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At least 55 records · Page 3

PHALANX: Expendable Projectile Sensor Networks for Planetary Exploration

Technologies enabling long-term, wide-ranging measurement in hard-to-reach areas are a critical need for planetary science inquiry. Phenomena of interest include flows or variations in volatiles, gas composition or concentration, particulate density, or even simply temperature. Improved measurement of these processes enables understanding of exotic geologies and distributions or correlating indicators of trapped water or biological activity. However, such data is often needed in unsafe areas such as caves, lava tubes, or steep ravines not easily reached by current spacecraft and planetary robots. To address this capability gap, we have developed miniaturized, expendable sensors which can be ballistically lobbed from a robotic rover or static lander - or even dropped during a flyover. These projectiles can perform sensing during flight and after anchoring to terrain features. By augmenting exploration systems with these sensors, we can extend situational awareness, perform long-duration monitoring, and reduce utilization of primary mobility resources, all of which are crucial in surface missions. We call the integrated payload that includes a cold gas launcher, smart projectiles, planning software, network discovery, and science sensing: PHALANX. In this paper, we introduce the mission architecture for PHALANX and describe an exploration concept that pairs projectile sensors with a rover “mothership.” Science use cases explored include reconnaissance using ballistic cameras, volatiles detection, and building timelapse maps of temperature and illumination conditions. Strategies to autonomously coordinate constellations of deployed sensors to self-discover and localize with peer ranging (i.e. a “local GPS”) are summarized, thus providing communications infrastructure beyond-line-of-sight (BLOS) of the rover. Capabilities were demonstrated through both simulation and physical testing with a terrestrial prototype. The approach to developing a terrestrial prototype is discussed, including design of the launching mechanism, projectile optimization, micro-electronics fabrication, and sensor selection. Results from early testing and characterization of commercial-off-the-shelf (COTS) components are reported. Nodes were subjected to successful burn-in tests over 48 hours at full logging duty cycle. Integrated field tests were conducted in the Roverscape, a half-acre planetary analog environment at NASA Ames, where we tested up to 10 sensor nodes simultaneously coordinating with an exploration rover. Ranging accuracy has been demonstrated to be within +/-10cm over 20m using commodity radios when compared to high-resolution laser scanner ground truthing. Evolution of the design, including progressive miniaturization of the electronics and iterated modifications of the enclosure housing for streamlining and optimized radio performance are described. Finally, lessons learned to date, gaps toward eventual flight mission implementation, and continuing future development plans are discussed.

Dille, Michael↗

Rock Driller

The next series of planetary exploration missions require a method of extracting rock and soil core samples. Therefore a prototype ultrasonic core driller (UTCD) was developed to meet the constraints of Small Bodies Exploration and Mars Sample Return Missions. The constraints in the design are size, weight, power, and axial loading. The ultrasonic transducer requires a relatively low axial load, which is one of the reasons this technology was chosen. The ultrasonic generator breadboard section can be contained within the 5x5x3 limits and weighs less than two pounds. Based on results attained the objectives for the first phase were achieved. A number of transducer probes were made and tested. One version only drills, and the other will actually provide a small core from a rock. Because of a more efficient transducer/probe, it will run at very low power (less than 5 Watts) and still drill/core. The prototype generator was built to allow for variation of all the performance-effecting elements of the transducer/probe/end effector, i.e., pulse, duty cycle, frequency, etc. The heart of the circuitry is what will be converted to a surface mounted board for the next phase, after all the parameters have been optimized and the microprocessor feedback can be installed.

