Flow characteristics of spray impingement in PFI injection systems

The present paper addresses an experimental study of the dynamic exchanges between the impact of an intermittent spray and the liquid film formed over the target, based on detailed phase Doppler anemometry (PDA) measurements of droplet size, velocity and volume flux in the vicinity of the impact. The flow configuration is that of a pulsed injector spraying gasoline onto a flat disc to simulate the port fuel injection (PFI) of an internal combustion engine operating at cold-start conditions. The measurements evidence that the outcome of impact cannot be accurately predicted based on the characteristics of the free spray, but requires precise knowledge of the flow structure, induced by the target. The implications for spray–wall interaction modelling are then discussed based on the application of conservation equations to the mass, momentum and energy exchanged between the impinging droplets and the liquid film. The results show that the liquid film starts to form in the vicinity of the stagnation region at early stages of injection and a non-negligible proportion of droplets impinging at outer regions splash after interaction with the film. Film disruption is mainly driven by the intermittent axial momentum of impinging droplets, which enhances the vertical oscillations. The radial momentum imparted to the liquid film at the stagnation region is fed back onto secondary droplets emerging later during the injection cycle at outwards locations, where momentum of impacting droplets is much smaller. As a consequence, although the number of splashed droplets is enhanced by normal momentum, their size and ejection velocity depends more on the radial spread induced onto the liquid film and, hence, on the radial momentum at impact. The analysis further shows that existing spray–wall interaction models can be improved if the dynamic exchanges between the impacting spray and the liquid film are accounted.     

Assessment of a 3D CFD model for GDI spray impact against wall through experiments based on different optical techniques

Performance of internal combustion engines is well known being greatly affected by the air-fuel mixture formation process. In spark ignition engines, in particular, the gasoline direct injection (GDI) technology is currently preferred, as it allows obtaining the desired air-to-fuel ratio distribution at each regime of operation, either by creating stoichiometric mixtures under high power demands, or through charge stratification around the spark plug at intermediate or lower loads. The impact of the gasoline spray on the piston or cylinder walls is a key factor, especially under the so-called wall-guided mixture formation mode. The impact causes droplets rebound and/or the deposition of a liquid film (wallfilm). After being rebounded, droplets undergo what is called secondary atomization. The wallfilm, on the other hand, may remain of no negligible size and evaporate slowly, leading to increased unburned hydrocarbons and particulate matter emissions.Optimization of the heterogeneous mixture behavior in GDI engines is fundamental for guaranteeing high energetic and environmental performance over the whole working map. Computational fluid dynamics (CFD) can be useful in this perspective to effect proper choices of control strategies. Assessment of predictive engine models, able to describe the complex phenomena underlying energy conversion in modern engines, is therefore mandatory to the scope.In the present paper, a basic study is performed on gasoline sprays issuing from high pressure injectors under controlled conditions: the experimental characterization of multi-hole and single-hole GDI sprays in their impact over a plate is carried out with the aim of creating a set of data to be used for the validation of a properly developed simulation model. The multi-hole spray allows accounting for the jet-to-jet interaction and represents a condition closer to the actual gasoline supply mode in present GDI engines. The single-hole injector configuration is instead preferred for a more detailed study, as it allows capturing effects related to the role that diverse parameters characterizing the liquid droplet dynamics play during and after their impingement on heated solid surfaces. The CFD model is conceived with the scope of its future application within numerical calculations of entire engine working cycles. A highly portable free spray sub-model allows correctly reproducing the injection dynamics under different conditions in a confined vessel, while the spray-wall impingement sub-model is shown being able to highlight to an acceptable extent the gasoline splashing and deposition phenomena.     

