Browse Topic: Fuel systems

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Experimental and Numerical Analysis of Direct Injection Process for Hydrogen-Fuelled Internal Combustion Engines2025-01-0307To be published on 07/02/2025
In the context of the clean transport sector, there has been growing interest in the use of hydrogen in internal combustion engines due to its potential to nearly eliminate all engine-out criteria pollutants, while maintaining high thermal efficiency through the use of a lean combustion process. Direct Injection (DI) is widely recognized as a method for enhancing thermal efficiency and minimizing the risk of abnormal combustion. However, a major challenge is the reduced time available for mixture homogenization, making injection timing a critical parameter to optimize. To address this, a comprehensive experimental campaign was conducted in a constant volume vessel to assess the performance of a hydrogen injector using the Schlieren technique. The jet behavior was analyzed by varying injector recess, injection pressure, and back pressure. Subsequently, the case study was replicated in a 3D Computational Fluid Dynamics (CFD) environment, addressing the complexities associated with
Pucillo, Francesco, Piano, Andrea, Millo, Federico, Giordana, Sergio, Rapetto, Nicola, Vargiu, Luca
Technical Paper
Numerical analysis of direct-injection and combustion inside a H2 engine2025-01-0301To be published on 07/02/2025
The direct injection of hydrogen (H2) inside internal combustion engines (ICEs) is gaining large research interest over the port-fuel injection strategy, because of several advantages as higher volumetric efficiencies, increased power output and reduced risks of abnormal combustion. However, the required high pressure ratios across the injector nozzle produce moderate-to-high under-expanded jets, characterized by complex flow structures. This poses a challenge for the numerical modelling of the mixture preparation by means of 3D computational fluid dynamic (CFD) approaches. In this work, a validated 3D-CFD methodology has been employed to simulate the closed-valve cycle of a direct injection H2 engine equipped with a centrally mounted hollow-cone injector and a non-axisymmetric piston bowl. First, injection and mixture preparation have been studied considering an early injection at the beginning of the compression stroke, and a delayed injection in the second half of the compression
Capecci, Marcolucio, Sforza, Lorenzo, Lucchini, Tommaso, D'Errico, Gianluca, Pezza, Vincenzo, Tosi, Sergio
Technical Paper
In-Depth Experimental Investigation into Performance and Emission Characteristics of a Diesel Light-Duty Engine Fuelled with Pure Hydrogen2025-01-0314To be published on 07/02/2025
Transitioning to zero-carbon fuels is pivotal for expediting the reduction of carbon emissions. Hydrogen demonstrates significant adaptability and emerges as a principal zero-carbon alternative fuel for carbon-based internal combustion engine (ICE) platforms. Implementing hydrogen in both spark ignition (SI) and compression ignition (CI) engines has proven to be both economically viable and timely; nevertheless, it presents several technical challenges that must be addressed. The study analyses the performance and emissions of a single-cylinder boat engine converted from diesel to 100% hydrogen. A port fuel injection (PFI) system was adopted to operate the engine with hydrogen by replacing the diesel injector with a spark plug engine without any modification to the cylinder head. The engine features an automated shutdown system to mitigate intake backfire risks associated with hydrogen PFI systems. A comprehensive engine characterization was conducted at a wide range of relative air-to
Mohamed, Mohamed, Zaman, Zayne, Lu, Enshen, Feng, Yizhuo, Wang, Xinyan, Zhao, Hua
Technical Paper
Comprehensive optical and numerical investigation of hydrogen spray formation for a commercial gasoline hollow-cone injector2025-01-0313To be published on 07/02/2025
Hydrogen produced from renewable sources offers the opportunity to reduce future emissions and enable CO2-neutral mobility by both adapting existing internal combustion engines (ICE) and developing new combustion engine systems. One challenge of hydrogen direct injection (DI) ICE is to optimize the mixture formation to ensure low engine out emissions as well as high efficiencies. In the study presented in this paper, a conventional piezo hollow-cone gasoline injector, commonly used in passenger car series, was adapted for high-pressure hydrogen direct injection applications. Therefore, optical measurements within a low pressure chamber (LPC) were conducted using a high-speed Schlieren imaging measurement technique to visualize the injection behavior and spray pattern at various injection conditions. The visualization of density gradients during the injection process showed a slightly decreased relative gaseous penetration length (GPL) of 4% for hydrogen in comparison to helium while
Fleischmann, Maximilian, Mirsch, Niklas, Ghanoum, Mohamad, Morcinkowski, Bastian, Adomeit, Philipp, Pischinger, Stefan
Technical Paper
Impact of the distribution of charging and hydrogen refueling stations on their reachability for craft vehicles with a defined usage profile2025-01-0310To be published on 07/02/2025
This paper examines the impact of the distribution of charging and hydrogen refueling stations on their reachability for craft vehicles with a defined usage profile. A simulation-based methodology is presented for this purpose. The simulation models daily trips for craft vehicles, considering amongst others the company location, the client stops, the operating radius and the mean daily driving distance. Based on these inputs, the number of charging or refueling opportunities for typical daily trips of the craft vehicle is calculated. To investigate the impact of locations on the frequency of encountering energy provisions, simulations are conducted in three regions: Ulm (urban), Stuttgart (metropolitan), and Munderkingen (rural). Furthermore, the impact of different locations within the same infrastructural area is examined by assessing multiple company locations in Ulm. The findings indicate that the urban zone of Ulm is characterized by a highly dense electric fast charging
Heilmann, Oliver, Müller, Julian, Heinrich, Marco, Cortès, Sven, Schlick, Michael, Kulzer, André Casal
Technical Paper
Higher Content n-Butanol Blending Ratios in Diesel Fuel Spray and Combustion Characteristics: Addressing Oxygenated Fuel Challenges with Spark-Assisted Combustion Strategies2025-01-0210To be published on 06/16/2025
This study investigates the effects of oxygenated fuels, specifically long-chain alcohols, impact fuel atomization and combustion behavior in CI engines. The objective is to examine how higher n-butanol blending ratios in diesel fuel influence spray dynamics and combustion performance under varying engine conditions using an advanced combustion strategy. Experiments were conducted using a constant volume chamber (CVC) and a rapid compression-expansion machine (RCEM), both designed to replicate CI engine conditions. N-butanol was blended with diesel at ratios ranging from 70% to 90% with 10% increments, and key parameters such as spray formation, cone angle, penetration length, in-cylinder pressure, combustion performance, and efficiency were analyzed. The study also evaluated the effects of varying injection pressures on spray behavior. The results demonstrate that increasing n-butanol content significantly alters spray and combustion characteristics. Higher n-butanol proportions lead
Warsita, I Wayan, Lim, Ocktaeck
Technical Paper
Effects of Injection and Intake Timing on Atomization and Combustion in a Hybrid Gasoline Direct Injection Optical Engine under the Low-Speed Low-Load Condition2025-01-0203To be published on 06/16/2025
