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While gasoline surrogate development has progressed in the areas of more complex surrogate mixtures and in kinetic modeling tools and mechanism development, it is generally recognized that further development is still needed. This paper represents a small step in supporting this development by providing comparisons between experimental engine data and surrogate-based kinetic models. In our case, the HCCI engine data comes from a port-injected, single-cylinder research engine with intake-air heating for combustion phasing control. Timing sweeps were run at constant fuel rate for three market gasolines and five surrogate mixtures. Modeling was done using the CHEMKIN software with a gasoline mechanism set containing 1440 species and 6572 reactions. Five pure compounds were selected for the surrogate blends and include iso-octane, n-heptane, toluene, methylcyclohexane, and 1-hexene.

One scenario for reducing engine out NOx in a spark ignition engine is to introduce small amounts of supplemental hydrogen to the combustion process. The supplemental hydrogen enables a gasoline engine to run lean where NOx emissions are significantly reduced and engine efficiency is increased relative to stoichiometric operation. This paper reports on a mass and energy balance model that has been developed to evaluate the overall system efficiencies of a thermal reformer-heat exchanger system capable of delivering hydrogen to the air intake of a gasoline engine. The mass and energy balance model is utilized to evaluate the conditions where energy losses associated with fuel reformation may be offset by increases in engine efficiencies.

Internal combustion engines are operated under conditions of high exhaust gas recirculation (EGR) to reduce NOx emissions and promote enhanced combustion modes such as HCCI. However, high EGR under certain conditions also promotes nonlinear feedback between cycles, leading to the development of combustion instabilities and cyclic variability. We employ a two-zone phenomenological combustion model to simulate the onset of combustion instabilities under highly dilute conditions and to illustrate the impact of these instabilities on emissions and fuel efficiency. The two-zone in-cylinder combustion model is coupled to a WAVE engine-simulation code through a Simulink interface, allowing rapid simulation of several hundred successive engine cycles with many external engine parametric effects included.

A systems-level modeling framework developed to estimate the life cycle cost of medium- and heavy-duty trucks is discussed in this paper. Costs are estimated at a resolution of five major subsystems and 30+ subsystems, each representing a specific manufacturing technology. Interrelationships among various subsystems affecting cost are accounted for. Results of a specific Class 8 truck are finally discussed to demonstrate the modeling framework's capability, including the analysis of cost-effectiveness of some of the competing alternative system design options being considered by the industry today.

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible spark ignition (SI). A high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio (rc) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. To achieve efficiency improvements, engine experiments were coupled with computational fluid dynamics simulations to guide and explain experimental trends between the original engine and the high stroke-to-bore ratio design (1.5:1). The effects of EGR and late intake valve closing (IVC) and fuel characteristics are investigated through their effects on knock mitigation. Direct injection of 91 RON E10 gasoline, 99 RON E0 gasoline, and liquified petroleum gas (i.e., propane/autogas) were evaluated with geometric rc ranging from 13.3:1 to 16.8:1.

G-Equation models represent propagating flame fronts with an implicit two-dimensional surface representation (level-set). Level-set methods are fast, as transport source terms for the implicit surface can be solved with finite-volume operators on the finite-volume domain, without having to build the actual surface. However, they include approximations whose practical effects are not properly understood. In this study, we improved the numerics of the FRESCO CFD code’s G-Equation solver and developed a new method to simulate kernel growth using signed distance functions and the analytical sphere-mesh overlap. We analyzed their role for simulating propane/air flames, using three well-established constant-volume configurations: a one-dimensional, freely propagating laminar flame; a disc-shaped, constant-volume swirl combustor; and torch-jet flame development through an orifice from a two-chamber device.

The widespread adoption of boosted, downsized SI engines has brought pre-ignition phenomena into greater focus, as the knock events resulting from pre-ignitions can cause significant hardware damage. Much attention has been given to understanding the causes of pre-ignition and identify lubricant or fuel properties and engine design and calibration considerations that impact its frequency. This helps to shift the pre-ignition limit to higher specific loads and allow further downsizing but does not fundamentally eliminate the problem. Real-time detection and mitigation of pre-ignition would thus be desirable to allow safe engine operation in pre-ignition-prone conditions. This study focuses on advancing the time of detection of pre-ignition in an engine cycle where it occurs.