Experimental and Numerical Simulations of Spray Impingement and Combustion Characteristics in Gasoline Direct Injection Engines under Variable Driving Conditions

Gasoline direct injection (GDI) increases engine power output and reduces emissions. In GDI engines, increasing injection pressure improves atomization, which increases thermal efficiency at the cost of wall wetting. When wall wetting occurs, both soot emissions and fuel consumption increase. Wall wetting in GDI engines under cold driving conditions has rarely been considered. In this study, experimental data characterizing droplet splashing/spreading phenomena were collected to inform numerical simulations of combustion characteristics and wall wetting subject to variable driving conditions and excess air ratio, λ. Fully 3D and unsteady numerical simulations were carried out to predict flow-field, combustion, and spray-impingement characteristics. To simulate a GDI engine, a spray-impingement model was developed using both experimental data and previous modeling efforts. The excess air ratio and driving-condition temperature were the variable parameters considered in this study. When decreasing λ from 1.0 to 0.7 by increasing the fuel-injection rate (fuel rich), the cylinder pressure increases to 61 % of the pressure when λ=1.0. Because of increasing the fuel-injection rate, the increased momentum in the fuel spray increases both wall wetting and soot generation. At low driving-condition temperatures, the cylinder pressure was up to 63 % less than that under warm conditions, but with increased soot generation. Simulations revealed a correlation between wall wetting and the soot emissions. Soot generation was most sensitive to changes in wall wetting.     

Heat flux characteristics of spray wall impingement with ethanol,butanol, iso-octane,gasoline and E10 fuels

Future fuel stocks for spark-ignition engines are expected to include a significant portion of bio-derived components with quite different chemical and physical properties to those of liquid hydrocarbons. State-of-the-art high-pressure multi-hole injectors for latest design direct-injection spark-ignition engines offer some great benefits in terms of fuel atomisation, as well as flexibility in in-cylinder fuel targeting by selection of the exact number and angle of the nozzle’s holes. However, in order to maximise such benefits for future spark-ignition engines and minimise any deteriorating effects with regards to exhaust emissions, it is important to avoid liquid fuel impingement onto the cylinder walls and take into consideration various types of biofuels. This paper presents results from the use of heat flux sensors to characterise the locations and levels of liquid fuel impingement onto the engine’s liner walls when injected from a centrally located multi-hole injector with an asymmetric pattern of spray plumes. Ethanol, butanol, iso-octane, gasoline and a blend of 10% ethanol with 90% gasoline (E10) were tested and compared. The tests were performed in the cylinder of a direct-injection spark-ignition engine at static conditions (i.e. quiescent chamber at 1.0 bar) and motoring conditions (at full load with inlet plenum pressure of 1.0 bar) with different engine temperatures in order to decouple competing effects. The collected data were analysed to extract time-resolved signals, as well as mean and standard deviation levels of peak heat flux. The results were interpreted with reference to in-cylinder spray formation characteristics, as well as fuel evaporation rates obtained by modelling. In addition, high-speed images of single droplets of fuel impinging onto the array of the heat flux sensor were acquired with simultaneous sampling of the heat flux signal in an attempt to provide further interpretation. The single droplet tests showed ability of the signals to quantify droplet mass impinged on the sensor. Analysis of the peak heat flux at static engine conditions quantified values of fuel temperature at impingement in agreement with the wet bulb temperatures predicted by the droplet evaporation model. Comparison of the static and motoring engine heat flux signals around the bore showed the effect of the intake flow on the spray’s pattern at impingement and demonstrated fuel presence on the liner that survived at exhaust valve open timing. The general behaviour was different for the alcohols to that of the hydrocarbons, with ethanol exhibiting the effect of its high latent heat on the signals and butanol exhibiting effects related to poor atomization and slow evaporation.     

Experimental study of the flow regimes resulting from the impact of an intermittent gasoline spray

