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Annual Progress Report for the Advanced Combustion Engine Research and Development (R&D) subprogram supporting the mission of the Vehicle Technologies Program by removing the critical technical barriers to commercialization of advanced internal combustion engines (ICEs) for passenger and commercial vehicles that meet future federal emissions regulations.
The Wave Disk Engine (WDE) is an innovative prime mover that works on the cutting edge principles of unsteady flow and combustion, and takes advantage of shock waves reducing mechanical parts in the energy conversion process. Currently the main devices to convert chemical energy into motion are the Gas Turbine, the Otto Engine (Gasoline), and Diesel Engine. All three devices use moving mechanical parts to transmit work internally for cycle completion. Such mechanical parts add inertia, weight, and cost to an engine and cause frictional losses reducing efficiency. The WDE is a device that uses principles of both: of internal combustion engines for heat addition, and gas turbine for extracting mechanical energy. It references the Humphrey cycle that is more efficient than the Otto, Brayton, or Diesel cycle. For work extraction, the WDE uses turbomachinery gas-expansion, which is known as a most efficient mechanical way of energy conversion. This is combined with constant volume combustion, which is known as a most efficient way of burning combustible (pressure gain combustion). The combination of high efficiency principles results in a design that has a potential beyond the current state-of-the-art efficiencies. The WDE uses shock waves for generating compression of ingested air or mixture, and confined combustion for generating effective heat release in a device that is relatively simple and cost-effective.
Methane (CH 4 ) reforming was carried out in an internal combustion engine (an “engine reformer”). We successfully produced syngas from the partial oxidation of natural gas in the cylinder of a diesel engine that was reconfigured to perform spark ignition. Performing the reaction in an engine cylinder allows some of the exothermicity to be captured as useful work. Intake conditions of 110 kPa and up to 480 °C allowed low cycle‐to‐cycle variability ( COV nimep < 20 %) at methane‐air equivalence ratios ( ϕ M ) of 2.0, producing syngas with an H 2 ‐to‐CO ratio of 1.4. Spark ignition timing was varied between 45–30° before top‐dead‐center (BTDC) piston position, showing significant improvement with delayed timing. Hydrogen (H 2 ) and ethane (C 2 H 6 ) were added to simulate recycle from a downstream synthesis reactor and realistic natural gas compositions, respectively. Adding these gases yielded a stable combustion up to hydrocarbon‐air equivalence ratios ( ϕ HC ) of 2.8 with COV nimep < 5 %. Ethane concentrations (with respect to methane) of up to 0.2 L/L (20 vol%) (with and without H 2 ) produced robust and stable combustions, demonstrating that the engine can be operated across a range of natural gas compositions. Engine exhaust soot concentrations demonstrated elevated values at ϕ HC > 2.4, but < 1 mg/L below these equivalence ratios. These results demonstrate that the engine reformer could be a key component of a compact gas‐to‐liquids synthesis plant by highlighting the operating conditions under which high gas conversion, high H 2‐ to‐CO ratios close to 2.0, and low soot production are possible.
Hydrogen (H 2 ) is a promising fuel for reducing emissions in heavy-duty internal combustion engines (ICEs), but its low quenching distance increases the risk of flame propagation into narrow crevice regions, such as piston-liner gaps. This work uses detailed CFD simulations with finite-rate chemistry to investigate premixed H 2 –air flame quenching in a two-dimensional (2D) region consistent with the piston-liner gap of a diesel ICE. Model accuracy was assessed by comparison with experimentally measured quenching distances in an annular stepwise diverging tube (ASDT). A parametric study was conducted to assess the influence of crevice width (0.05–1.18 mm), pressure (50–150 bar), unburned gas temperature (431–573 K), and equivalence ratio ( Φ= 0.3–0.6). Results show that the critical Péclet number for flame survival is no greater than 3.25, consistent with prior literature, even under ultra-lean and high-pressure conditions (Φ ≤ 0.3, > 50 bar). Additionally, flames with Péclet numbers exceeding 6.15 exhibited front wrinkling, suggesting the onset of velocity-driven instabilities and enhanced flame robustness. These findings help define thresholds for flame quenching in confined geometries and support the safe design of H 2 fueled ICEs.