With the growing trend of hybridization in modern engines, hybrid gasoline direct injection (GDI) engines are typically designed for high-load, mid-to-high-speed operation to achieve optimal fuel economy. However, these engines inevitably operate under low-speed, low-load conditions where insufficient intake air often leads to poor air-fuel mixing and weak turbulence, resulting in suboptimal combustion. Adjusting intake and injection timing presents a simple and effective approach to optimizing the combustion process in hybrid GDI engines. In this study, an optical engine with a combustion system geometry identical to that of an advanced hybrid GDI engine is used. The engine features a compression ratio of 15.0:1 and is equipped with a variable timing camshaft for intake timing control and an electronically controlled system for injection timing. High-speed color imaging, using transparent pistons and cylinder liners, captures the in-cylinder spray development and combustion processes
Cui, Mingli, Fu, Jinhong, Man, Xingjia, Nour, Mohamed, Zhang, Weixuan, Li, Xuesong, Xu, Min
Technical Paper
A Comprehensive Experimental Analysis of Ethanol 27% Fuel Blend in a Turbocharged Gasoline Direct Injection Engine2025-01-0245To be published on 06/16/2025
India is committed to achieving a 20% ethanol blend in petrol (E20) by 2025, as part of its national biofuels policy to reduce carbon emissions, enhance energy security, and support the agricultural economy. Building on E20's achievement in reducing GHG emissions, E27 fuel—which contains 27% ethanol in gasoline—is one of the means of advancing India's ethanol strategy and reducing dependency on fossil fuels. In line with the literature and the preliminary study, an experimental analysis utilizing fuel blends ranging from E10 to E40 was conducted. It was found that E27 provides the optimal balance of emissions reduction and performance without requiring engine modifications, complying with the government's aim to boost ethanol blending and cut carbon emissions by 2030. This study examines a turbocharged gasoline direct injection (TGDI) engine powered passenger car that was tested using E27 fuel for a mileage accumulation of 20,000 km under real-world driving conditions. This evaluation
D R, Vigneshwar, Bhakthavachalu, Vijayabaskar, Muralidharan, M.
Technical Paper
Flame developments of pilot diesel ignited hydrogen jet in an optical dual direct injection engine2025-01-0237To be published on 06/16/2025
This study aims to characterise the flame development for hydrogen-diesel dual direct injection (H2DDI) in an optically accessible heavy-duty engine through high-speed imaging of the natural combustion luminosity. A single hole, side mounted injector was used to inject H2 at 350 bar in addition to a centrally mounted eight-hole diesel injector providing the ignition source for the H2. The diesel pilot flame was examined without H2 to establish the combustion characteristics of the pilot flame. The pilot fuel energy was reduced from 1200J to 120J while examining the distribution of the pilot flame as the H2 energy fraction was increased. The flame distribution transitioned from an initial quasi-steady diesel flame at peak load (1200 J), to a piston bowl wall-centric flame distribution (840 J) and then to an injector centric flame (120 J). The pilot fuel quantity of 120 J was selected to investigate the ignition process of hydrogen main fuel mixtures supplying 90% energy (only 10% energy
Heaton, Alastar, Chan, Qing Nian, Kook, Sanghoon
Technical Paper
An Experimental Study on Aqueous Ammonia and Diesel Dual-Fuel Combustion with Ignition Improving Additives in a Compression Ignition Engine2025-01-0231To be published on 06/16/2025
Ammonia is a potential vector of renewably produced hydrogen for combustion systems and decarbonisation of transport. However, anhydrous ammonia remains dangerous and difficult to handle due to its volatility and toxicity. Therefore, a water-based solution of ammonium hydroxide (NH4OH) was proposed to investigate the potential use as a fuel in a compression-ignition engine. Ammonium hydroxide, also referred to as aqueous ammonia, is liquid phase under atmospheric conditions; therefore, the storage of such a fuel does not require high pressure. Previous work has established that ammonium hydroxide solution could contribute to energy release during co-combustion with fossil diesel. However, the presence of water reduced combustion stability and limited the extent to which aqueous ammonia could displace diesel. In addition, the characteristics of pollutant emissions of burning such a fuel remained less understood. This study therefore explores the potential of ignition improving additives
Han, Yanlin, Hellier, Paul, Ladommatos, Nicos
Technical Paper
Hydrogen Jet Characteristics of an Outward-opening Injector based on Schlieren Imaging2025-01-0228To be published on 06/16/2025
Hydrogen was considered as a promising carbon-free fuel for future society. The application of hydrogen in internal combustion engines has drawn more and more attentions. Jet performance of hydrogen injection plays a crucial role in characteristics of the hydrogen fuelled engines, in terms of mixture preparation, combustion and heat release in cylinder. In this research, an outward-opening injector was developed for hydrogen direct injection application. The jet performance was studied using high-speed schlieren imaging in a constant volume chamber and the effects of injection and ambient pressures on jet characteristics were investigated. The results show that, the hydrogen jet exhibits a conical structure in the near-field and overall presents a bell-shaped appearance under relatively low ambient pressure, which differs from irregular structure under relatively high ambient pressure. The pressure ratio, defined as the ratio of injection pressure to chamber pressure, significantly
HU, Chaoqun, HU, Longbiao, Chen, Haie, Li, Liguang, Wu, Zhijun, Deng, Jun
Technical Paper
Research on Combustion Characteristics of Flash-Boiling Spray in Cylinders Based on Machine Learning Methods2025-01-0205To be published on 06/16/2025
With the increasing number of vehicles in operation, exhaust emissions from engines have exerted negative impacts on ecological environments, prompting researchers to actively pursue cleaner and more efficient in-cylinder combustion strategies. Flash-boiling spray technology, capable of generating superior fuel atomization under relatively low injection pressures, has emerged as a promising approach for achieving performance breakthroughs in gasoline direct injection (GDI) engines. While current research primarily focuses on morphological characterization and mechanistic analysis of flashboiling spray, there remains insufficient understanding of flame development characteristics under flash boiling spray conditions within engine cylinders. This study systematically investigates the combustion characteristics of TPRF and PRF fuels under both subcooled and flash-boiling spray conditions through the integration of image processing and machine learning methodologies. Experimental
Zhang, Weixuan, Shahbaz, Muhammad, Cui, Mingli, Li, Xuesong, Xu, Min
Technical Paper
Morphology Experiment of Icing Effect on Spray Propagation2025-01-0222To be published on 06/16/2025
The working conditions of combustion systems have been going extreme under the desire of human beings exploring the unknown. Cold environments can be a significant impact on the spraying of fuel not only by changing the fuel properties including viscosity and surface tension, but also by freezing the parts. In the present study, methanol spray from a commercial injector is studied via high-speed imaging, with the liquid fuel being frozen to sub-zero degrees at the injector tip. It is observed that water components from the environment will freeze at the injector tip, creating crystal structures on the surface. During the injection, the ice components will be flushed by the liquid, and the spray morphology of the starting cycle will be strongly altered, resulting in wider spray angles, much shorter penetrations, and particle structures can be observed in the downstream of the flow field. The results of the experiment provide a clear view and quantified evaluation of the freezing impact