The present paper reports a complete set of measurements made with a two-component phase Doppler anemometer of the two-phase flow generated at the impact of a transient gasoline spray onto a flat surface. The spray is generated by a pintle injector and the fuel used was gasoline. The measurements of droplet size–velocity were processed to provide time fluxes of number, mass, normal momentum, and energy of the poly-dispersion of droplets ejected at impact, and analyzed based on predictive tools available in the literature. The results show that splash is the dominant mechanism by which secondary droplets are ejected from the surface, either in the stagnation region or in the core region of the spray. In the stagnation region, a large fraction of each incident droplet adheres to the surface and the axial incident momentum contributes with a larger parcel than tangential momentum. As a result, the normal velocity of ejected droplets is much smaller than that of the original incident droplets, while tangential velocity is enhanced. The region near the stagnation point is immediately flooded upon impact of the leading front of the spray, forming a liquid film that is forced to move radially outwards as droplets continue to impinge during the steady period. Spray/wall interaction in the core region thus occurs in the presence of a moving thin liquid film, which enhances transfer of tangential momentum. As a result, film spreading and dynamics as a result of impingement forces are crucial to accurate model spray/wall interaction. The outer region of the spray is dominated by the vortical structure induced by shear forces, which entrains small responsive secondary droplets to re-impinge. Furthermore, prediction of the outcome of spray impact requires a precise knowledge of the two-phase flow in the presence of the target.     

Heat transfer during spray/wall interaction with urea water solution: An experimental parameter study

Understanding the spray/wall interaction of urea water solution in automotive selective catalytic reduction (SCR) of NO_x is crucial for robust system performance. The spray impingement of aqueous urea solution on walls at temperatures from 120 to 420 ^∘C is investigated experimentally by using high-speed and infrared thermographic recordings. To evaluate wall wetting and spatially resolved heat transfer, the evaporated mass fraction during spray/wall interaction is described quantitatively through an energy balance. Heat transfer at different wall temperatures shows typical non-linear characteristics analogous to those known from pool boiling experiments (Nukiyama boiling curve). The performed extensive parameter study on the influence of injected fluid, injection duration, injection pressure, wall thickness and wall material reveal significant shifts of the boiling regime boundaries and the related characteristic temperatures, e.g. temperature of critical heat flux and Leidenfrost temperature. These basic findings help to understand spray/wall interaction phenomena and give hints for improvement of automotive SCR system design by taking into account the change of the injection system parameters and the choice of advantageous wall material properties.     

A laser induced fluorescence technique for quantifying transient liquid fuel films utilising total internal reflection

This paper describes the development of a laser induced fluorescence (LIF) technique to quantify the thickness and spatial distribution of transient liquid fuel films formed as a result of spray–wall interaction. The LIF technique relies on the principle that upon excitation by laser radiation the intensity of the fluorescent signal from a tracer like 3-pentanone is proportional to the film thickness. A binary solution of 10% (v/v) of 3-pentanone in iso-octane is used as a test fuel with a Nd:YAG laser as the excitation light source (utilising the fourth harmonic at wavelength 266 nm) and an intensified CCD camera is used to record the results as fluorescent images. The propagation of the excitation laser beam through the optical piston is carefully controlled by total internal reflection so that only the fuel film is excited and not the airborne droplets above the film, which had been previously shown to induce significant error. Other known sources of error are also carefully minimised. Calibrated temporally resolved benchmark results of a transient spray from a gasoline direct injector impinging on a flat quartz crown under atmospheric conditions are presented, with observations and discussion of the transient development of the fuel film. The calibrated measurements are consistent with previous studies of this event and demonstrate the applicability of the technique particularly for appraisal of CFD predictions. The potential utilisation of the technique under typical elevated ambient conditions is commented upon.     

Heat transfer between a heated plate and an impinging transient diesel spray

An experimental investigation was performed to determine the heat-transfer distribution in the vicinity of a transient diesel spray impinging on a heated flat plate. The spray prior to impingement was characterised in terms of simultaneous droplet sizes and velocities by phase-Doppler anemometry while during its impingement on the plate, which was heated at temperatures between 150–205°C, the instantaneous surface temperature and associated rates of wall heat transfer were monitored by fast response thermocouples. The parameters examined in this work included the distance between the nozzle and the wall surface, the radial distance from the impingement point, the injection frequency, the injected volume and the pre-impingement wall temperature. The results showed that the wall heat transfer rates are dependent on the spray characteristics prior to impingement; the higher the velocity of arrival of the droplet is, the higher the heat transfer. A correlation was thus developed for the instantaneous and spatially-resolved spray/wall heat transfer based on experimentally-determined Nusselt, Reynolds, Prandtl and Weber numbers over a wide range of test conditions.     