The gas exchange process is known to be a significant source of cyclic variability in Internal Combustion Engines (ICE). Traditionally, Large Eddy Simulations (LES) are expected to capture these cycle-to-cycle variations. This paper reports a numerical effort to establish best practices for capturing cyclic variability with LES tools in a Transparent Combustion Chamber (TCC) spark ignition engine. The main intention is to examine the sensitivity of cycle averaged mean and Root Mean Square (RMS) flow fields and Proper Orthogonal Decomposition (POD) modes to different computational hardware, adaptive mesh refinement (AMR) and LES sub-grid scale (SGS) models, since these aspects have received little attention in the past couple of decades. This study also examines the effect of near-wall resolution on the predicted wall shear stresses. LES is pursued with commercially available CONVERGE code. Two different SGS models are tested, a one-equation eddy viscosity model and dynamic structure model. The results seem to indicate that both mean and RMS fields without any SGS model are not much different than those with LES models, either one-equation eddy viscosity or dynamic structure model. Computational hardware results in subtle quantitative differences, especially in RMS distributions. The influence of AMR on both mean and RMS fields is negligible. The predicted shear stresses near the liner walls is also found to be relatively insensitive to near-wall resolution except in the valve curtain region.
From the earliest days of internal-combustion engines, technological visionaries dreamed about engines running on fuel made from plants. In those early days, however, it was much easier to refine fuels from crude oil, which could be obtained cheaply in many parts of the world by simply drilling a hole in the ground. However, humanity now knows that the supply of fossil fuel is limited. One day, we will run out of fossil fuel, and we will need fuel from alternative sources. One possible alternative is biofuels, but these remain a dream away today, simply because producing such fuels costs as much as $\$$10 per gallon and requires petroleum products for their production. But this long-held dream may transcend the veil of sleep into the realm of reality, thanks to the development of a technology designed to harvest algae more easily and cost effectively—algae that are major candidates for producing tomorrow’s biofuels. At Los Alamos National Laboratory, we have developed the world’s first “magnetic algae.” We say magnetic, but more specifically our genetically engineered algae are paramagnetic. Paramagnetic materials are themselves not magnetic. Instead, such materials are pulled by magnetic fields. Hence, a magnetic needle made from soft iron is actually paramagnetic, because a magnet can pull it from a haystack. For the first time ever, we have genetically modified a model algae strain to make what is called intracellular magnetic nanoparticles.
This is the final report of the UC Davis Fuel Cell, Hydrogen, and Hybrid Vehicle (FCH2V) GATE Center of Excellence which spanned from 2005-2012. The U.S. Department of Energy (DOE) established the Graduate Automotive Technology Education (GATE) Program, to provide a new generation of engineers and scientists with knowledge and skills to create advanced automotive technologies. The UC Davis Fuel Cell, Hydrogen, and Hybrid Vehicle (FCH2V) GATE Center of Excellence established in 2005 is focused on research, education, industrial collaboration and outreach within automotive technology. UC Davis has had two independent GATE centers with separate well-defined objectives and research programs from 1998. The Fuel Cell Center, administered by ITS-Davis, has focused on fuel cell technology. The Hybrid-Electric Vehicle Design Center (HEV Center), administered by the Department of Mechanical and Aeronautical Engineering, has focused on the development of plug-in hybrid technology using internal combustion engines. The merger of these two centers in 2005 has broadened the scope of research and lead to higher visibility of the activity. UC Davis's existing GATE centers have become the campus's research focal points on fuel cells and hybrid-electric vehicles, and the home for graduate students who are studying advanced automotive technologies. The centers have been highly successful in attracting, training, and placing top-notch students into fuel cell and hybrid programs in both industry and government.
