cooling water and no chill (baseline).

The effects of cetane number, aromatics content and 90% distillation temperature (T90) on HCCI combustion were investigated using a fuel matrix designed by the Fuels for Advanced Combustion Engines (FACE) Working Group of the Coordinating Research Council (CRC). The experiments were conducted in a single-cylinder, variable compression ratio, Cooperative Fuel Research (CFR) engine. The fuels were atomized and partially vaporized in the intake manifold. The engine was operated at a relative air/fuel ratio of 1.2, 60% exhaust gas recirculation (EGR) and 900 rpm. The compression ratio was varied over the range of 9:1 to 15:1 to optimize the combustion phasing for each fuel, keeping other operating parameters constant. The results show that cetane number and T90 distillation temperature significantly affected the combustion phasing. Cetane number was clearly found to have the strongest effect.

Computational fluid dynamics (CFD) model has been widely applied in internal combustion (IC) engine research. The integration of chemical kinetic model with CFD provides an opportunity for researchers to investigate the detailed chemical reactions for better understanding the combustion process of IC engines. However, the simulation using CFD has generally focused on the examination of primary parameters, such as temperature and species distributions. The detailed investigation on chemical reactions is limited. This paper presents the development of a post-processing tool capable of calculating the rate of production (ROP) of interested species with the known temperature, pressure, and concentration of each species in each cell simulated using CONVERGE-SAGE CFD model.

Strain-controlled low-cycle fatigue (LCF) experiments were conducted on ductile cast iron at total strain rates of 1.2/min, 0.12/min and 0.012/min in a temperature range of RT ~ 800°C. An integrated creep-fatigue (ICF) life prediction framework is proposed, which embodies a deformation mechanism based constitutive model and a thermomechanical damage model. The constitutive model is based on the decomposition of inelastic deformation into plasticity and creep mechanisms, which can describe both rate-independent and rate-dependent cyclic responses under wide strain rate and temperature conditions. The damage model takes into consideration of i) plasticity-induced fatigue, ii) intergranular embrittlement, iii) creep and iv) oxidation. Each damage form is formulated based on the respective physical mechanism/strain.

Structural adhesive joints are expected to retain integrity in their entire service-life that normally involves cyclic loading concurrent with environmental exposure. Under such a severe working condition, effective determination of fatigue life at different temperatures is crucial for reliable joint design. The main goal of this work was thus defined as evaluation of fatigue performance of adhesive joints at their extreme working temperatures in order to be compared with their fracture properties under static loading. A series of standard double-cantilever-beam (DCB) specimens have been bonded by three structural 3M epoxy adhesives selected from different applications. The specimens were tested under monotonic and cyclic opening loads (mode-I) in order to evaluate the quasi-static and fatigue performances of selected adhesives at room temperature, 80°C and -40°C.

Due to numerous engine power-loss events associated with high-altitude convective weather, ice accretion within an engine due to ice-crystal ingestion is being investigated. The National Aeronautics and Space Administration (NASA) and the National Research Council (NRC) of Canada are starting to examine the physical mechanisms of ice accretion on surfaces exposed to ice-crystal and mixed-phase conditions. In November 2010, two weeks of testing occurred at the NRC Research Altitude Facility utilizing a single wedge-type airfoil designed to facilitate fundamental studies while retaining critical features of a compressor stator blade or guide vane. The airfoil was placed in the NRC cascade wind tunnel for both aerodynamic and icing tests. Aerodynamic testing showed excellent agreement compared with CFD data on the icing pressure surface and allowed calculation of heat transfer coefficients at various airfoil locations.

Lightweight tubular products offering enhanced stiffness and strength have always been of major concern for transportation and recreational applications. Hence, industries have turned to complex-shaped tubes to increase product performance and reduce energy costs. High-performance aluminum alloys, like 7075 for instance, have good mechanical properties such as high strength, but low formability at ambient temperature. Fortunately, hot tensile tests on 7075 samples have yielded an increase in formability with temperature. Therefore, testing has recently been launched at the Aluminum Technology Center to develop a new product application. More precisely, a 1,000-ton hydraulic press was equipped with +600°C heating plates and fitted with a bicycle handlebar mold. The plates provide 10 separate heating zones that can be adjusted independently. A thermo-mechanical model was also developed using LS-DYNA to determine tube temperatures around the heating zones.

Homogeneous Charge Compression Ignition (HCCI) combustion characteristics of dual-stage autoignition fuels were examined over the speed range of 600 to 1700 rpm using a Cooperative Fuels Research (CFR) engine. A fuel vaporizer was used to preheat and partially vaporize the fuel inside the intake plenum. The air and fuel were well-mixed prior to entering the cylinder. Since low temperature heat release (LTHR) is known to be an important factor that affects HCCI combustion of fuels that exhibit dual-stage autoignition behavior, a detailed heat release analyses were performed on both time and crank angle bases. At the lower and upper speeds, the operating ranges were compared as a function of air/fuel ratio (AFR) and exhaust gas recirculation (EGR) from the knocking to misfiring limits. The AFR-EGR operating region was more limited at 1700 rpm than at 900 rpm for the commercial ULSD fuel. Combustion stability was problematic at higher engine speeds.