zeng, Tingxi, Wang, Shangning, Zhang, Yijia, Hung, David, Xu, Min
Technical Paper
numerical investigation into the combustion and emission characteristics of ammonia direct injection mechanism2025-01-0241To be published on 06/16/2025
Ammonia is an attractive option because of its relatively low greenhouse gas (GHG) emissions, high energy density, competitive cost, and ubiquitous infrastructure for manufacturing, storage, and distribution. In this work, the optimum combustion characteristics are investigated to propose an efficient ammonia engine for future investigation. The effects of ammonia addition on diesel combustion characteristics were numerically investigated in a CI engine. The investigation was conducted by structured 3D CFD modeling to analyze the combustion characteristics. The validation of the boundary condition was compared to the designed experimental ammonia engine. The direct injection timing of 10o-50oBTDC and injection pressure 300-800 bar was proposed to identify the optimum autoignition characteristics. The equivalence ratios 1, 0.75, 0.5, and 0.25 were used in order to analyze the high cetane number characteristics and the air-fuel ratio.
setiawan, ardhika, Lim, Ocktaeck
Technical Paper
Parametric Analysis of Injector Operational Parameters, Charge Dilution, and Intake Valve Opening on In-Cylinder Motion and Flame Development in an Automotive, Lean-Burn, Gasoline Engine with High-Tumble2025-01-0198To be published on 06/16/2025
The effect of injection pressure, start of injection (SOI) timing, charge dilution, and valve timing on charge motion and early flame development was investigated for a pre-production automotive gasoline engine. Experiments were performed in a single-cycle optical engine designed to represent the high-tumble (Tumble ratio = 1.8), lean-burn engine. Time-resolved particle image velocimetry (PIV) was used to characterize velocity flow fields throughout the swept volume during the intake and compression strokes. Diffuse back illuminated imaging allowed for visualization and quantification of the injected liquid fuel spray and its interactions with the tumble vortex. Hydroxyl (OH*) chemiluminescence imaging was performed to image spark channel elongation and early flame kernel development. It was observed that an optimal injection timing of 320° before top dead center (bTDC) resulted in attenuation of the tumble motion and an associated reduction in compression flows that shifted the tumble
MacDonald, James, Ekoto, Isaac, Han, Donghee, Lee, Jonghyeok
Technical Paper
Evaluating the Impact of Displacing Injected Gasoline with Aspirated Ammonia in a Direct Injection Spark Ignition Engine2025-01-0226To be published on 06/16/2025
Replacing fossil fuels with renewable ammonia could provide a crucial step towards the decarbonisation of transport sectors. However, many challenges remain in utilising ammonia within combustion systems: the volumetric energy density of ammonia is significantly lower than that of gasoline, exposure to ammonia (including ammonia slip) can be detrimental to human health, and the production of emissions, including unregulated emissions (such as N2O), from ammonia combustion can be catastrophic for the environment if not treated appropriately. Therefore, there is a need to determine the efficacy of ammonia as a fuel for internal combustion engines and the impact on the efficiency of energy release and the resulting exhaust emissions. A modern spark ignition engine was modified such that ammonia was aspirated through the engine intake air to incrementally displace engine gasoline and maintain a constant work output. It was found that displacing the fuel energy supplied by direct injected
Sivaranjitham, Annaniya Mitchell, Hellier, Paul, Ladommatos, Nicos, Millington, Paul, Alcove Clave, Silvia
Technical Paper
Catalyzing the Hydrogen Economy: Designing Low-Cost Refueling Modules for India's Mobility Revolution2025-01-0187To be published on 06/16/2025
The likely depletion of fossil fuel reserves in the next fifty years and growing environmental concerns caused by petroleum fuel-based vehicles highlight the urgent need for sustainable alternatives. India, a developing country, requires a significant amount of energy to sustain its growth, most of which is imported. Hydrogen is one of the cleanest fuels and offers sustainable pathways to a low-carbon future. The government of India has already launched a Green Hydrogen mission and has set up a very ambitious target for 2030. However, the absence of adequate refueling infrastructure is a significant blockade to India's widespread adoption of hydrogen-powered vehicles. The mobile hydrogen refueling station (MHRS) is a flexible system that enables lower initial capital costs than fixed hydrogen refueling stations and allows for the gradual build-up of hydrogen mobility fleets. Such a system could be very useful in India, and it integrates advanced safety features, including hydrogen leak
Mathur, Animesh, Nayak, Ajay, Kumar, Naveen
Technical Paper
Understanding how blending different ratios of renewable fuels with diesel impacts the toxicity of exhaust particulates to human health.2025-01-0207To be published on 06/16/2025
The urgent need to decarbonise transport has increased the utilisation of renewable fuels with current hydrocarbons. Heavy duty vehicle electrification solutions are yet to be realised and therefore the reliance on diesel engines may still be present for decades to come. Currently, the diesel supplied to fuel stations across the UK is a 7% blended biodiesel, whilst in South Korea a 5% blend is utilised. Biodiesel is produced from renewable sources for example; crops, waste residue and oils or biomass. Particulates from diesel combustion are known to be toxic, due to the presence of polyaromatic hydrocarbons (PAHs) however there is very limited understanding of blending oxygenated fuels on the toxicity of the particulates produced. PAHs are aromatic structures that can be metabolised into chemicals which can disrupt DNA replication and potentially influence cancer mechanisms if inhaled in high quantities. Soyabean methyl-ester (SME) was blended at lower ratios, e.g., 5%, 10%, 15% and
Hailwood, Emma, Hellier, Paul, Ladommatos, Nicos, Leonard, Martin
Technical Paper
Comparison of renewable methanol and gasoline fuel spray vaporization using direct-injection technology2025-01-0225To be published on 06/16/2025
Considering the large opportunity to reduce net lifecycle carbon emissions through the use renewable methanol, we address spray technologies needed to overcome the challenge of wall wetting and poor vaporization for methanol and the need for improved computational modeling of these processes. High-speed extinction imaging followed by computed tomography reconstruction is utilized to provide three-dimensional liquid volume fraction for reference fuel injectors, to be used for model validation activities. The first injector is the symmetric 8-hole Spray M injector for the Engine Combustion Network, and the second injector is an asymmetric 6-hole injector designed for lateral-cylinder mounting. The degree of plume interaction and vaporization are characterized at representive injection conditions, showing substantially higher concentrations of liquid for methanol than gasoline even with preheated fuel temperatures (90 degrees C).