A modified Mercedes 1.7-liter, direct-injection diesel engine was operated in both normal and high-efficiency clean combustion (HECC) combustion modes. Four steady-state engine operating points that were previously identified by the Ad-hoc fuels working group were used as test points to allow estimation of the hot-start FTP-75 emissions levels in both normal and HECC combustion modes. The results indicate that operation in HECC modes generally produce reductions in NOX and PM emissions at the expense of CO, NMHC, and H2CO emissions. The FTP emissions estimates indicate that aftertreatment requirements for NOX are reduced, while those for PM may not be impacted. Cycle-average aftertreatment requirements for CO, NMHC, and H2CO may be challenging, especially at the lowest temperature conditions.

An optical-based sensor for detecting particulate matter (PM) in diesel engine exhaust has been demonstrated. The position of the sensor during the experiments was the exhaust manifold prior to the turbocharger. The sensor is constructed of fiber optics which transmit 532-nm laser light into the exhaust pipe and collect backscattered light in a 180° geometry. Due to the optical nature of the probe, PM sensing can occur at high temporal rates. Experiments conducted by changing the fuel injection properties of one cylinder of a four cylinder engine demonstrated that the sensor can resolve cycle dependent events. The feasibility of the probe for examining PM emissions in the exhaust manifold will be discussed.

Operation of spark-ignition (SI) engines with high levels of charge dilution through exhaust gas recirculation (EGR) achieves significant engine efficiency gains while maintaining stoichiometric operation for compatibility with three-way catalysts. Dilution levels, however, are limited by cyclic variability - including significant numbers of misfires - that becomes more pronounced with increasing dilution. This variability has been shown to have both stochastic and deterministic components. Stochastic effects include turbulence, mixing variations, and the like, while the deterministic effect is primarily due to the nonlinear dependence of flame propagation rates and ignition characteristics on the charge composition, which is influenced by the composition of residual gases from prior cycles.

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.

A central challenge for efficient auto-ignition controlled low-temperature gasoline combustion (LTGC) engines has been achieving the combustion phasing needed to reach stable performance over a wide operating regime. The negative valve overlap (NVO) strategy has been explored as a way to improve combustion stability through a combination of charge heating and altered reactivity via a recompression stroke with a pilot fuel injection. The study objective was to analyze the thermal and chemical effects on NVO-period energy recovery. The analysis leveraged experimental gas sampling results obtained from a single-cylinder LTGC engine along with cylinder pressure measurements and custom data reduction methods used to estimate period thermodynamic properties. The engine was fueled by either iso-octane or ethanol, and operated under sweeps of NVO-period oxygen concentration, injection timing, and fueling rate.

Interest in operational cost reduction is driving engine manufacturers to consider low-cost fuel substitution in heavy-duty diesel engines. These dual-fuel (DF) engines could be operated either in diesel-only mode or operated with premixed natural gas (NG) ignited by a pilot flame of compression-ignited direct-injected diesel fuel. Under certain conditions, dual-fuel operation can result in increased cycle-to-cycle variability (CCV) during combustion. CFD can greatly help in understanding and identifying critical parameters influencing CCV. Innovative modelling techniques and large computing resources are needed to investigate the factors affecting CCV in dual-fuel engines. This paper discusses the use of the High Performance Computing resource Titan, at Oak Ridge National Laboratory, to investigate CCV of a dual-fuel engine.

Lean NOx Trap (LNT) catalysts are capable of reducing NOx in lean exhaust from diesel engines. NOx is stored on the catalyst during lean operation; then, under rich exhaust conditions, the NOx is released from and reduced by the catalyst. The process of NOx release and reduction is called regeneration. One method of obtaining the rich conditions for regeneration is to inject additional fuel into the engine cylinders while throttling the engine intake air flow to effectively run the engine at rich air:fuel ratios; this method is called “in-cylinder” regeneration. In-cylinder regeneration of LNT catalysts has been demonstrated and is a candidate emission control technique for commercialization of light-duty diesel vehicles to meet future emission regulations. In the study presented here, a 1.7-liter diesel engine with a LNT catalyst system was used to evaluate in-cylinder regeneration techniques.