HRL Laboratories and General Motors (GM), pursued this effort to increase the efficiency of internal combustion engines (ICEs) by developing and implementing temperature-following thermal barrier coatings (TBCs) to decrease heat loss from the combustion chamber. HRL developed microsphere TBCs based on hollow high-temperature alloy spheres with average diameter of 50 μm and wall thickness ~1 μm (microspheres) that achieve unprecedented low thermal conductivity and heat capacity (10X lower than the state of the art) while offering exceptional environmental and mechanical resistance.> In current ICEs, approximately 29% of the fuel’s energy is lost to the cooling system and about 22% goes into moving the car. By limiting heat losses from the combustion chamber with insulating coatings, fuel energy can be redirected into additional piston work and into the exhaust stream. The additional energy that goes into the exhaust stream can be turned into useful work through the use of an exhaust energy recovery device, such as turbocompounding and/or through driving a turbocharger to increase the power density of the engine allowing downsizing. Insulating coatings for piston crowns have been pursued in the past, but previous materials—typically ceramics—exhibited low thermal conductivity but retained high heat capacity. Such materials reduce heat losses but stabilize at a high surface temperature. The high surface temperature heats the incoming gases, which lowers volumetric efficiency and increases propensity for knock, resulting in degraded engine performance. This program developed an innovative new material that combines low thermal conductivity with low heat capacity. These unique properties allow it to follow rapid changes in gas temperature during each combustion cycle. A metallic microsphere TBC has been demonstrated that exhibits increased surface temperature during the combustion period, resulting in reduced heat transfer losses, while still returning to a low surface temperature during the gas exchange period. A 10X lower thermal conductivity and heat capacity than state-of-the-art thermal barrier coatings has been demonstrated. These unprecedented thermal properties are achieved through the coating architecture, which consists of closed pores on the microscale and exhibits a total porosity of 90% to 95%. By selecting a high-temperature nickel alloy as the coating material, the ductility and strength of metals can be harnessed to achieve much better durability and damage tolerance than brittle ceramic coatings can achieve.
This paper presents a dynamic model of an internal combustion engine coupled to a variable pitch propeller. The low-order, nonlinear time-dependent model is useful for simulating the propulsion system of general aviation single-engine light aircraft. This model is suitable for investigating engine diagnostics and monitoring and for control design and development. Furthermore, the model may be extended to provide a tool for the study of engine emissions, fuel economy, component effects, alternative fuels, alternative engine cycles, flight simulators, sensors, and actuators. Results show that the model provides a reasonable representation of the propulsion system dynamics from zero to 10 Hertz.
Recent decades have seen increasingly restrictive regulations applied to gasoline engines. Gasoline combustion chemistry must be investigated to achieve a better understanding and control of internal combustion engine efficiency and emissions. In this work, several gasoline fuels, namely the FACE (Fuel for Advanced Combustion Engines) gasolines, were selected as targets for oxidation study in jet-stirred reactors (JSR). The study is facilitated by formulating various gasoline surrogate mixtures with known hydrocarbon compositions to represent the real gasolines. Surrogates included binary mixtures of n-heptane and iso-octane, as well as more complex multi-component mixtures. Here, the oxidation characteristics of FACE gasolines and their surrogates were experimentally examined in JSR-1 and numerically simulated under the following conditions: pressure 1 bar, temperature 500–1050 K, residence time 1.0 and 2.0 s, and two equivalence ratios (Φ= 0.5 and 1.0). In the high temperature region, all real fuels and surrogates showed similar oxidation behavior, but in the low temperature region, a fuel’s octane number and composition had a significant effect on its JSR oxidation characteristics. Low octane number fuels displayed more low temperature reactivity, while fuels with similar octane number but a larger number of n-alkane components were more reactive. A gasoline surrogate kinetic model was examined with FACE gasoline experiments either measured in JSR-2, or taken from previous work under the following conditions: pressure 10 bar, temperature 530–1200 K, residence time 0.7 s, and three equivalence ratios (Φ = 0.5, 1.0 and 2.0). Comparison between FACE gasoline experimental results with surrogate model predictions showed good agreement, demonstrating considerable potential for surrogate fuel kinetic modeling in engine simulations.
Engine manufacturers are continually attempting to improve the performance and the overall efficiency of internal combustion engines. The thermal efficiency is typically improved by raising the operating temperature of essential engine components in the combustion area. This reduces the heat loss to a cooling system and allows a greater portion of the heat to be used for propulsion. Further improvements can be achieved by diverting part of the air from the compressor, which would have been used in the combustor for combustion purposes, into the turbine components. Such a process is called active cooling. Increasing the operating temperature, decreasing the cooling air, or both can improve the efficiency of the engine. Furthermore, lightweight, strong, tough hightemperature materials are required to complement efficiency improvement for nextgeneration gas turbine engines that can operate with minimum cooling. Because of their low-density, high-temperature strength, and thermal conductivity, ceramics are being investigated as potential materials for replacing ordinary metals that are currently used for engine hot section components. Ceramic structures can withstand higher operating temperatures and other harsh environmental factors. In addition, their low densities relative to metals helps condense component mass (ref. 1). The objectives of this program at the NASA Glenn Research Center are to develop manufacturing technology, a thermal barrier coating/environmental barrier coating (TBC/EBC), and an analytical modeling capability to predict thermomechanical stresses, and to do minimal burner rig tests of silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Furthermore, and in support of the latter objectives, an optimization exercise using finite element analysis and nondestructive evaluation (NDE) was carried out to characterize and evaluate silicon nitride plates with cooling channels.
