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Striving for sustainable transportation solutions, hydrogen is often identified as a promising energy carrier and internal combustion engines are seen as a cost effective consumer of hydrogen to facilitate the development of a large-scale hydrogen infrastructure. Driven by efficiency and emissions targets defined by the U.S. Department of Energy, a research team at Argonne National Laboratory has worked on optimizing a spark-ignited direct injection engine for hydrogen. Using direct injection improves volumetric efficiency and provides the opportunity to properly stratify the fuel-air mixture in-cylinder. Collaborative 3D-CFD and experimental efforts have focused on optimizing the mixture stratification and have demonstrated the potential for high engine efficiency with low NOx emissions. Performance of the hydrogen engine is evaluated in this paper over a speed range from 1000 to 3000 RPM and a load range from 1.7 to 14.3 bar BMEP.

Increasing injection pressure and decreasing nozzle hole diameter have been proved to be two effective approaches to reduce the exhaust emissions and to improve the fuel economy. Recently, the micro-hole nozzles and ultra-high injection pressures are applicable in commercial Diesel engines. But the mechanism of these two latest technologies is still unclear. The current research aims at providing information on the spray and mixture formation processes of the micro-hole nozzle (d=0.08mm) under the ultra-high injection pressure (Pinj=300MPa). The flat wall impinging sprays were focused on and the laser absorption-scattering (LAS) technique was employed to obtain the qualitative and quantitative information at both atmospheric and elevated conditions. The spray parameters were collected, the mixing rate was discussed, and the effects of various parameters on mixture formation were clarified.

The pressing need to improve U.S. energy independence and reduce climate forcing fossil fuel emissions continues to motivate the development of high-efficiency internal combustion engines. A recent trend has been to downsize and turbocharge automotive spark-ignited engines coupled with direct fuel injection to improve engine efficiency while maintaining vehicle performance. In-line with recent trends in state-of-the-art engine technology, the focus of this study is lean and EGR dilute combustion in a gasoline direct injection (GDI) engine. The lean and dilute operating limits are defined by combustion stability typically in terms of COVIMEP so experiments were carried out on an automotive size single-cylinder research engine to characterize combustion stability. From a 20,000 cycle sequence analysis, lean operating conditions exhibit binary high- to low-IMEP cycle sequences. This may be because the cycle-to-cycle feedback mechanisms are physically limited to one or two cycles.

Hydrogen is widely considered a promising fuel for future transportation applications for both, internal combustion engines and fuel cells. Due to their advanced stage of development and immediate availability hydrogen combustion engines could act as a bridging technology towards a wide-spread hydrogen infrastructure. Although fuel cell vehicles are expected to surpass hydrogen combustion engine vehicles in terms of efficiency, the difference in efficiency might not be as significant as widely anticipated [1]. Hydrogen combustion engines have been shown capable of achieving efficiencies of up to 45 % [2]. One of the remaining challenges is the reduction of nitric oxide emissions while achieving peak engine efficiencies. This paper summarizes research work performed on a single-cylinder hydrogen direct injection engine at Argonne National Laboratory.

The objective of the paper is to characterize the diesel spray under the ambient conditions relevant for direct injection (D.I.) diesel engines. The particular emphasis is on the comparisons between laser measurements and predictions by empirical correlations and theoretical analyses. The ultraviolet-visible laser absorption-scattering (LAS) imaging technique is employed to quantitively determine the spray/mixture properties of the diesel spray injected by a hole-type injector, in terms of spray tip penetration and spatial concentration distributions of liquid and vapor phase. The structure of evaporating spray is obtained and analyzed. Based on the penetration correlations in the literature, a non-dimensional analysis of the spray tip penetration data is carried out. The results indicate that a self-similar state of the evaporating fuel spray is achieved.

It is well know that the internal flow field and nozzle geometry affected the spray behavior, but without high-speed microscopic visualization, it is difficult to characterize the spray structure in details. Single-hole diesel injectors have been used in fundamental spray research, while most direct-injection engines use multi-hole nozzle to tailor to the combustion chamber geometry. Recent engine trends also use smaller orifice and higher injection pressure. This paper discussed the quasi-steady near-nozzle diesel spray structures of an axisymmetric single-hole nozzle and a symmetric two-hole nozzle configuration, with a nominal nozzle size of 130 μm, and an attempt to correlate the observed structure to the internal flow structure using computational fluid dynamic (CFD) simulation. The test conditions include variation of injection pressure from 30 to 100 MPa, using both diesel and biodiesel fuels, under atmospheric condition.

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.

