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In stationary natural gas engines, lean-burn combustion offers higher engine efficiencies with simultaneous compliance with emission regulations. A prominent problem that one encounters with lean operation is cyclic variations. Advanced ignition systems offer a potential solution as they suppress cyclic variations in addition to extending the lean ignition limit. In this article, the performance of three ignition systems-conventional spark ignition (SI), single-point laser ignition (LI), and prechamber equipped laser ignition (PCLI)-in a single-cylinder natural gas engine is presented. First, a thorough discussion regarding the efficacy of several metrics, besides coefficient of variation of indicated mean effective pressure (COV_IMEP), in representing combustion instability is presented. This is followed by a discussion about the performance of the three ignition systems at a single operational condition, that is, same excess air ratio (λ) and ignition timing (IT). Next, these metrics are compared at the most optimal operational points for each ignition system, that is, at points where λ and IT are optimized to achieve highest efficiency. From these observations, it is noted that PCLI achieves the highest increase in engine efficiency, Δη = 2.1% points, and outperforms the other two methods of ignition. A closer look reveals that the coefficient of variation in ignition delay (COV_ID) was negligible, whereas that in coefficient of variation in combustion duration (COV_CD) was significantly lower by 2.2% points. However, the metrics COV_ID and COV_CD are not well correlated with COV_IMEP.

Numerous studies have demonstrated that exhaust gas recirculation (EGR) can attenuate knock propensity in spark ignition (SI) engines at naturally aspirated or lightly boosted conditions. In this study, we investigate the role of cooled EGR under higher load conditions with multiple fuel compositions, where highly retarded combustion phasing typical of modern SI engines was used. It was found that under these conditions, EGR attenuation of knock is greatly reduced, where EGR doesn’t allow significant combustion phasing advance as it does under lighter load conditions. Detailed combustion analysis shows that when EGR is added, the polytropic coefficient increases causing the compressive pressure and temperature to increase. At sufficiently highly boosted conditions, the increase in polytropic coefficient and additional trapped mass from EGR can sufficiently reduce fuel ignition delay to overcome knock attenuation effects. Kinetic modeling demonstrates that the effectiveness of EGR to mitigate knock is highly dependent on the pressure-temperature condition. Experiments at 2000 rpm have confirmed reduced fuel ignition delay under highly boosted conditions relevant to modern downsized boosted SI engines, where in-cylinder pressure is higher and the temperature is cooler. At these conditions, charge reactivity increases compared to naturally aspirated conditions, and attenuation of knock by EGR is reduced.

This paper offers new insights into a partial fuel stratification (PFS) combustion strategy that has proven to be effective at stabilizing overall lean combustion in direct injection spark ignition engines. To this aim, high spatial and temporal resolution optical diagnostics were applied in an optically accessible engine working in PFS mode for two fuels and two different durations of pilot injection at the time of spark: 210 µs and 330 µs for E30 (gasoline blended with ethanol by 30% volume fraction) and gasoline, respectively. In both conditions, early injections during the intake stroke were used to generate a well-mixed lean background. The results were compared to rich, stoichiometric and lean well-mixed combustion with different spark timings. In the PFS combustion process, it was possible to detect a non-spherical and highly wrinkled blue flame, coupled with yellow diffusive flames due to the combustion of rich zones near the spark plug. The initial flame spread for both PFS cases was faster compared to any of the well-mixed cases (lean, stoichiometric and rich), suggesting that the flame propagation for PFS is enhanced by both enrichment and enhanced local turbulence caused by the pilot injection. Different spray evolutions for the two pilot injection durations were found to strongly influence the flame kernel inception and propagation. PFS with pilot durations of 210 µs and 330 µs showed some differences in terms of shapes of the flame front and in terms of extension of diffusive flames. Yet, both cases were highly repeatable.