Wan, Kevin, Clemente Mallada, Rafael, Oh, Heechang, Dhanji, Meghnaa, Buen, Zachary, White, Logan, Pickett, Lyle
Technical Paper
Endoscopic imaging of split-injected gas jet developments in a multi-cylinder hydrogen low-pressure direct-injection spark-ignition engine2025-01-0236To be published on 06/16/2025
Split injection is widely used in conventional spark ignition engines to control mixture formation. To utilise split injection in a hydrogen direct injection engine, it is important to understand gas jet development and its variations with injection timing. This is because prolonged duration of gaseous fuel direct injection is challenged by complex jet-flow interaction involving tumble flow, which could be more significant than the short-injected liquid fuel. The ambient air pressure and density during the gas injection also changes depending on the injection timing, adding more complexity. This study performs endoscopic high-speed imaging of gas jet laser shadowgraph in an inline four-cylinder low-pressure direct-injection spark ignition (H2LPDI) engine. Due to safety concern and its known similarity in macroscopic jet developments, helium was used as an alternative gas to hydrogen. The results showed that the gas jet development changes greatly with the split injection timing
Zhang, ChengHua, Kim, Dongchan, Kook, Sanghoon, Lee, Seung Woo
Technical Paper
An experimental and numerical study of ultra-lean combustion characteristics of methanol direct injection using various coil spark ignition strategies2025-01-0200To be published on 06/16/2025
Methanol is significantly emerging as a promising alternative fuel in the pursuit of carbon neutrality. This study aims to analyze the combustion characteristics of methanol in a spark-ignition (SI) engine operating under high compression ratios and ultra-lean conditions through both experimental and simulation approaches. The objective is to derive optimized combustion efficiency by employing various ignition strategies based on discharge energy. To this end, experiments were conducted using a Rapid Compression Expansion Machine (RCEM) to replicate realistic engine environments. The effects of discharge energy and spark duration across different spark coil configurations were investigated through both experimental methods and computational fluid dynamics (CFD) simulations. The experimental results showed that the use of multiple spark coils achieved an energy release rate of approximately 239 mJ/s, more than twice that of the single-coil configuration. Simulation results were in good
Choi, Jeongyeon, Lim, Ocktaeck
Technical Paper
A Comparative Assessment of Port Fuel Injection and Direct Injection of Hydrogen in Internal Combustion Engines: Performance, Efficiency, and Emissions2025-01-0239To be published on 06/16/2025
With the transition toward low-carbon fuels-based transportation systems, hydrogen is becoming increasingly promising as a sustainable internal combustion engine (ICE) fuel. There are two pathways for introducing hydrogen: Port Fuel Injection (PFI) and Direct Injection (DI) in an engine, which greatly affects performance, efficiency, and emissions. In the Port Fuel Injection (PFI); hydrogen is introduced into the intake manifold and mixed with air before reaching the combustion chamber. This approach is preferred due to its affordability, ease of use, and compatibility with current engine configurations. Because of PFI's more uniform air-fuel mixture, combustion is smoother, and NOx emissions are reduced. On the other hand, it raises the possibility of pre-ignition, particularly when engine loads are high, and a decrease in volumetric efficiency due to a reduction in the volume of intake air as hydrogen replaces it. Direct injection gives exact control over the timing and volume of
Ahirwar, Sachin, Kumar, Naveen
Technical Paper
Powering the Future of Sustainable Flight2025-01-0147To be published on 05/02/2025
Eaton Aerospace is collaborating with original equipment manufacturers (OEMs) on the advancement of technologies to increase aircraft efficiency, enable aircraft electrification, and reduce carbon emissions. Leveraging our expertise as an intelligent power management company, Eaton’s products and research include hydraulic power packs, electromechanical actuation (EMA), thermal management systems, and sustainable aviation fuel (SAF). Eaton Blended Power TM systems improve efficiency through eliminating all centralized hydraulic circuits with distributed power that is provided by a combination of hydraulic power packs and EMA for a More Electric Aircraft (MEA). EMA systems, including electrical synchronization, eliminate the usage of hydraulics and provide additional functionality that benefits the flight efficiency of the aircraft. With MEA comes higher energy and thermal densities, resulting in the need for advanced thermal management. Eaton’s scalable and modular thermal management
Skinner, Jeff, Proul, Margaret, Devan, Stephen, Clendenin, Laura, Hutchinson, Lewis, Masson, Andrew, May, Frank, Momotiuk, Andy, Zuzelski, Chris
Technical Paper
Enhancing Low Temperature Lean Combustion of CH4-H2 Blends through a Prechamber Equipped Engine2024-32-004404/18/2025
The use of hydrogen as a sustainable fuel in the short term is hampered by the impossibility of large scale use due low availability. In order to promote decarbonization, complementary solution for a smooth transition is to dilute it in a mixture with methane, in a current Port Fuel Injection (PFI) internal combustion engine (ICE). This can be done as a retrofit after limited structural modifications, such as the introduction of a passive prechamber. Such a solution allows a reduction of the carbon footprint of traditional ICEs through more efficient combustion (both the prechamber technology and the hydrogen fuel properties promote an increase in combustion speed) and a reduced carbon content in the fuel. The present research activity has been carried out through numerical investigation based on three-dimensional CFD analyses to simulate the behavior of a natural gas engine fueled with CH4-H2 blends. The combustion mechanism for the fuel blend was validated against measurements of the
Balduzzi, Francesco, Ferrara, Giovanni, Di Iorio, Silvana, Sementa, Paolo
Technical Paper
Experimental Study of Port Water Injection System on Single Cylinder Diesel Engine Performance and Exhaust Emission2024-32-002504/18/2025