Peterson, Thomas M.↗

Indirect Dark Matter Searches at Ultrahigh Energy Neutrino Detectors

High to ultrahigh energy neutrino detectors can uniquely probe the properties of dark matterχby searching for the secondary products produced through annihilation and/or decay processes. We evaluate the sensitivities to dark matter thermally averaged annihilation cross section〈σv〉and partial decay width into neutrinos Γ χ→ν ̄ν (in the mass scale 10 7 ≤ m χ /GeV ≤ 10 15 ) for next generation observatories like POEMMA and GRAND. We show that in the range 10 7 ≤ m χ /GeV ≤ 10 11 , space-based Cherenkov detectors like POEMMA have the advantage of full-sky coverage and rapid slewing, enabling an optimized dark matter observation strategy focusing on the Galactic center. We also show that ground-based radio detectors such as GRAND can achieve high sensitivities and high duty cycles in radio quiet areas. We compare the sensitivities of next generation neutrino experiments with existing constraints from IceCube and updated 90% C.L. upper limits on〈σv〉and Γ χ→ν ̄ν using results from the Pierre Auger Collaboration and ANITA. We show that in the range 10 7 ≤ m χ /GeV ≤ 10 11 POEMMA and GRAND10k will improve the neutrino sensitivity to particle dark matter by factors of 2 to 10 over existing limits, whereas GRAND200k will improve this sensitivity by two orders of magnitude. In the range 10 11 ≤ m χ /GeV ≤ 10 15 , POEMMA’s fluorescence observation mode will achieve an unprecedented sensitivity to dark matter properties. Finally, we highlight the importance of the uncertainties related to the dark matter distribution in the Galactic halo, using the latest fit and estimates of the Galactic parameters.

Particle astrophysics↗

Spacecraft reliability/maintainability optimization.

Description of a procedure to develop a methodology to optimize man-serviced systems for reliability and maintainability. The spacecraft systems are analyzed using failure modes and effects analysis and maintenance analysis, component mean-time-between failure, duty cycle, type of redundancy, and cost information to develop parametric data on various time intervals. Included are crew time-to-repair, cost, weight, and volume effects of increasing subsystem reliability above the baseline. Results are presented for space systems using the existing data from a research and applications module. These results show the minimum cost of sustaining mission operations.

Sharmahd, J. N.↗

Probing the Properties of Superheavy Dark Matter Annihilating or Decaying into Neutrinos With Ultra-High Energy Neutrino Experiments

The evidence for dark matter particles,x, is compelling based on Galactic to cosmological scale observations. Thus far, the promising weakly interacting massive particle scenario have eluded detection, motivating alternative models of dark matter. We consider scenarios involving super-heavy dark matter (SHDM) that potentially can decay or annihilate to neutrinos and antineutrinos. In the mass range m(sub x) =10(exp 7) −10(exp 15) GeV, we evaluate the sensitivities of future observatories PO-EMMA and GRAND for indirect dark matter detection via the measurement of neutrino-induced extensive air showers (EAS), compute the Auger and ANITA limits using their last up-to-date sensitivities, and compare them with IceCube limits. We also show that the uncertainties related to the dark matter distribution in the Galactic halo have a large impact on the neutrino flux. We show that a ground-based radio detector such as GRAND can achieve high sensitivities due to its large effective area and high duty cycle. Space-based Cherenkov detectors such as POEMMA that measure the EAS optical Cherenkov signal have the advantage of full-sky coverage and rapid slewing, enabling an optimized SHDM observation strategy focusing on the Galactic Center. We show that increasing the field of view of the Cherenkov detectors can significantly enhance the sensitivity. Moreover, POEMMA’s fluorescence observation mode that measures EAS above20EeV will achieve state-of-the-art sensitivity to SHDM properties at the highest mass scales.

Claire Guepin↗

Simulation and Optimization of Volatile Fatty Acid Upgrading Strategies for Sustainable Transportation Fuel Production

Underutilized wet waste is a promising feedstock for production of carbon-neutral or carbon-negative liquid transportation fuels. Arrested methanogenesis of wet wastes by microbes, which produces mixtures of C2-C8 carboxylic acids (volatile fatty acids, VFAs), is practiced industrially at a pilot scale and the VFA products can be catalytically upgraded to molecules suitable for use as transportation fuels (alcohols and alkanes) via sequential ketonization and hydrogenation, both steps of which have been demonstrated with high (>90%) yield at the lab scale. We present in this work a simulation-based decision-making framework which evaluates upgrading strategies of VFAs to alcohol- and hydrocarbon-based neat and blended diesel, jet, and gasoline fuels. The processes utilize sequential upgrading steps (ketonization and hydrogenation) accompanied by one distillation step (either separating VFAs before ketonization or alcohols after ketone hydrogenation) to form two liquid streams: a light alcohol stream best suited as a light-duty fuel and a heavy alcohol or hydrocarbon stream best suited as a diesel or jet fuel. Suitability of the liquid products as transportation fuels and maximum blending levels with petrofuels comes from simulation of critical fuel properties (boiling point, flash point, lower heating value, viscosity, melting point, water solubility, and cetane/octane number). Catalytic upgrading steps and fuel property mixing models used by the simulation are experimentally validated. We demonstrate the flexibility of the decision-making algorithm by evaluating processing scenarios for experimentally-observed VFA profiles with varied carbon chain length distributions. Processing scenarios are optimized for either maximum total renewable carbon utilization or production of heavy-duty (jet or diesel) fuels. We evaluate the economic viability and CO2 emissions of each proposed upgrading scenario using techno-economic and life cycle analyses. The decision-making framework developed in this work can also be used to down-select promising strategies for upgrading of other bio-based feedstocks to sustainable fuels and chemicals.