Air flow and pressure inside a pressure-swirl spray and their effects on spray development

Air flow and pressure inside a pressure-swirl spray for direct injection (DI) gasoline engines and their effects on spray development have been analyzed at different injector operating conditions. A simulation tool was utilized and the static air pressure at the centerline of the spray was measured to investigate the static pressure and flow structure inside the swirl spray. To investigate the effect of static air pressure on swirl spray development, a liquid film model was applied and the Mie-scattered images were captured. The simulation and experiment showed that recirculation vortex and air pressure drop inside the swirl spray were observable and the air pressure drop was greater at high injection pressure. At high fuel temperature, the air pressure at the nozzle exit showed higher value compared to the atmospheric pressure and then continuously decreased up to few millimeters distance from the nozzle exit. The pressure drop at high fuel temperatures was more than that of atmospheric temperature. This reduced air pressure was recovered to the atmospheric pressure at further downstream. The results from the liquid film model and macroscopic spray images showed that the air pressure started to affect the liquid film trajectory about 3 mm from the nozzle exit and this effect was sustained until the air pressure recovered to the atmospheric pressure. However, the entrained air motion and droplet size have more significant influence on the spray development after the most of the liquid sheet is broken-up and the spray loses its initial momentum.     

Effects of turbulence enhancement on combustion process using a double injection strategy in direct-injection spark-ignition (DISI) gasoline engines

Direct-injection spark-ignition (DISI) gasoline engines have been spotlighted due to their high thermal efficiency. Increase in the compression ratio that result from the heat absorption effect of fuel vaporization induces higher thermal efficiency than found in port fuel injection (PFI) engines. Since fuel is injected at the cylinder directly, various fuel injection strategies can be used. In this study, turbulent intensity was improved by a double injection strategy while maintaining mixture homogeneity. To analyze the turbulence enhancement effects using the double injection strategy, a side fuel injected, homogeneous-charge-type DISI gasoline engine with a multi-hole-type injector was utilized. The spray model was evaluated using experimental data for various injection pressures and the combustion model was evaluated for varied ignition timing. First and second injection timing was swept by 20 degree interval. The turbulent kinetic energy and mixture inhomogeneity index were mapped. First injection at the middle of the intake stroke and second injection early in the compression stroke showed improved turbulent characteristics that did not significantly decrease with mixture homogeneity. A double injection case that showed improved turbulent intensity while maintaining an adequate level of mixture homogeneity and another double injection case that showed significantly improved turbulent intensity with a remarkable decrease in mixture homogeneity were considered for combustion simulation. We found that the improved turbulent intensity increased the flame propagation speed. Also, the mixture homogeneity affected the pressure rise rate.     

A comparison between spray cooling and film flow cooling during the rewetting of a hot surface

The paper is dealing with a research carried out at the Institute of Thermal-Fluid Dynamics to investigate the rewetting of a hot surface. The rewetting of the hot surface by spray cooling has been analyzed in previous works. After the droplet impingement, the liquid film falls along the surface, and rewetting by falling film takes place. The experiment was characterized by a 1-dimensional liquid spray, i.e., drops having a uniform, constant diameter, impinging on the heated surface. The cooling rate of the hot surface has been detected as a function of wall temperature, drop diameter and velocity, and impact point of the spray. The working feature of the spray is based on the varicose rupture of the liquid jet: imposing a periodic (symmetrical) perturbation with appropriate amplitude and frequency on the jet surface, the flow is “constrained” to break soon after leaving the nozzle, eventually obtaining constant diameter drops, depending on the nozzle diameter and liquid velocity. In this paper, previous results with spray cooling are compared with experimental runs in which the spray injection is replaced with a falling film all along the test section. The rewetting velocity has been calculated from the response of the thermocouples placed on the heated wall and using a digital image system based on the video image registered during the runs.     