Vehicle emission standards have become more and more stringent and have driven the development of advanced engine design with low-cost emission control technologies. For small diesel engine which is used in three-wheel (3W) passenger and load carrying vehicles, it was major task to improve lower engine rpm torque and performance to comply with stringent exhaust emissions standard as well, especially for Oxides of Nitrogen (NOx) and Particulate Matter (PM) emissions. Bharat Stage (BS) VI emission standards for three-wheel vehicles was implemented from April 2020 onwards in India. Water injection technology has proven advantageous for low-cost solution with Mechanical fuel injection system on small diesel engines, Intake port water injection is the easiest method to introduce water to engine cylinder, which calls for minimal modification of existing engine structure. In the present study 435cc naturally aspirated DI Diesel engine used for three-wheel vehicle was explored by adding water
Syed, Kaleemuddin, Chaudhari, Sandip, Khairnar, Girish, Katariya, Rahul, Jagtap, Pranjal, Bhoite, Vikram
Technical Paper
CFD Analysis of Pintle-Nozzle Spray for Swirl Chamber Type Small Diesel Engine -Application of Hole-Nozzle Atomization Model to Pintle-Nozzle2024-32-010904/18/2025
Swirl chamber combustion system is commonly used for IDI (In-Direct Injection) diesel engine. It is characterized by swirl combustion chamber arranged in cylinder head, main combustion chamber with shallow piston recess and connecting throat where fuel spray and flame mixture is ejected out from the swirl chamber to the main chamber [1]. Fuel is supplied in the swirl chamber and a pintle type nozzle is often used in this type engine as its simple structure and robustness for operating condition. In this paper, numerical simulation of a pintle nozzle spray was focused on and simulated results were compared with high speed photo data obtained in a constant volume vessel (CVV). Spray angle and tip penetration were mainly evaluated, but simulated angle and penetration could not be matched simultaneously to these characteristics of the pintle nozzle spray when conventional spray models were used for the simulation. To overcome this mismatch, “Multi-hole replacement model” was newly
Okazaki, Tadao, Fujiwara, Tsukasa
Technical Paper
Real-Time Control of Hydrogen Injection in a PFI Internal Combustion Engine based on an Online Physics-Based Model for Estimating Trapped Air and EGR2024-32-010304/18/2025
The use of hydrogen in port fuel injection (PFI) engines faces challenges related to abnormal combustions that must be addressed, especially in transient operation. The in-cylinder air-to-fuel ratio and the amount of trapped exhaust gas have a significant impact on the probability of abnormal combustion as well as NOx emissions, and should be real-time monitored in hydrogen engines. Thus, the real-time estimation of the composition and thermodynamic state of the trapped gas mixture is crucial during transient operations, although highly challenging. This study proposes an on-line real-time physics-based MIMO (Multi-Input-Multi-Output) model to accurately estimate the amount of trapped air and exhaust gas in the cylinder at the intake valve closing (IVC) event, based on the instantaneous in-cylinder pressure measurement. With proper estimation accuracy, the injector can be controlled to correctly provide the amount of fuel necessary to achieve the target air-to-fuel ratio (AFR) and
Galli, Claudio, Ciampolini, Marco, Drovandi, Lorenzo, Romani, Luca, Balduzzi, Francesco, Ferrara, Giovanni, Vichi, Giovanni, Minamino, Ryota
Technical Paper
Fuel Film Measurement in a SI Gasoline Engine Using a Newly Developed MEMS Sensor2024-32-007104/18/2025
The previously developed capacitance sensor for detecting a liquid fuel film was modified to apply to the in-cylinder measurement. On the developed sensor surface, comb-shaped electrodes were circularly aligned. The capacitance between the electrodes varies with the liquid fuel film adhering. The capacitance variation between the electrodes on the sensor surface was converted to the frequency variation of the oscillation circuit. In the previous study, it was revealed that the frequency of the oscillation circuit varies with the variation of the liquid fuel coverage area on the sensor surface. The developed sensor was installed in the combustion chamber of the rapid compression and expansion machine, and the performance of the developed sensor was examined. Iso-octane was used as a test fuel to explore the sensor that had been developed. As a result, the adherence of the liquid fuel directly injected into the cylinder was successfully detected under the quiescent and motoring
Kuboyama, Tatsuya, Moriyoshi, Yasuo, Takayama, Satoshi, Nakabeppu, Osamu
Technical Paper
Development of Cylinder Deactivation Control during Idle for Conventional Engines2024-32-001904/18/2025
This report examines the advancement and utilization of cylinder deactivation technology that enhances fuel efficiency in conventional engines without hardware modifications. It operates by halting fuel supply to some of the cylinders in multi-cylinder engines and increasing the output power of the remaining active cylinders to maintain an idle state. By implementing this technology in the mass-produced 90° V-twin engine, the U502, and deactivating one of its two cylinders, fuel consumption during idling is reduced by over 30%. The focus of this study is on the technology developed to minimize engine speed fluctuations during the transition to cylinder deactivation and reactivation for the engine. By making various modifications to the fuel injection control sequence and optimizing the throttle opening of each cylinder in idle and driving conditions, engine speed fluctuations were minimized. This allows users to reduce fuel consumption while maintaining the engine’s original
YANAGIDA, Shoji
Technical Paper
Techniques and Analysis Methods Used in Development of 13.4kW Horizontal Water-Cooled Diesel Engine2024-32-011604/18/2025
Horizontal water-cooled diesel engines are single-cylinder engines equipped with all the necessary components for operation such as a fuel tank and a radiator. Due to their versatility, there are used in a wide range of applications in Asia, Africa, South America, etc. It is necessary to comply with strengthened emissions regulations year by year in countries where environmental awareness is increasing such as China, India, etc. We have developed a new compact and high-power 13.4kW(18HP) engine which meets these needs. We realized a high-power density by using our unique expertise to maintain an engine size and increase a displacement. In addition, by optimizing a layout of crankcase ribs through structural analysis, we have achieved a maximum bore and “Reduction of the weight of the crankcase and lubricating oil consumption (LOC), and reduction of friction with narrow-width low-tangential load piston rings”. Furthermore, by designing an intake port using 3D CFD, we have optimized a
Shiomi, Kenta, Hosoya, Ryosuke, Komai, Yoshinobu, Takashima, Yusuke, Kitamura, Takahiro, Fujiwara, Tsukasa, Suematsu, Kosuke
Technical Paper
Research on Basic Characteristics of a Two-Stroke Opposed Piston Engine2024-32-011204/18/2025