Reynolds-averaged Navier-Stokes (RANS) modeling is expected to deliver an ensemble-averaged result for the majority of turbulent flows. This could lead to the conclusion that multi-cycle internal combustion engine (ICE) simulations performed using RANS must exhibit a converging numerical solution after a certain number of consecutive cycles. However, for some engine configurations unsteady RANS simulations are not guaranteed to deliver an ensemble-averaged result. In this paper it is shown that, when using RANS modeling to simulate multiple engine cycles, the cycle-to-cycle variations (CCV) generated from different initial conditions at each cycle are not damped out even after a large number of cycles. A single-cylinder GDI research engine is simulated using RANS modeling and the numerical results for 20 consecutive engine cycles are evaluated for two specific operating conditions.

The group-hole nozzle concept is regarded as a promising approach to facilitate better fuel atomization and evaporation for direct injection diesel engine applications. In the present work, the spray and mixture properties of group-hole nozzle with close, parallel or a small included angle orifices were investigated experimentally by means of the ultraviolet-visible laser absorption-scattering (LAS) imaging technique, in comparison with the conventional single-hole nozzle. Three series of group-hole nozzles were designed to investigate the effect of group-hole nozzle specification while varying the included angle and interval between the orifices. The results suggested that: 1) Group-hole nozzle with very close, parallel orifices presents the similar spray characteristics with those of the single-hole nozzle.

Turbocharged gasoline direct injection (GDI) engines are quickly becoming more prominent in light-duty automotive applications because of their potential improvements in efficiency and fuel economy. While EGR dilute and lean operation serve as potential pathways to further improve efficiencies and emissions in GDI engines, they also pose challenges for stable engine operation. Tests were performed on a single-cylinder research engine that is representative of current automotive-style GDI engines. Baseline cases were performed under steady-state operating conditions where combustion phasing and dilution were varied to determine the effects on indicated efficiency and combustion stability. Sensitivity studies were then carried out by introducing binary low-high perturbation of spark timing and injection duration on a cycle-by-cycle basis under EGR dilute and lean operation to determine dominant feedback mechanisms.

This paper reports on research activities aiming to improve the efficiency of direct injected, hydrogen powered internal combustion engines. In a recent major change in the experimental setup the hydrogen single cylinder research engine at Argonne National Laboratory was upgraded to a new engine geometry providing increased compression ratio and a longer piston stroke compared to its predecessor. The higher compression ratio and the more advantageous volume to surface ratio of the combustion chamber are both intended to improve the overall efficiency of the experimental setup. Additionally, a new series of faster acting, piezo-activated injectors is used with the new engine providing increased flexibility for the optimization of DI injection strategies. This study focuses on the comparison of experimental data of the baseline versus the improved single cylinder research engine for similar engine operating conditions.

The necessity to study spray-wall interaction in internal combustion engines is driven by the evidence that fuel sprays impinge on chamber and piston surfaces resulting in the formation of wall films. This, in turn, may influence the air-fuel mixing and increase the hydrocarbon and particulate matter emissions. This work reports an experimental and numerical study on spray-wall impingement and liquid film formation in a constant volume combustion vessel. Diesel and n-heptane were selected as test fuels and injected from a side-mounted single-hole diesel injector at injection pressures of 120, 150, and 180 MPa on a flat transparent window. Ambient and plate temperatures were set at 423 K, the fuel temperature at 363 K, and the ambient densities at 14.8, 22.8, and 30 kg/m3. Simultaneous Mie scattering and schlieren imaging were carried out in the experiment to perform a visual tracking of the spray-wall interaction process from different perspectives.

The previous study indicates that the detonation waves generated by acetylene/oxygen mixture can converge in the combustion chamber. In order to verify the destructive effect of detonation wave convergence on piston materials, the detonation bomb device was modified to fundamentally investigate the material failures of aluminum alloy for pistons. The results show that the specimens are destroyed in the middle and edge region after dozens of detonations, which is consistent with the typical characteristics of the piston failures in engines. Therefore, the hypothesis that failures of piston material is caused by the detonation wave convergence is verified.

The group-hole (GH) nozzle concept that uses two closely spaced micro-orifices to substitute the conventional single orifice has the potential to facilitate better fuel atomization and evaporation, consequently attenuate the soot emission formed in direct-injection (D.I.) diesel engines. Studies of quantitative mixture properties of the transient fuel spray injected by the group-hole nozzles were conducted in a constant volume chamber via the laser absorption-scattering (LAS) technique, in comparison with conventional single-hole nozzles. Specific areas investigated involved: the non-evaporating and the evaporating ambient conditions, the free spray and the spray impinging on a flat wall conditions. The particular emphasis was on the effect of one of key parameters, the interval between orifices, of the group-hole (SH) nozzle structure.