The elevated global attention around GHG emissions in recent years have driven regulatory bodies to the creation of ever-increasing standards. Research suggests that combining biofuels, such as ethanol, with advanced combustion techniques, such as pre-chamber ignition systems, offers a promising path for the development of internal combustion engines for light vehicles among these tightening standards. For pre-chamber systems, a separate cavity is employed where the combustion is initiated before the partially burned gases are ejected through connecting orifices into the main combustion chamber. These gases carry high levels of kinetic, thermal, and chemical energy, increasing turbulence in the main chamber and reducing combustion duration and ignition delay. Aiming to analyze the influence of pre-chamber material, internal volume, and orifice configuration over combustion characteristics, two values of internal volume and two configurations of orifices were combined into four distinct pre-chamber geometries. These were machined in both stainless steel l304 and a copper–chromium–zircon (CuCr1Zr) alloy, totaling eight articles. Utilizing an AVL 5495 single-cylinder research engine (SCRE) operating at 14:1 compression ratio and E96 fuel, the pre-chambers were, then, installed and tested for two operating conditions of engine speed and load. The clearance volume was adjusted as to compensate for the added volume of the pre-chamber. An analysis of the results indicated reductions of NO X emissions of up to 73% in addition to improvements in fuel conversion efficiencies of up to 2%. Furthermore, reductions of up to 15% in combustion duration were observed, reducing tendencies to knocking. This improvement also allows for future increases in compression ratios, thereby, enhancing fuel conversion efficiency. The obtained results also indicate that the optimal pre-chamber design is highly dependent in the engine’s operation conditions.

Particulate matter (PM) indices—those linking PM emissions from gasoline engines to the composition and properties of the fuel—have been a topic of significant study over the last decade. It has long been known that fuel composition has a significant impact on particulate emissions from gasoline engines. Since gasoline direct injection (GDI) engines have become the market-leading technology, this has become more significant because the evaporative behavior of fuel increases in importance. Several PM indices have been developed to provide metrics describing this behavior and correlating PM emissions. In this article, 16 different PM indices are identified and collected—to the authors’ knowledge, all of the indices are available at the time of writing. The indices are reviewed and discussed in the context of the information required to calculate them, as well as their utility. The authors believe that there is a need for indices that provide both a detailed and robust correlation, as well as those that are less sophisticated yet sufficient for specific use cases. Future research is suggested to guide the technical community toward improvements in the indices’ methods and equations for both high and low fidelity and high and low time investment.

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio, and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. A high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the first to two papers describing the development of a combustion system combining lean-stratified combustion with Miller cycle for downsized boosted applications. The work was completed under a multi-year US DOE project. The goal was to define a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. Some of the unique challenges in synergistically combining the two concepts are highlighted in this paper. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute (lean plus EGR) mixtures when properly matched to fuel spray characteristics, a multiple-injection strategy, and a high-energy ignition system. Other challenges specific to meeting exhaust emissions requirements with a high-efficiency engine are also explored in this study. In this Part 1 of the paper, the single-cylinder combustion system design, analysis, and testing is described. Multi-cylinder engine system design, analysis and development is described in Part 2 of the paper [1].

Ducted fuel injection (DFI) has been proposed as a strategy to enhance the fuel/charge gas mixing within the combustion chamber of a direct-injection mixing-controlled compression ignition engine. The concept involves injecting each fuel spray through a small tube within the combustion chamber to facilitate the creation of a leaner mixture in the autoignition zone, relative to a conventional free-spray configuration (i.e., a fuel spray that is not surrounded by a duct). While previous experiments demonstrated that DFI lowers both soot incandescence and soot mass in a constant-volume combustion vessel with a single-component normal-alkane fuel (n-dodecane), this study provides the first evidence that the technology provides similar benefits in an engine application using a commercial diesel fuel containing ~30 wt% aromatics. The present study investigates the effects on engine-out emissions and efficiency with a two-orifice injector tip for charge gas mixtures containing 16 and 21 mol% oxygen. The result is that DFI is confirmed to be effective at curtailing engine-out soot emissions. It also breaks the tradeoff between emissions of soot and nitrogen oxides (NOₓ) by simultaneously attenuating soot and NOₓ with increasing dilution.