This study investigated the performance characteristics of a two-stroke opposed piston engine that is capable of constantly operating with high power output and high efficiency. An investigation was also made of the performance obtained by applying a pseudo uniflow condition as a measure against large hydrocarbon (HC) emissions owing to blow-by of unburned mixture, which is an issue of two-stroke engines. The test engine had a displacement of 127 cm3 and a bore and stroke of 48 x 70 mm. One-point and dual-point ignition systems were used, and regular gasoline was supplied as the test fuel using a carburetor-based fueling system. Experiments were conducted at engine speeds of 1500 and 3000 rpm at ignition timings of 45 deg. and 35 deg. before top dead center. The results showed that large quantities of HC emissions were emitted because stable combustion was not achieved. This revealed that a stronger uniflow condition must be applied as a countermeasure rather than a simple pseudo
Fukushima, Shumpei, Uehara, Ryota, Hayashi, Yoshiaki, Igarashi, Ryo, Tokita, Kazuho, Iijima, Akira
Technical Paper
Investigation on the Applicability of Passive Type Pre-Chamber with One Port Fuel Injection System to Small Gasoline Engines2024-32-003304/18/2025
Pre-chamber combustion has been applied as a method of low fuel consumption in spark ignition engines, and in recent years the application of pre-chambers to gasoline engines has also been actively studied. In many gasoline engines, stoichiometric combustion is common. We decided that a passive type pre-chamber with only one port fuel injection is sufficient for stoichiometric combustion. The pre-chamber system relatively has two merits of lower cost and ease of installing than other prechamber systems. Therefore, we focused on investigating the effects of improving combustion speed and knock resistance in use of the passive type pre-chamber and the applicability of the pre-chamber system in various operating points. As the concrete approach, we evaluated the heat balance and the knock resistance with and without a pre-chamber in engine bench test. As a result, the knock resistance and the fuel consumption were improved. In addition, as a result of considering lean burn in the passive
Nakao, Yoshinori, Sakurai, Yota, Hisano, Atsushi, Saitou, Masahito, Suzuki, Tomoharu
Technical Paper
Basic Investigation of Thermodynamic Effects on a Hydrogen Two-Stroke Engine2024-32-003904/18/2025
The spark ignited two-stroke engine, as a cost-efficient power unit with low maintenance demand, is used millionfold for the propulsion of hand-held application, motorcycles, scooters, boats and others. The outstanding power to weight ratio is the key advantage for two-stroke engines. However, poor exhaust emissions, caused by high scavenge losses, especially on port controlled two-stroke engines, and a low efficiency are disadvantages of this combustion process. Under the aspect of increasing environment- and health awareness, the two-stroke technology driven with fossil resources, shows no future advantage. The anthropogenic climate change force for sustainable development of combustion engines whereby reduction of fuel consumption or usage of alternative fuels is an important factor. Best way of a decarbonization to fulfil future climate goals is the utilization of non-carbon fuels. In this field of fuels, hydrogen, with its high energy content and close inexhaustible availability
Yasuda, Terutaka, Oswald, Roland, Kirchberger, Roland
Technical Paper
Prediction of Pre-Ignition Borderline on Supercharged SI Engine by Livengood-Wu Integral2024-32-000804/18/2025
The LSPI (Low Speed Pre-Ignition) is one of the consecutive abnormal combustion cycles of supercharged SI engine with direct injection fuel supply system [1]. The LSPI occurs when the engine is running at low speed and high load condition. It is important for the SI engine to control essentially with alternative fuel, e-fuel and hydrogen in the future. It is considered that the LSPI would be caused by the autoignition of the deposit, the lubricating oil from ring crevice, the lubricating oil from piston crown and so on [2, 3, 4, 5]. Among of these causes, this research focuses on the scattering lubricating oil from piston crown. The previous our research has reported on the two points. One is about the frequency and quantity of the lubricating oil scattering from piston crown [6]. Another is about the frequency of abnormal combustion by the engine test [7]. As the result, it has been cleared that the frequency of abnormal combustion is 1/10 of scattering frequency of the lubricating
Omori, Takaya, Tanaka, Junya
Technical Paper
Study on Flex Fuel Compatible Coatings for Automotive Fuel Tank2024-32-007604/18/2025
Reducing CO2 emissions is now a major focus in India heading towards net zero emissions by 2070. India is the 3rd largest automobile market in the world and the transportation sector is the 3rd largest CO2 emitter. In this direction, it is necessary to reduce the carbon footprint from the automobile sector to combat climate change. The adoption of sustainable biofuels such as ethanol will enable us to reduce emissions, as ethanol is carbon neutral fuel. However, vehicle manufacturers are facing challenges in manufacturing flex fuel compatible parts in the vehicle mainly fuel systems. Ethanol has both nonpolar and polar bonds, making it miscible to both gasoline and water, thereby water contamination is inevitable in ethanol blend fuels. In addition, control of ethanol contamination by sulfates and chlorides during ethanol production is challenging. Thus, ethanol blend fuels are considered more corrosive and tendency towards deposit formation than normal gasoline fuels. Design and
Pandi, Dinesh Babu, Shanmugam, Gomathy Priya, Nagarkatti, Arun, Gopal, Manish, Anbalagan, Prathap
Technical Paper
Fuel Tank Filler Cap and Cap Retainer ThreadedJ1114_202504 (Current)04/14/2025
This SAE Recommended Practice was developed primarily for passenger car and truck applications, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
Recommended Practice
Fuel Tank Filler Cap and Cap RetainerJ829_202504 (Current)04/14/2025
This SAE Standard was developed primarily for passenger car and truck applications for the sizes indicated, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
Technical Standard
Fuel Tank Filler, Capless ClosureJ3144_202504 (Current)04/14/2025
This SAE Recommended Practice was developed primarily for passenger car and truck applications, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
Recommended Practice
Detailed Specification for Aircraft Pressure Refueling NozzleAS5877C (Current)04/14/2025
This SAE Aerospace Standard (AS) prescribes requirements for the various types of nozzles that are used for the refueling and defueling of aircraft fitted with pressure fuel servicing systems. It is to be used as a replacement for MIL-N-5877 and MS29520 and for all commercial applications.