Gasoline compression ignition (GCI) engines are considered an attractive alternative to traditional spark-ignition and diesel engines. In this work, a Machine Learning-Grid Gradient Algorithm (ML-GGA) approach was developed to optimize the performance of internal combustion engines. Machine learning (ML) offers a pathway to transform complex physical processes that occur in a combustion engine into compact informational processes. The developed ML-GGA model was compared with a recently developed Machine learning Genetic Algorithm (ML-GA). Detailed investigations of optimization solver parameters and variables limits extension were performed in the present ML-GGA model to improve the accuracy and robustness of the optimization process. Detailed descriptions of the different procedures, optimization tools and criteria that must be followed for a successful output are provided here. The developed ML-GGA approach was used to optimize the operating conditions (case 1) and the piston bowl design (case 2) of a heavy-duty diesel engine running on a gasoline fuel with a Research Octane Number (RON) of 80. The ML-GGA approach yielded > 2% improvements in the merit function, compared to the optimum obtained from a thorough computational fluid dynamics (CFD) guided system optimization. The predictions from the ML-GGA approach were validated with engine CFD simulations. This study demonstrates the potential of ML-GGA to significantly reduce the time needed for optimization problems, without loss in accuracy compared to traditional approaches.
The present invention relates to techniques for lowering friction between moving surfaces of, for example, an internal combustion engine. Friction reduction is achieved by adding texture modifications to surfaces that come in contact with each other. Texture modifications that reduce friction in accordance with the present invention include dimples of varying geometries and depths ion the surfaces of components. The present invention also relates to the fabrication technique for applying the textures to the surfaces. In another embodiment, the patterned soft mask is applied onto a large surface (flat or curved including cylindrical rollers surfaces) to be followed by electrochemical etching to imprint the textures onto the component. And, in another embodiment, a diamond-like-carbon (DLC) film may be applied to the turbine component to also reduce friction.
The present invention relates to techniques for lowering friction between moving surfaces of, for example, an internal combustion engine. Friction reduction is achieved by adding texture modifications to surfaces that come in contact with each other. Texture modifications that reduce friction in accordance with the present invention include dimples of varying geometries and depths ion the surfaces of components. The present invention also relates to the fabrication technique for applying the texture to the surfaces. In another embodiment, the patterned soft mask is applied onto a large surface (flat or curved including cylindrical rollers surfaces) to be followed by electrochemical etching to imprint the textures onto the component And, in another embodiment, a diamond-like-carbon (DLC) film may be applied to the turbine component to also reduce friction.
The ever increasing demand to develop highly fuel efficient engines coincides with the need to minimize air pollution originating from the exhaust gases of internal combustion engines. Dramatically improved fuel efficiency can be achieved at air-to-fuel ratios much higher than stoichiometric. In the presence of oxygen in large excess, however, traditional three-way catalysts are unable to reduce NOx. Among the number of lean-NOx reduction technologies, selective catalytic reduction (SCR) of NOx by NH3 over Cu- and Fe-ion exchanged zeolite catalysts has been extensively studied over the past 30+ years. Despite the significant advances in developing a viable practical zeolite-based catalyst for lean NOx reduction, the insufficient hydrothermal stabilities of the zeolite structures considered cast doubts about their real-world applicability. During the past decade a renewed interest in zeolite-based lean NOx reduction was spurred by the discovery of the very high activity of Cu-SSZ-13 (and the isostructural Cu-SAPO-34) in the NH3 SCR of NOx. These new, small-pore zeolite-based catalysts not only exhibited very high NOx conversion and N2 selectivity, but also exhibited exceptional high hydrothermal stability at high temperatures. In this review we summarize the key discoveries of the past ~5 years that lead to the introduction of these catalysts into practical application. The review first briefly discusses the structure and preparation of the CHA structure-based zeolite catalysts, and then summarizes the key learnings of the rather extensive (but not complete) characterisation work. Then we summarize the key findings of reaction kinetics studies, and provide some mechanistic details emerging from these investigations. At the end of the review we highlight some of the issues that are still need to be addressed in automotive exhaust control catalysis. Funding A.M.B. and I.L.G. would like to thank EPSRC for funding. F.G., C.H.F.P. and J.Sz. gratefully acknowledge financial support from the US Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.