aviation fuel↗

Zero Emission Cargo Transport (ZECT) II Demonstration: South Coast Air Quality Management District (Final Report)

The South Coast Air Quality Management District (South Coast AQMD), California Air Resources Board (CARB) and Southern California Association of Governments (SCAG) — the agencies responsible for preparing the State Implementation Plan required under the federal Clean Air Act — have agreed that attainment of federal air quality standards for the region will require a transition to the broad use of zero and near-zero emission energy sources in cars, trucks and other equipment. Accordingly, the 2012 South Coast AQMD Air Quality Management Plan, the SCAG 2012 Regional Transportation Plan, and the “Vision for Clean Air: A Framework for Air Quality and Climate Control Planning” all identify the need to immediately enact a phasing in of zero and near-zero emission technologies to meet air quality goals. In 2014, South Coast AQMD was awarded grant funding under the US Department of Energy Zero Emission Cargo Transport (ZECT) II Demonstration program to develop and demonstrate zero-emission drayage trucks for goods movement operations between the Port of Los Angeles (POLA) and Port of Long Beach (POLB) near dock rail yards and warehouses: 1) development and demonstration of zero-emission fuel cell range extended electric drayage trucks and 2) development and demonstration of hybrid electric drayage trucks. The purpose of this project was to accelerate deployment of zero emission cargo transport technologies to reduce harmful diesel emissions, petroleum consumption and greenhouse gases in the surrounding communities along the goods movement corridors that are impacted by heavy diesel traffic and the associated air pollution. Between 2014 – 2024, six ZECT II zero-emission fuel cell drayage truck platforms, including fuel cell range extended and CNG hybrid trucks, were successfully designed, developed, integrated, built, tested, and demonstrated with drayage fleet operators in transportation corridors within areas of the South Coast AQMD jurisdiction in Southern California such as in and around POLA and POLB. Portable hydrogen refueling was deployed to support the fuel cell vehicles. The project had real-time improvement with on-going debugging and optimizations while the vehicles were under demonstration. All platforms demonstrated sufficient or excess power, torque, and energy to support 82,000lbs Gross Vehicle Weight Rating and gradeability to perform their daily duty cycles. Collectively, the trucks drove over 23,000 miles during their respective demonstration phases. The ZECT II project was the first of its kind to demonstrate the commercial viability that supported the additional technology breakthroughs for Class 8 zero emission trucks and validations as well as the regulatory basis for all the zero-emission regulation that we know today, such as the Innovative Clean Transit regulation, Advanced Clean Trucks and Clean Fleet regulations.

08 HYDROGEN↗

Retinoid quantification by HPLC/MS(n)

Retinoic acid (RA) mediates most of the biological effects of vitamin A that are essential for vertebrate survival. It acts through binding to receptors that belong to the nuclear receptor transcription factor superfamily (Mangelsdorf et al. 1994). It is also a highly potent vertebrate teratogen. To determine the function and effects of endogenous and exogenous RA, it is important to have a highly specific, sensitive, accurate, and precise analytical procedure. Current analyses of RA and other retinoids are labor intensive, of poor sensitivity, have limited specificity, or require compatibility with RA reporter cell lines (Chen et al. 1995. BIOCHEM: Pharmacol. 50: 1257-1264; Creech Kraft et al. 1994. BIOCHEM: J. 301: 111-119; Lanvers et al. 1996. J. Chromatogr. B Biomed. Appl. 685: 233-240; Maden et al. 1998. DEVELOPMENT: 125: 4133-4144; Wagner et al. 1992. DEVELOPMENT: 116: 55-66). This paper describes an HPLC/mass spectrometry/mass spectrometry product ion scan (HPLC/MS(n)) procedure for the analysis of retinoids that employs atmospheric pressure chemical ionization MS. The retinoids are separated by normal-phase column chromatography with a linear hexane-isopropanol-dioxane gradient. Each retinoid is detected by a unique series of MS(n) functions set at optimal collision-induced dissociation energy (30% to 32%) for all MS(n) steps. The scan events are divided into three segments, based on HPLC elution order, to maximize the mass spectrometer duty cycle. The all-trans, 9-cis, and 13-cis RA isomers are separated, if desired, by an isocratic hexane-dioxane-isopropanol mobile phase. This paper describes an HPLC/MS(n) procedure possessing high sensitivity and specificity for retinoids.