AE-5C Aviation Ground Fueling Systems Committee
Technical Standard
Detecting Piston Ring–Cylinder Liner Metal–Metal Contact in a Fired Large Marine Diesel Engine Using Piezoelectric Transducers03-18-03-001704/09/2025
Shear-polarized ultrasonic sensors have been instrumented onto the outer liner surface of an RTX-6 large marine diesel engine. The sensors were aligned with the first piston ring at top dead center and shear ultrasonic reflectometry (comparing the variation in the reflected ultrasonic waves) was used to infer metal–metal contact between the piston ring and cylinder liner. This is possible as shear waves are not supported by fluids and will only transmit across solid-to-solid interfaces. Therefore, a sharp change in the reflected wave is an indicator of oil film breakdown. Two lubricant injection systems have been evaluated—pulse jet and needle lift-type injectors. The needle lift type is a prototype injector design with a reduced rate of lubricant atomization relative to pulse jet injectors. This is manifested as a smaller reduction in the reflected ultrasonic wave, showing less metal–metal contact had occurred. During steady-state testing, the oil feed rate was varied; the high flow
Rooke, Jack, Li, Xiangwei, Dwyer-Joyce, Robert S.
Journal Article
Investigation of Dimethyl Ether Injection Profiles in High-Pressure Direct Injection System2025-01-846404/01/2025
The majority of transportation systems continue to rely on internal combustion engines powered by fossil fuels. Heavy-duty applications, in particular, depend on diesel engines due to their high brake efficiency, power density, and robustness. Despite significant advancements in diesel engine technology that have reduced emissions and improved efficiency, complex and costly after-treatment systems remain necessary to meet the stringent emission regulations. Dimethyl ether (DME), which can be produced from various renewable feedstocks and possesses high chemical reactivity, is a promising alternative for heavy-duty applications, particularly in compression ignition direct injection engines. Its high reactivity, volatility, and oxygenated composition offer significant potential to address emission challenges while reducing reliance on after-treatment systems. However, DME’s lower energy density requires adjustments in injection parameters (such as injection pressure and duration) or
Cong, Binghao, Leblanc, Simon, Tjong, Jimi, Ting, David, Yu, Xiao, Zheng, Ming
Technical Paper
Liquid Viscosity Decoupling Measurement Based on U-Shaped Tungsten Wire Sensor2025-01-846004/01/2025
In this paper, based on the cylindrical flow theory of incompressible viscous fluids and the equivalent circuit model of resonant sensing elements, a theoretical model for the measurement of liquid viscosity with a U-Shaped tungsten wire resonance sensor was established. This model can measure the liquid viscosity independently without liquid density or coupled detection of liquid density. The experimental results show that the decoupling of liquid viscosity and its density can be achieved at Re<1. The liquid viscosity is strongly linear with the resonant conductance. The viscosity measurement error is less than 7.24% in the viscosity range of 7.235cP to 85.2cP.
Shan, Baoquan, Shen, Yitao, Yang, Jianguo, Wu, Dehong
Technical Paper
Numerical Investigation on Behaviors of Under-Expanded Hydrogen Jets: Influence of Straight Nozzle Geometry2025-01-845904/01/2025
In internal combustion engines, hydrogen is considered as one of the most promising alternatives to replace fossil fuels and reduce CO2 emissions. In such a context, traditional injectors for hydrocarbon fuels are currently being tailored to be used with hydrogen, or a single-hole/multi-hole cap mounted at the injector tip was used to obtain better mixing and air utilization. Nevertheless, the hydrogen injection can be accompanied by the formation of highly under-expanded jets and will significantly influence the downstream mixing process. Therefore, in order to achieve a better understanding on hydrogen-air mixture, this work aims to numerically investigate the influence of the nozzle geometry on the jet behaviors in the near nozzle region. The nozzle diameter ranges from 0.1 mm to 2.0 mm and the nozzle length is from 1mm to 2mm. The injection pressure ranges from 10 bar to 70 bar. As the boundary condition varied, differences in both the internal flow of different nozzle structures
Jiahui, Lang, Li, Yanfei, Xu, Lubing, Xiao, Ma, Shuai, Shijin
Technical Paper
Characterization of Dimethyl Ether (DME) Spray Using ECN Spray D Under Engine-Relevant Conditions2025-01-845704/01/2025
This research experimentally investigates the spray vaporization of high-pressure dimethyl ether (DME) using a single-hole research injector focusing on nominal operating conditions from the Engine Combustion Network (ECN). DME is a synthetic alternative to diesel fuel, offering both high reactivity and potential reductions in particulate emissions. Because DME only features half of the energy density of diesel fuel, a specifically designed fuel system with a high mass flow rate to meet the energy delivery requirements is needed. The unique physical properties of DME, including higher vapor pressure and lower viscosity, introduce challenges like cavitation and unique evaporation characteristics that deviate from typical diesel fuel. These features are likely to lead to differences in fuel mixing and combustion. This study aims to provide detailed experimental data on DME spray characteristics under engine-like conditions, helping the development of predictive CFD models for optimal
Yi, Junghwa, Wan, Kevin, Pickett, Lyle, Manin, Julien
Technical Paper
Operating the Tour Split-Cycle Engine on Hydrogen/Methane Fuel Blends to Achieve High Efficiency and Reduction of Both GHG and NOx Emissions2025-01-842204/01/2025
Decarbonized or low carbon fuels, such as hydrogen/methane blends, can be used in internal combustion engines to support ambitious greenhouse gas (GHG) emission reduction goals worldwide, including achieving carbon neutrality by 2045. However, as the volumetric concentration of H2 in these fuel blends surpasses 30%, the in-cylinder flame propagation and combustion rates increase significantly, causing an unacceptable increase in nitrogen oxides (NOx) emissions, which is known to have substantial negative effects on human health and the environment. This rise in engine-out NOx emissions is a major concern, limiting the use of H2 fuels as a means to reduce GHG emissions from both mobile and stationary power generation engines. In this study, an experimental investigation of the combustion performance and emissions characteristics of a 4th generation Tour split-cycle engine was undertaken while operating on 100% methane and various hydrogen/methane fuel blends (30%, 40%, and 50% by volume