Traditional autonomous vehicle perception subsystems that use onboard sensors have the drawbacks of high computational load and data duplication. Infrastructure-based sensors, which can provide high quality information without the computational burden and data duplication, are an alternative to traditional autonomous vehicle perception subsystems. However, these technologies are still in the early stages of development and have not been extensively evaluated for lane detection system performance. Therefore, there is a lack of quantitative data on their performance relative to traditional perception methods, especially during hazardous scenarios, such as lane line occlusion, sensor failure, and environmental obstructions.

With increasingly stringent regulations mandating the improvement of vehicle fuel economy, automotive manufacturers face growing pressure to develop and implement technologies that improve overall system efficiency. One such technology is an automatic (auto) stop-start feature. Auto stop-start reduces idle time and reduces fuel use by temporarily shutting the engine off when the vehicle comes to a stop and automatically re-starting it when the brake is released, or the accelerator is pressed. As mandated by the U.S. Congress, the U.S. Environmental Protection Agency (EPA) is required to keep the public informed about fuel saving practices. This is done, in partnership with the U.S. Department of Energy (DOE), through the fueleconomy.gov website. The “Fuel-Saving Technologies” and “Gas Mileage Tips” sections of the website are focused on helping the public make informed purchasing decisions and encouraging fuel-saving driving habits.

Rapid vehicle powertrain development has become a technological breakthrough for the design and implementation of vehicles that meet and exceed the fuel efficiency, cost, and performance targets expected by today’s consumer. Recently, advances in large scale additive manufacturing have provided the means to bridge hardware-in-the-loop with preproduction mule chassis testing. This paper details a case study from Oak Ridge National Laboratory bridging the powertrain-in-the-loop development process with vehicle systems implementation using big area additive manufacturing (BAAM). For this case study, the use of a component-in-the-loop laboratory with math-based models is detailed for the design of a battery electric powertrain to be implemented in a printed prototype mule. The ability for BAAM to accelerate the mule development process via the concept of computer-aided design to part is explored.

The low temperature conditions that occur during high efficiency clean combustion (HECC) often lead to the formation of partially oxidized HC species such as aldehydes, ketones and carboxylic acids. Using the diesel fuels specified by the Fuels for Advanced Combustion Engines (FACE) working group, carbonyl species were collected from the exhaust of a light duty diesel engine operating under HECC conditions. High pressure liquid chromatography - mass spectrometry (LC-MS) was used to speciate carbonyls as large as C 9 . A relationship between carbonyl species formed in the exhaust and fuel composition and properties was determined. Data were collected at the optimum fuel efficiency point for a typical road load condition. Results of the carbonyl analysis showed changes in formaldehyde and acetaldehyde formation, formation of higher molecular weight carbonyls and the formation of aromatic carbonyls.

The effects of cetane number (CN) on homogeneous charge compression ignition (HCCI) performance and emissions were investigated in a single cylinder engine using intake air temperature for control. Blends of the diesel secondary reference fuels for cetane rating were used to obtain a CN range from 19 to 76. Sweeps of intake air temperature at a constant fueling were performed. Low CN fuels needed to be operated at higher intake temperatures than high CN fuels to achieve ignition. As the intake air temperature was reduced for a given fuel, the combustion phasing was retarded, and each fuel passed through a phasing point of maximum indicated mean effective pressure (IMEP). Early combustion phasing was required for the high CN fuels to prevent misfire, whereas the maximum IMEP for the lowest CN fuel occurred at a phasing 10 crank angle degrees (CAD) later.

In this study the authority of the available engine controls are characterized as the high load limit of homogeneous charge compression ignition (HCCI) combustion is approached. A boosted single-cylinder research engine is used and is equipped with direct injection (DI) fueling, a laboratory air handling system, and a hydraulic valve actuation (HVA) valve train to enable negative valve overlap (NVO) breathing. Results presented include engine loads from 350 to 650 kPa IMEPnet and manifold pressure from 98 to 190 kPaa. It is found that in order to increase engine load to 650 kPa IMEPnet, it is necessary to increase manifold pressure and external EGR while reducing the NVO duration. While both are effective at controlling combustion phasing, NVO duration is found to be a "coarse" control while fuel injection timing is a "fine" control.