NASA Discipline Developmental Biology↗

Analysis and Control of a Three-Port Converter with High-Frequency AC Link for Hybrid Unmanned/Autonomous Aerial Vehicles

In this study, a three-port resonant converter with a high-frequency isolation link for hybrid unmanned/autonomous aerial vehicle (UAV/AAV) applications is analyzed. The rectified engine-generator set output supplies the first input ports while the other is connected to a battery energy storage system. Input ports consist of half-bridge high-frequency inverters, whereas output port utilizes a semi-bridgeless active rectifier. This rectifier is formed by replacing rectifier low-side diodes with active switching devices. A phase-shift duty-cycle control is implemented for switching signals to regulate the power share and flow between ports. The proposed control system implemented achieves zero voltage switching (ZVS), reduces switching losses, and minimum current flow optimization ensures regulation in a wide range of output power. Compared to the existing bidirectional pulse width modulation (PWM) converters, the proposed system decreases the number of power conversion stages and provides centralized control without needing communications between the ports. The proposed control technique operating in closed-loop control achieves the power flow between ports under various load conditions. Finally, theoretical analysis demonstrates the proposed converter’s viability and laboratory experimental validations at 500 W full power.

33 ADVANCED PROPULSION SYSTEMS↗

Integrated payload and mission planning, phase 3. Volume 4: Optimum utilization of Spacelab racks and pallets

The methodology to optimize the utilization of Spacelab racks and pallets and to apply this methodology to the early STS Spacelab missions was developed. A review was made of Spacelab Program requirements and flow plans, generic flow plans for racks and pallets were examined, and the principal optimization criteria and methodology were established. Interactions between schedule, inventory, and key optimization factors; schedule and cost sensitivity to optional approaches; and the development of tradeoff methodology were addressed. This methodology was then applied to early spacelab missions (1980-1982). Rack and pallet requirements and duty cycles were defined, a utilization assessment was made, and several trade studies performed involving varying degrees of Level IV integration, inventory level, and shared versus dedicated Spacelab racks and pallets.

Logston, R. G.↗

Optimized Gear Selection to Maximize Energy Savings in Electric Traction Drives for Medium and Heavy Duty Vehicles

Multi‑gear transmission systems are commonly used in electric traction drives for medium and heavy‑duty vehicles, while most passenger‑vehicle electric drivetrains rely on a single fixed ratio to reduce cost, weight, and complexity. Using multiple gear ratios can enable downsizing of the motor and inverter while still meeting performance requirements. Additionally, appropriately chosen ratios allow the motor to operate more frequently in high‑efficiency regions, improving overall energy usage and reducing operating costs over the drive cycle. This paper presents a systematic approach for selecting optimal gear ratios for electric drive systems. A neural‑network model is first developed to represent motor losses across the full torque–speed range using data generated from finite element analysis. This model enables fast, accurate evaluation of motor efficiency under varying operating conditions. A genetic‑algorithm‑based optimization framework is then applied to identify gear ratios that maximize energy cost savings over the drive cycle, with the resulting optimal ratios stored for real‑time implementation.

Gadiyar, Nishanth [ORNL] (ORCID:0000000348267524)↗

Compact, Achromatic Non-scaling FFAG Accelerator for HEP, Commercial and Medical Applications (CRADA FRA-2008-0005 Final Report)

