Zachary Falgout

Cavitation Inside High-Pressure Optically Transparent Fuel Injector Nozzles

Nozzle-orifice flow and cavitation have an important effect on primary breakup of sprays. For this reason, a number of studies in recent years have used injectors with optically transparent nozzles so that orifice flow cavitation can be examined directly. Many of these studies use injection pressures scaled down from realistic injection pressures used in modern fuel injectors, and so the geometry must be scaled up so that the Reynolds number can be matched with the industrial applications of interest. A relatively small number of studies have shown results at or near the injection pressures used in real systems. Unfortunately, neither the specifics of the design of the optical nozzle nor the design methodology used is explained in detail in these papers. Here, a methodology demonstrating how to prevent failure of a finished design made from commonly used optically transparent materials will be explained in detail, and a description of a new design for transparent nozzles which minimizes size and cost will be shown. The design methodology combines Finite Element Analysis with relevant materials science to evaluate the potential for failure of the finished assembly. Finally, test results imaging a cavitating flow at elevated pressures are presented.

Optical sectioning for measurements in transient sprays

We describe a practical arrangement for optical sectioning by means of time-gated backscatter imaging using ultrafast illumination and a CS2-based optical Kerr effect shutter. This arrangement can reveal additional information when probing transient turbid media such as fuel injection sprays or complex multiphase flows which require single-shot imaging with sufficient time resolution to freeze the dynamics of the flow.

Novel design for transparent high-pressure fuel injector nozzles.

The efficiency and emissions of internal combustion (IC) engines are closely tied to the formation of the combustible air-fuel mixture. Direct-injection engines have become more common due to their increased practical flexibility and efficiency, and sprays dominate mixture formation in these engines. Spray formation, or rather the transition from a cylindrical liquid jet to a field of isolated droplets, is not completely understood. However, it is known that nozzle orifice flow and cavitation have an important effect on the formation of fuel injector sprays, even if the exact details of this effect remain unknown. A number of studies in recent years have used injectors with optically transparent nozzles (OTN) to allow observation of the nozzle orifice flow. Our goal in this work is to design various OTN concepts that mimic the flow inside commercial injector nozzles, at realistic fuel pressures, and yet still allow access to the very near nozzle region of the spray so that interior flow structure can be correlated with primary breakup dynamics. This goal has not been achieved until now because interior structures can be very complex, and the most appropriate optical materials are brittle and easily fractured by realistic fuel pressures. An OTN design that achieves realistic injection pressures and grants visual access to the interior flow and spray formation will be explained in detail. The design uses an acrylic nozzle, which is ideal for imaging the interior flow. This nozzle is supported from the outside with sapphire clamps, which reduces tensile stresses in the nozzle and increases the nozzles injection pressure capacity. An ensemble of nozzles were mechanically tested to prove this design concept.