Accurate predictions of low-temperature heat release (LTHR) are critical for modeling auto-ignition processes in internal combustion engines. While LTHR is typically obscured by deflagration, extremely late ignition phasing can lead to LTHR prior to the spark, a behavior known as pre-spark heat release (PSHR). In this research, PSHR in a boosted direct-injection spark-ignition engine was studied using 3-D computational fluid dynamics (CFD) and detailed chemical kinetics. The turbulent combustion was modeled via a hybrid approach that incorporates the G-equation model for tracking the turbulent flame front, and the well-stirred reactor model with detailed chemistry for assessing the low-temperature reactions in unburnt gas. Simulations were conducted using Co-Optima alkylate and E30 fuels at operating conditions characterized by different PSHR intensities. The predicted in-cylinder pressure and heat release rate were found to agree well with experiments. It was found the estimate of previous-cycle trapped residuals is of utmost importance for capturing PSHR correctly. A simulation best practice was developed which keeps the detailed chemistry solver active throughout the entire simulation, allowing to track the evolution of intermediate species from one cycle to the next. Following the validation, the dynamics of PSHR were analyzed in detail employing the pressure-temperature (P-T) trajectory framework. It was shown that PSHR correlated with the first-stage ignition delay of the fuel, hence showing close relation to the in-cylinder P-T trajectory and the chemical kinetics. Besides, it was indicated that LTHR is a self-limiting process that has the effect of attenuating the thermal stratification in the combustion chamber. Furthermore, it was observed the occurrence of PSHR caused the P-T trajectory of end-gas to overlap with the negative temperature coefficient region of the fuel’s ignition-delay maps. This effect was more significant in the fuel-rich regions where engine knock tendency would be generally higher, with potential implications on knock control and mitigation.
The main objective of the project is to develop advanced, low cost conversions of small (< 25 hp) gasoline internal combustion engines (ICEs) to run on hydrogen fuel while maintaining the same performance and durability. This final technical report summarizes the results of i) the details of the conversion of several small gasoline ICEs to run on hydrogen, ii) the durability test of a converted hydrogen engine and iii) the demonstration of a prototype bundled canister solid hydrogen storage system. Peak power of the hydrogen engine achieves 60% of the power output of the gasoline counterpart. The efforts to boost the engine power with various options including installing the over-sized turbocharger, retrofit of custom-made pistons with high compression ratio, an advanced ignition system, and various types of fuel injection systems are not realized. A converted Honda GC160 engine with ACS system to run with hydrogen fuel is successful. Total accumulative runtime is 785 hours. A prototype bundled canister solid hydrogen storage system having nominal capacity of 1.2 kg is designed, constructed and demonstrated. It is capable of supporting a wide range of output load of a hydrogen generator.
The figure presents a cross-sectional view of a supercharged, variable-compression, two-cycle, internal-combustion engine that offers significant advantages over prior such engines. The improvements are embodied in a combination of design changes that contribute synergistically to improvements in performance and economy. Although the combination of design changes and the principles underlying them are complex, one of the main effects of the changes on the overall engine design is reduced (relative to prior two-cycle designs) mechanical complexity, which translates directly to reduced manufacturing cost and increased reliability. Other benefits include increases in the efficiency of both scavenging and supercharging. The improvements retain the simplicity and other advantages of two-cycle engines while affording increases in volumetric efficiency and performance across a wide range of operating conditions that, heretofore have been accessible to four-cycle engines but not to conventionally scavenged two-cycle ones, thereby increasing the range of usefulness of the two-cycle engine into all areas now dominated by the four-cycle engine. The design changes and benefits are too numerous to describe here in detail, but it is possible to summarize the major improvements: Reciprocating Shuttle Inlet Valve The entire reciprocating shuttle inlet valve and its operating gear is constructed as a single member. The shuttle valve is actuated in a lost-motion arrangement in which, at the ends of its stroke, projections on the shuttle valve come to rest against abutments at the ends of grooves in a piston skirt. This shuttle-valve design obviates the customary complex valve mechanism, actuated from an engine crankshaft or camshaft, yet it is effective with every type of two-cycle engine, from small high-speed single cylinder model engines, to large low-speed multiple cylinder engines.