Given the importance of the fuel-injection process on the combustion and emissions performance of gasoline direct injected engines, there has been significant recent interest in understanding the fluid dynamics within the injector, particularly around the needle and through the nozzles. The pressure losses and transients that occur in the flow passages above the needle are also of interest. Simulations of these injectors typically use the nominal design geometry, which does not always match the production geometry. Computed tomography (CT) using x-ray and neutron sources can be used to obtain the real geometry from production injectors, but there are trade-offs in using these techniques. X-ray CT provides high resolution, but cannot penetrate through the thicker parts of the injector. Neutron CT has excellent penetrating power but lower resolution.

The concept of two closely spaced micro-orifices (group hole nozzle) has been studied as a promising technology for the reduction of soot emission from direct injection (DI) diesel engines by improving the fuel atomization and evaporation. One of the main issues on group hole nozzle is the arrangement of orifices with various distances and angles. In this study, the ignition and combustion characteristics of wall-impinging diesel sprays from group-hole nozzles were investigated with various angles between two micro-orifices (included angles). A laser absorption scattering (LAS) technique for non-axisymmetric sprays, developed based on a LAS technique for axisymmetric spray, was applied to investigate the liquid/vapor mass distribution of wall-impinging sprays. The direct flame images and OH radical images inside a high pressure constant volume vessel were captured to analyze the effect of included angle on spray ignition and combustion characteristics.

Modeling unsteady turbulent flame development in lifted spray flames is important as a strong correlation exists between pollutant formation and the transient flame features such as auto-ignition, flame propagation and flame stabilization. Detailed chemistry mechanisms with large number of species are required to resolve the chemical kinetics accurately. These factors make high-fidelity simulation of engine combustion computationally expensive. In this work, a turbulent combustion model is proposed based on tabulation of flamelets. The aim is to develop a comprehensive combustion modeling approach incorporating detailed chemistry mechanisms, turbulence models and highly resolved grids leveraging the computational cost advantage of tabulation. A novel technique of implementing unsteady flamelet libraries without the use of progress variables is implemented for igniting sprays called Tabulated Flamelet Model (TFM).

Energy security and climate change are two of the main drivers for development of sustainable and renewable transportation solutions. Entities around the globe have been working on strategic plans to reduce energy consumption and curb greenhouse gas emissions. In this context hydrogen is frequently mentioned as the fuel and energy carrier of the future. The U.S. Department of Energy's (DOE's) FreedomCAR and Vehicle Technologies (FCVT) Program has identified hydrogen-powered internal combustion engine (ICE) vehicles as an important mid-term technology on the path to a large-scale hydrogen economy. DOE has set challenging goals for hydrogen internal combustion engines including 45% peak brake thermal efficiency (BTE). This paper summarizes recent research engine test results employing hydrogen direct injection with different injection strategies.

This paper focuses on detailed numerical simulations of direct injection diesel and gasoline sprays from production grade, multi-hole injectors. In a dual-fuel engine the direct injection of both the fuels can facilitate appropriate mixture preparation prior to ignition and combustion. Diesel and gasoline sprays were simulated using high-fidelity Large Eddy Simulations (LES) with the dynamic structure sub-grid scale model. Numerical predictions of liquid penetration, fuel density distribution as well as transverse integrated mass (TIM) at different axial locations versus time were compared against x-ray radiography data obtained from Argonne National Laboratory. A necessary, but often overlooked, criterion of grid-convergence is ensured by using Adaptive Mesh Refinement (AMR) for both diesel and gasoline. Nine different realizations were performed and the effects of random seeds on spray behavior were investigated.

Reynolds-averaged Navier-Stokes (RANS) turbulence model has been used extensively for diesel engine simulations due to its computational efficiency and is expected to remain the workhorse computational fluid dynamics (CFD) tool for industry in the near future. Alternatively, large eddy simulations (LES) can potentially deal with complex flows and cover a large disparity of turbulence length scales, which makes this technique more and more attractive in the engine community. An n-dodecane spray flame (Spray A from Engine Combustion Network) was simulated using a dynamic structure LES model to understand the transient behavior of this turbulent flame. The liquid spray was treated with a traditional Lagrangian method and the gas-phase reaction was closed using a delta probability density function (PDF) combustion model. A 103-species skeletal mechanism was used for n-dodecane chemical kinetic model.