Proton and light-ion accelerators have many research and medical applications, but the current state of technology in accelerators severely limits their widespread use: (1) synchrotrons have an intrinsic low duty cycle and become quite large for light ions; and (2) cyclotrons do not have energy variability and require complex superconducting magnets for high energy. A new concept in non-scaling Fixed-Field Alternating-Gradient (FFAGs) has been invented that incorporates both the energy variability of the synchrotron and the high duty cycle of the cyclotron. The concept uses normal-conducting, combined-function magnets that apply only constant (dipole) and linear-gradient (quadrupole) fields to stabilize the accelerator. This project will develop an optimized design for a new non-scaling and cost-effective innovation in FFAG accelerators. The accelerator design will have optics that can stably accelerate protons to 250 MeV (or higher) and carbon ions to =200 MeV, an energy considered ideal for radiation therapy. Phase I will optimize, fully simulate, and demonstrate the feasibility of this accelerator. Commercial Applications and other Benefits as described by the awardee: The fixed-field acceleration concept should eliminate some of the most pronounced technical difficulties, expense, maintenance, and required expertise faced in conventional proton and light-ion accelerators. In addition to the application for high energy physics, these accelerators should have application in cancer treatment, radiopharmaceuticals, and medical isotope production, and materials science.

43 PARTICLE ACCELERATORS↗

Stochastic Model Predictive Control With Gaussian Wind Direction Preview for Wake Steering

This article addresses the problem of wake steering control for wind farms that explicitly consider the tradeoff between farm-level power generation and yaw duty cycle under variable and uncertain wind conditions. A novel stochastic model predictive control (MPC) algorithm is presented, which utilizes a stochastic model of the freestream wind field components in a receding horizon framework to compute optimal yaw set points that maximize the expected value of the farm power while constraining the yaw actuation. Different configurations of the algorithm are evaluated using a steady-state wind farm simulator. The proposed stochastic MPC algorithm can plan control actions over a future prediction horizon based on probabilistic estimates of the incoming wind magnitude and direction.

17 WIND ENERGY↗

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗

Cycle-to-cycle variability in spark-assisted compression ignition engines near optimal mean combustion phasing

Stoichiometric spark-assisted compression ignition (SACI) combustion with exhaust gas recirculation (EGR) dilution has demonstrated higher part-load thermal efficiencies compared to spark-ignited engines, while maintaining ultra-low tailpipe emissions. However, SACI is often characterized by high cyclic variability in heat release or torque output, which poses a challenge to its implementation in light-duty vehicles. This paper presents an experimental investigation of cyclic variability in stoichiometric SACI combustion under EGR-dilute conditions, while maintaining mean combustion phasing (θ 50 ) near optimal timing for thermal efficiency. The present work focuses on SACI conditions where the flame-based heat release fraction is between approximately 10% and 40% of the overall heat release, and therefore contributes significantly to the combustion process. For the SACI conditions examined, the variability in θ 50 was driven by variability in autoignition timing, which in turn correlated with the start of measurable heat release (θ 02 ). High variability in θ 50 caused unstable work output due to very late combustion with poor or no end-gas autoignition. The use of a high ignition energy dual-coil offset ignition system had negligible impact in reducing θ 50 variability. Analysis of experimental data from close to 1000 operating conditions showed that the magnitude of θ 50 variability correlates with the flame-based heat release fraction ([Formula: see text]), for a large range of intake pressures, spark timings and exhaust gas recirculation levels. For the SACI conditions examined, combustion phasing variability was largely determined by flame-based combustion and particularly the initial flame formation (θ IGN-02 ), and minimally by the end-gas autoignition heat release. The analysis also demonstrated that θ 50 variability is amplified as the contribution of the flame to the overall heat release increases.

Engineering↗

Design and Study of Inductively Coupled Plasma Chamber Components Using the SupRISE Test Device at DIII-D

The DIII-D National Fusion Facility aims to increase the auxiliary heating power for the tokamak by upgrading the Neutral Beam Injection (NBI) system. In collaboration with North Carolina State University, the conventional ‘arc and filament’ NBI ion sources will be converted to inductively coupled plasma (ICP) sources which utilize radio frequency (RF) coupling to maximize reliability for high power operation. In support of this initiative, a full scale test device (SupRISE, Superior Radiofrequency Ion Source Experiment) is currently under construction at the DIII-D Facility. In preparation for the construction of a full scale prototype that can be installed on the DIII-D NBI system, experiments on SupRISE will be conducted to determine the optimal RF frequency for high power coupling, Faraday shield slit configuration, and ICP chamber length. SupRISE is comprised of an approximately 30 x 70 cm quartz dielectric vessel with an internal Faraday shield enclosed in a secondary vacuum chamber to ensure structural stability of the dielectric. Actively cooled front and back plates are designed to reduce the thermal stresses on the plasma facing components and mate with the existing accelerator used by the NBI system at DIII-D. 50 kW of RF power will be coupled to the plasma through the quartz over a variable frequency range of 4-8 MHz to sustain a plasma density of ∼ 10 18 m −3 for a 10 s ON, 210 s OFF duty cycle. Various modelling efforts have been employed to simulate the thermal and stress profiles over the primary components of the SupRISE device as well as the inductance behavior of the RF antenna. These simulation results and the final design for SupRISE will be presented. An additional reduced-scale predecessor ICP source (called RISE) has been used to develop a predictive match model that will be applied to frequency optimization studies on SupRISE. Furthermore, the outcomes of this research and complementary efforts at North Carolina State University are essential for the incorporation of ICP NBI positive ion sources at the DIII-D facility.