Although rare-earth magnesium (Mg-RE) alloys are widely used in various industries, they show much poorer machinability for shaping into desired dimensions than conventional magnesium ones. The most critical issues associated with cutting Mg-RE alloys are high risk of chip ignition and short tool life dominating the chip removal process. The present paper aims to address the tool performances on the machinability of Mg-RE alloys under dry cutting. Four types of tools covering uncoated and diamond-coated ones were examined, and a special focus was devoted to explore the effects of various tool parameters on the milling responses of Mg-RE alloys as well as the underlying wear mechanisms. The experiments reveal that the cutting tools with larger rake, clearance, and helix angles can achieve high-quality milling of Mg-RE alloys at controllable cutting temperatures. The cutting parameters can be maintained at a certain level, such as the cutting speed of 120–240 m/min and the feed per tooth of 0.1–0.2 mm/z, to meet the requirements of safe milling of Mg-RE alloys without ignition risk.

Modern spark ignition internal combustion engines rely on fast combustion rates and high dilution to achieve high brake thermal efficiencies. To accomplish this, new engine designs have moved towards increased tumble ratios and stroke-to-bore ratios. Increased tumble ratios correlate positively with increases in turbulent kinetic energy and improved fuel and residual gas mixing, all of which favor faster and more efficient combustion. Longer stroke-to-bore ratios allow higher geometric compression ratios and use of late intake valve closing to control peak compression pressures and temperatures. The addition of dilution to improve efficiency is limited by the resulting increase in combustion instabilities manifested by cycle-to-cycle variability. A number of effects - preferential diffusion, turbulence-combustion interactions, stochastic flow patterns, laminar-turbulent flame kernel transitions, and relative length and velocity scales between flame and turbulence - are believed to be responsible for the increase in cycle-to-cycle variations, where their contributions are likely interlinked. Several studies have shown the influence of stochastic flow characteristics on the nature of combustion instabilities, such as velocity patterns on flame kernel formation and cycle-to-cycle variations in residual gas. However, few have focused on the specific effects of fuel properties. The objective of this work is to contrast the effects of dilution on propane stoichiometric combustion against gasoline. Dilution tolerance experiments were conducted in a purpose-built high stroke-to-bore ratio single cylinder engine with both gasoline and LPG. Three-dimensional full cycle computational fluid dynamics (CFD) simulations employing a level-set combustion approach and Reynolds averaged Navier-Stokes (RANS) turbulence modeling was used to qualitatively assess the changes in length and velocity scales for turbulence and the flame. The experimental results showed that LPG can tolerate higher exhaust gas recirculation (EGR) dilution under a variety of conditions. Analysis of CFD simulations showed that propane flames are likely less sensitive to influences from the flow field due to less thickening of the flame and higher effective flame speeds.

This article describes the results of a response surface model (RSM)-based numerical optimization campaign for spray-guided spark assistance at cold operations in a heavy-duty gasoline compression ignition (GCI) engine. On the basis of an earlier work on spark-assisted GCI cold combustion, a space-filling design of experiments (DoE) method was first undertaken to investigate a multitude of hardware design variables and engine operating parameters. The main design variables included the number of injector nozzles, fuel split quantities and injection timings, and spark timing. The objective variables were engine combustion efficiency (ŋc), maximum pressure rise rate (MPRR), and engine-out nitrogen oxide (NOx) emissions. A total of 150 design candidates were automatically generated using the Sobol sequence method provided by the commercial software package, CAESES. Then, closed-cycle computational fluid dynamic (CFD) spark-assisted GCI simulations under cold idling operations were performed. The outcomes from the CFD-DoE design campaign were utilized to construct high-fidelity RSMs that allowed for further design optimization of the spark plug- and fuel injector-related design variables, along with fuel injection strategy parameters. A merit function with respect to objective variables was formulated with an appropriate weight assignment on each objective variable. Finally, the best design candidate was identified from the RSM-based optimization process and further validated in the CFD analysis. The best design candidate showed the potential to significantly improve combustion efficiency (ŋc > 90%) over the baseline at cold idle while satisfying MPRR and NOx emissions constraints (MPRR < 5 bar/CAD and NOx < 4.5 g/kWh).