The coupling influence of airflow and temperature on the wall-wetted fuel film distribution

The coupling influence of airflow and temperature on the two-dimensional distribution of the film resulted from fuel spray impinging on a horizontal flat wall was studied with experiments. The horizontal airflow direction was perpendicular to the vertical axis of the injection spray. The results show that, as air velocity increases, the film shape turns from a circle to an oblong. As wall temperature increases, the film area shrinks. Film thickness decreases as wall temperature or air velocity increases. The boiling point of the fuel is an important temperature to affect the film area and the film thickness. Film center moves more far away in the downstream direction as air velocity increases. For a certain air velocity, film center moves less far away as wall temperature increases.     

A study on the fuel injection and atomization characteristics of soybean oil methyl ester (SME)

The spray atomization characteristics of an undiluted biodiesel fuel (soybean oil methyl ester, SME) in a diesel engine were investigated and compared with that of diesel fuel (ultra low sulfur diesel, ULSD). The experimental results were compared with numerical results predicted by the KIVA-3V code. The spray characteristics of the spray tip penetration, spray area, spray centroid and injection delay were analyzed using images obtained from a visualization system. The Sauter mean diameter (SMD) was analyzed using a droplet analyzer system to investigate the atomization characteristics.It was found that the peak injection rate increases and advances when the injection pressure increases due to the increase of the initial injection momentum. The injection rate of the SME, which has a higher density than diesel fuel, is higher than that of diesel fuel despite its low injection velocity. The high ambient pressure induces the shortening of spray tip penetration of the SME. Moreover, the predicted spray tip penetration pattern is similar to the pattern observed experimentally. The SMD of the SME decreases along the axial distance. The predicted local and overall SMD distribution patterns of diesel and SME fuels illustrate similar tendencies when compared with the experimental droplet size distribution patterns.     

Spray impact onto flat and rigid walls: Empirical characterization and modelling

An experimental study of spray impact onto horizontal flat and rigid surfaces is presented and used as input data for a new empirical model. A phase Doppler instrument has been used to measure drop size and two components of velocity directly above the target. The average film thickness formed due to spray impact has been measured using a high-speed CCD camera. The spray–wall interaction has been characterized in terms of correlations for the velocity and trajectory of secondary droplets and the mass and number ratio of the secondary spray. The novel aspect of the model is that the correlations are based on mean statistics over many events and not on the outcome of single drop impact experiments. Furthermore a rather large range of oblique impact angles have been studied and incorporated into the empirical models as an influencing factor.     

Study of mass and momentum transfer in diesel sprays based on X-ray mass distribution measurements and on a theoretical derivation

In this paper, a research aimed at quantifying mass and momentum transfer in the near-nozzle field of diesel sprays injected into stagnant ambient air is reported. The study combines X-ray measurements for two different nozzles and axial positions, which provide mass distributions in the spray, with a theoretical model based on momentum flux conservation, which was previously validated. This investigation has allowed the validation of Gaussian profiles for local fuel concentration and velocity near the nozzle exit, as well as the determination of Schmidt number at realistic diesel spray conditions. This information could be very useful for those who are interested in spray modeling, especially at high-pressure injection conditions.     

High-speed imaging for direct-injection gasoline engine research and development

In recent years, new laser and camera technology have enabled the development of high-speed imaging diagnostics for measurements at frame rates commensurate with the time scales of turbulent mixing, combustion, and emission formation in internal combustion engines. The ability to study the evolution of in-cylinder flow, fuel/air mixing, ignition, and combustion within individual cycles and for many consecutive cycles provides new insights into the physics and chemistry of internal combustion engine performance. Data for model development and device development are obtained with unprecedented access to the identification of random events such as cycle to cycle variation and ignition instabilities. This paper summarizes high-speed diagnostics developments with a focus on application to spark-ignition direct-injection gasoline engines. A range of optical techniques is described along with examples of applications in research and near-production engines. Measurements of in-cylinder velocities were conducted with particle image velocimetry. The spray evolution was followed with Mie scattering. Quantitative fuel distributions were recorded with laser-induced fluorescence. Fuel impingement on surfaces was quantified with refractive index matching. Combined velocity and fuel measurements were used to study ignition reliability. Chemiluminescence techniques provided insights into the evolution of the spark plasma as well as the growing flame kernel. Chemiluminescence and black body radiation imaging yielded insights into the formation and oxidation of soot.     