DIII-D↗

Computer simulation of the heavy-duty turbo-compounded diesel cycle for studies of engine efficiency and performance

Reductions in heat loss at appropriate points in the diesel engine which result in substantially increased exhaust enthalpy were shown. The concepts for this increased enthalpy are the turbocharged, turbocompounded diesel engine cycle. A computer simulation of the heavy duty turbocharged turbo-compounded diesel engine system was undertaken. This allows the definition of the tradeoffs which are associated with the introduction of ceramic materials in various parts of the total engine system, and the study of system optimization. The basic assumptions and the mathematical relationships used in the simulation of the model engine are described.

Assanis, D. N.↗

Ducted Fuel Injection And Cooled Spray Technologies For Particulate Control In Heavy-duty Diesel Engines (Final Report)

Cooled Spray (CS) and Ducted Fuel Injection (DFI) are in-cylinder technologies for diesel engines that can reduce particulate matter and soot emissions and data has been published showing that these technologies can reduce soot emissions by 75-100% for some engines at some operating conditions. However, little is known about scaling the devices for engine size. Additionally, the performance of either technology over the engine duty cycle has not been explored. This project addresses both of these points through single-cylinder engine investigations. The objectives of this project are to provide details about dimensional scaling of these devices and to demonstrate 75% PM reduction over a range of operating conditions on a single-cylinder engine. Two engines were used for this project: a 125mm bore optically accessible engine at Sandia National Laboratories and a 168mm bore metal engine at Southwest Research Institute. The optical engine was used to study the performance of DFI and CS inserts for a large injector orifice diameter injector that is characteristic of a locomotive engine and to perform scaling studies for DFI. The metal engine was used to perform scaling and alignment studies for CS and to evaluate the technology for both EGR and non-EGR engines over the engine operating map. Modifications were required for both engines to accept the prototype inserts being tested. The optical engine required a new fuel injector, cylinder head and piston so that tests could be run at the pressures and engine speeds required. Additionally, a novel rotating stage was designed for the optical engine to simplify alignment of the modules. The metal engine required a modified cylinder head to accept CS inserts and a modified piston to provide additional space around the fuel injector for the CS inserts. Tests on the optical engine showed that DFI reduces PM emissions for both small injector orifices (0.170mm diameter) and large injector orifices (0.290mm). For high load testing, the DFI modules were not as effective as at low load testing, but it was acknowledged that minimal geometric optimization was performed and more improvements may be possible. Comparing DFI to CS and conventional diesel combustion (CDC), DFI performed better than CS or CDC. The CS geometries used in these studies may not be ideal for that engine and additional modifications likely would improve performance. Tests on the metal engine showed PM reductions as high has 80% at some operating conditions with duty-cycle PM reductions of ~50% for EGR and non-EGR configurations. The CS testing on the metal engine showed that chamfering of the fuel passage inlet either through hydro-erosion or mechanical grinding provided significant improvements in the PM reduction capabilities of the insert. Additionally, alignment sensitivities were explored and the data show that the tolerance to misalignment is approximately 0.05 to 0.1mm for the inserts that were studied here. Air-fuel ratio was shown to be important in the effectiveness of the CS inserts. In several tests, it was shown that the CS inserts are more effective at reducing the PM for high-AFR operating conditions compared to low AFR conditions. In summary, multiple designs were evaluated on both engines. It was found that for the conditions and configurations studied here, a fuel passage diameter of ~2.5mm performed best overall. Significant duty-cycle PM reductions are possible using these technologies and sensitivities to AFR, alignment fuel passage diameter and inlet fuel passage shaping were explored and are reported here. More PM reduction may be possible with improved geometric design and attention to alignment practices.

02 PETROLEUM↗