Bhanage, Pratik, Cho, Kukwon, Anderson, Bradley, Kemmet, Ryan, Tour, Gilad, Atkinson, Chris, Tour, Hugo, Tour, Oded
Technical Paper
A DEM-FEM Coupled Analysis of Ultrasonic Shot Peening Dynamics and Surface Modification Parameters in Aluminum Alloys2025-01-823904/01/2025
The significant mechanical features of aluminum alloy, including cost-effectiveness, lightweight, durability, high reliability, and easy maintenance, have made it an essential component of the automobile industry. Automobile parts including fuel tanks, cylinder heads, intake manifolds, brake elements, and engine blocks are made of aluminum alloy. The primary causes of its engineering failure are fatigue and fracture. Aluminum alloys' fatigue resistance is frequently increased by surface strengthening methods like ultrasonic shot peening (USP). This article discusses the shot peening dynamics analysis and the influence of ultrasonic shot peening parameters on material surface modification using the DEM-FEM coupling method. Firstly, the projectile motion characteristics under different processes are simulated and analyzed by EDEM. The projectile dynamics characteristics are imported into Ansys software to realize DEM-FEM coupling analysis, and the surface modification characteristics of
Adeel, Muhammad, Azeem, Naqash, Xue, Hongqian, Hussain, Muzammil
Technical Paper
Research on Motor Harmonic Injection Control in Hybrid System to Suppress the Torsional Vibration2025-01-851504/01/2025
Based on the harmonic current injection method used to suppress the torsional vibration of the electric drive system, the selection of the phase and amplitude of the harmonic current based on vibration and noise has been explored in this paper. Through the adoption of the active harmonic current injection method, additional torque fluctuations are generated by actively injecting harmonic currents of specific amplitudes and phases, and closed-loop control is carried out to counteract the torque fluctuations of the motor body. The selection of the magnitude of the injected harmonic current is crucial and plays a vital role in the reduction of torque ripple. Incorrect harmonic currents may not achieve the optimal torque ripple suppression effect or even increase the motor torque ripple. Since the actively injected harmonic current is used to counteract the torque ripple caused by the magnetic flux linkage harmonics of the motor body, the target harmonic current command is very important
Jing, Junchao, Zhang, Junzhi, Liu, Yiqiang, Huang, Weishan, Dai, Zhengxing
Technical Paper
Numerical Investigation of Fuel Injection Strategies for Ammonia-Diesel Dual-Fuel Engine2025-01-836804/01/2025
This study numerically investigates ammonia-diesel dual fuel combustion in a heavy-duty engine. Detailed and reduced reaction mechanisms are validated against experimental data to develop injection timing maps aimed at maximizing indicated thermal efficiency (ITE) while mitigating environmental impacts using stochastic reactor model (SRM). The equivalence ratio, ammonia energy share (AES), injection timing, and engine load are varied to optimize combustion efficiency and minimize emissions. The results demonstrate that advancing injection timing reduces ITE due to heightened in-cylinder temperatures, resulting in increased heat losses through walls and exhaust gases. Maximum chemical efficiency is observed at an equivalence ratio near 0.9 but decreases thereafter, influenced by ammonia’s narrow flammability range. Emission analysis highlights significant reductions in Global Warming Potential (GWP) and Eutrophication Potential (EP) with higher AES, driven by decreased CO2 and nitrogen
Karenawar, Shivraj Anand, Yadav, Neeraj Kumar, Maurya, Rakesh Kumar
Technical Paper
Spray Characterization in a Constant Volume Chamber of Aluminum Oxide Nanoparticles-Diesel Blends2025-01-845504/01/2025
Aluminum oxide (Al₂O₃) nanoparticles are considered a promising fuel additive to enhance combustion efficiency, reduce emissions, and improve fuel economy. This study investigates the spray characteristics of diesel fuel blended with aluminum oxide nanoparticles in a constant volume chamber. The blends were prepared by dispersing Al₂O₃ nanoparticles in diesel at varying concentrations (25, 50, and 100 mg of aluminum oxide nanoparticles into 1 L of pure diesel, respectively) using a magnetic stirrer and ultrasonication to ensure stable suspensions. Spray characterization was conducted in a high-pressure and high-temperature constant volume chamber, simulating actual engine conditions. The ambient temperatures for this experiment were set from 800 to 1200 K, and the oxygen concentrations were set from 21% to 13%. The study focused on key spray parameters such as spray penetration length, spray angle, and spray area, analyzed using high-speed imaging and laser diffraction techniques
Ji, Huangchang, Zhao, Zhiyu
Technical Paper
Development of a 6.7L Direct Injection, Lean Burn H2 Spark Ignition Engine for Medium- and Heavy-Duty Commercial Vehicles2025-01-839304/01/2025
This work is part of a production-intent program at Cummins to develop a 6.7L direct injection (DI), lean burn H2 spark ignition (SI) engine for medium- and heavy-duty commercial vehicles that are intended to be compliant with global VII criteria pollutants emissions standards. The engine features a low-pressure DI fuel injection system, a tumble-based combustion system with a pent-roof combustion chamber, two-stage boosting system without EGR, and dual overhead cams (DOHC) with cam phasers. The paper focuses primarily on the performance system architecture development encompassing combustion system, air-handling system, and valve strategy. Comprehensive 3D-CFD guided design analysis has been conducted to define the tumble ports, injection spray pattern, and injection strategy to optimize charge homogeneity and turbulence kinetic energy (TKE). In addition, the boosting system architecture and the valve strategy have been thoroughly evaluated through 1-D system-level engine cycle
Liu, Lei, Zhang, Yu, Qin, Xiao, Hui, He, Min, Xu, Leggott, Paul
Technical Paper
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