Stability evaluation of an accurately controllable multiple injection system

Aiming to further improve diesel engine fuel efficiency and exhaust emissions, we conducted tests of a newly devised rapidly operating secondary actuator that provides controllable multiple injection. Up to six shots per cycle were implemented under high-pressure injection. A high-speed camera and a flow rate metering system were used to obtain quantitative data regarding diesel spray and fuel flow dynamics. The advantages of the applied technique are very stable phasing, dwelling, duration, and dosing of multiple injection shots proved from data analysis.Abbreviations ARB Arbitrary waveform generator - CRIS Common rail injection system - DC Direct current - ECU Electronic control unit - EDU Electronic injection driving unit - fps Frames per second - HP High-pressure - LDA Laser Doppler anemometer (velocimeter) - ROSA Rapidly operating secondary actuator - RPM Revolutions per minute - SOI Start of injection - TDC Top dead center - TTL Transistor–transistor logic     

A novel transient wall heat transfer approach for the start-up of SI engines with gasoline direct injection

The introduction of CO₂-reduction technologies like Start–Stop or the Hybrid-Powertrain and the worldwide stringent emission legislation require a detailed optimization of the engine start-up. The combustion concept development as well as the calibration of the engine control unit makes an explicit thermodynamic analysis of the combustion process during the start-up necessary. Initially, the well-known thermodynamic analysis of in-cylinder pressure at stationary condition was transmitted to the highly non-stationary engine start-up. For this running mode of the engine the current models for calculation of the transient wall heat fluxes were found to be misleading. With a fraction of nearly 45% of the burned fuel energy, the wall heat is very important for the calculation of energy balance and for the combustion process analysis. Based on the measurements of transient wall heat transfer densities during the start-up presented in a former work (Lejsek and Kulzer in Investigations on the transient wall heat transfer at start-up for SI engines with gasoline direct injection. SAE Paper), the paper describes the development of adaptations to the known correlations by Woschni (MTZ 31:491, 1970), Hohenberg (Experimentelle Erfassung der Wandwärme von Kolbenmotoren. TU Graz, Habil., 1980) and Bargende (Ein Gleichungsansatz zur Berechnung der instationären Wandwärmeverluste im Hochdruckteil von Ottomotoren. TH Darmstadt, PhD-Thesis, 1991) for the application during engine start-up. To demonstrate the high accuracy of the model, the results of the cyclic resolved thermodynamic analysis using the presented novel approaches were compared with the results of the measurements. It is shown, that the novel heat flux models for the engine start-up process gives a cyclic resolved thermodynamic analysis to optimize the engine start-up pretty efficient.     

Atomization and spray characteristics of bioethanol and bioethanol blended gasoline fuel injected through a direct injection gasoline injector

The focus of this study was to investigate the spray characteristics and atomization performance of gasoline fuel (G100), bioethanol fuel (E100), and bioethanol blended gasoline fuel (E85) in a direct injection gasoline injector in a gasoline engine. The overall spray and atomization characteristics such as an axial spray tip penetration, spray width, and overall SMD were measured experimentally and predicted by using KIVA-3V code.The development process and the appearance timing of the vortices in the test fuels were very similar. In addition, the numerical results accurately described the experimentally observed spray development pattern and shape, the beginning position of the vortex, and the spray breakup on the spray surface. Moreover, the increased injection pressure induced the occurrence of a clear circular shape in the downstream spray and a uniform mixture between the injected spray droplets and ambient air. The axial spray tip penetrations of the test fuels were similar, while the spray width and spray cone angle of E100 were slightly larger than the other fuels. In terms of atomization performance, the E100 fuel among the tested fuels had the largest droplet size because E100 has a high kinematic viscosity and surface tension.     

Experimental and numerical analysis of high pressure diesel spray–wall interaction

The interaction between impacting and splashed droplets and air motion plays a fundamental role on the mixture formation process, which is a crucial aspect for the correct operation of modern DI Diesel engines as it greatly influences the combustion process and the exhaust emissions. A complete understanding of spray impingement is quite complex. A mixed numerical–experimental approach is proposed in this paper.