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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

An Experiment Investigation of Fully-Modulated, Turbulent Diffusion Flames in Reduced Gravity

Pulsed combustion appears to have the potential to provide for rapid fuel/air mixing, compact and economical combustors, and reduced exhaust emissions. The ultimate objective of this program is to increase the fundamental understanding of the fuel/air mixing and combustion behavior of pulsed, turbulent diffusion flames by conducting experiments in microgravity. In this research the fuel jet is fully-modulated (i.e., completely shut off between pulses) by an externally controlled valve system. This can give rise to drastic modification of the combustion and flow characteristics of flames, leading to enhanced fuel/air mixing mechanisms not operative for the case of acoustically excited or partially-modulated jets. In addition, the fully-modulated injection approach avoids the strong acoustic forcing present in pulsed combustion devices, significantly simplifying the mixing and combustion processes. Relatively little is known of the behavior of turbulent flames in reduced-gravity conditions, even in the absence of pulsing. The goal of this Flight-Definition experiment (PUFF, for PUlsed-Fully Flames) is to establish the behavior of fully-modulated, turbulent diffusion flames under microgravity conditions. Fundamental issues to be addressed in this experiment include the mechanisms responsible for the flame length decrease for fully-modulated, turbulent diffusion flames compared with steady flames, the impact of buoyancy on the mixing and combustion characteristics of these flames, and the characteristics of turbulent flame puffs under fully momentum-dominated conditions.

Hermanson, J. C.↗
NASA NTRS1990

STS-31: APU Controller Removal

The launch April 10 of the STS-31 was scrubbed at T-4 minutes due to a faulty valve in auxiliary power unit (APU) number one. The auxiliary power unit is a hydrazine-fueled, turbine-driven power unit that generates mechanical shaft power to drive a hydraulic pump that produces pressure for the orbiter's hydraulic system. This video shows the removal of the STS-31's auxiliary power unit (APU).

Source record↗
NASA NTRS2003

Buoyancy Effects in Fully-Modulated, Turbulent Diffusion Flames

Pulsed combustion appears to have the potential to provide for rapid fuel/air mixing, compact and economical combustors, and reduced exhaust emissions. The objective of this experiment (PuFF, for Pulsed-Fully Flames) is to increase the fundamental understanding of the fuel/air mixing and combustion behavior of pulsed, turbulent diffusion flames by conducting experiments in microgravity. In this research the fuel jet is fully-modulated (i.e., completely shut off between pulses) by an externally controlled valve system. This gives rise to drastic modification of the combustion and flow characteristics of flames, leading to enhanced fuel/air mixing compared to acoustically excited or partially-modulated jets. Normal-gravity experiments suggest that the fully-modulated technique also has the potential for producing turbulent jet flames significantly more compact than steady flames with no increase in exhaust emissions. The technique also simplifies the combustion process by avoiding the acoustic forcing generally present in pulsed combustors. Fundamental issues addressed in this experiment include the impact of buoyancy on the structure and flame length, temperatures, radiation, and emissions of fully-modulated flames.

Hermanson, J. C.↗
DOE OSTI2021

The Effect of Spark-Plug Heat Dispersal Range and Exhaust Valve Opening Timing on Cold-Start Emissions and Cycle-to-Cycle Variability

The partnership for advancing combustion engines (PACE) is a US Department of Energy consortium involving multiple national laboratories and includes a goal of addressing key efficiency and emission barriers in light-duty engines fueled with a market-representative E10 gasoline. A major pillar of the initiative is the generation of detailed experimental data and modeling capabilities to understand and predict cold-start behavior. Cold-start, as defined by the time between first engine crank and three-way catalyst light-off, is responsible for a large percentage of NOx, unburned hydrocarbon and particulate matter emissions in light-duty engines. Minimizing emissions during cold-start is a trade-off between achieving faster light-off of the three-way catalyst and engine out emissions during that period. In this study, gaseous and soot emissions were measured at a distance representative of the three-way catalyst position downstream of the engine at a 2 bar net indicated mean effective pressure (NIMEP) steady-state operating condition representative of cold-start. The test matrix included sweeps of ignition timing 15 degrees-before to 10 degrees-after top dead center firing (TDCf) across three different spark-plug heat dispersal ranges (HR). Additionally, the effect of varying exhaust valve opening (EVO) timing on combustion stability and emissions was also studied. Results show that the spark plug HR affects the coefficient of variation (COV) of NIMEP under all cold-start conditions, while the impact on emissions was found to be minimal. At very retarded spark timings, colder spark plugs required higher air and fuel flow to maintain the desired 2bar NIMEP load, but the fraction of fuel energy going into the exhaust was found to be similar for all spark plugs. Finally, retarding exhaust valve timings showed a simultaneous reduction in emissions while increasing the fraction of fuel energy being fed into the exhaust. However, engine COV was also observed to increase with retarded exhaust timings.

42 ENGINEERING↗
NASA NTRS1984

Detonation wave augmentation of gas turbines

The results of a feasibility study that examined the effects of using detonation waves to augment the performance of gas turbines are reported. The central ideas were to reduce compressor requirements and to maintain high performance in jet engines. Gasdynamic equations were used to model the flows associated with shock waves generated by the detonation of fuel in detonator tubes. Shock wave attenuation to the level of Mach waves was found possible, thus eliminating interference with the compressor and the necessity of valves and seals. A preliminary parametric study of the performance of a compressor working at a 4:1 ratio in a conceptual design of a detonation wave augmented jet engine in subsonic flight indicated a clear superiority over conventional designs in terms of fuel efficiency and thrust.

Wortman, A.↗
DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The influence of intake flow and coolant temperature on gasoline spray morphology during early-injection DISI engine operation

Multi-hole gasoline injectors operating at conditions spanning throttled early-intake stroke operation produce spray plumes that either remained separated or merge and collapse due to flash boiling. Flash boiling occurs due to the sudden expansion of gas bubbles in the liquid fuel at high fuel temperature and low ambient pressure. This study records high-speed images of spray-morphology changes due to in-cylinder flow, thereby revealing operating conditions that do and do not affect the self-induced morphology observed in quiescent vessels. Specifically, in a central-injection, four-valve, high-tumble engine, where the thermodynamic state and in-cylinder cross flow are dynamic. Motivated by cold start and hot restart operation, the fuel pressure, coolant temperature, in-cylinder air pressure, and engine rpm were systematically varied over relevant operating conditions, which bracketed the range from non- to flash-boiling sprays. The results reveal the operating conditions at which the in-cylinder cross flow disrupts the spray morphology as well as the extent of the disruption. At 650 rpm, the spray morphology was similar to that observed in quiescent vessels at nominally equivalent fuel temperature and in-cylinder pressure, indicating that the spray’s self-induced entrainment flow dominated the in-cylinder flow. However, for fuel temperature and ambient pressure near the transition between non- and flash-boiling, the intake cross flow at higher engine speed (1950 rpm) significantly disrupted the spray morphology. The high cross-flow velocity appears to induce plume merging and collapse, whereas none was evident at low rpm (650 rpm). This study led to the postulate that the spray merging and collapse are governed by the rate of atomization near the nozzle exit, presumed to be controlled by either or both aerodynamic atomization and flash-boiling intensity. It would then follow that spray modeling in CFD requires atomization models that blend the effects of both physical processes.

42 ENGINEERING↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part 2

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. Here, a high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine. This paper defines a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute mixtures when properly matched to fuel spray characteristics, injection strategy, and a high-energy ignition system. Boost system layout and base engine architecture were selected to minimize parasitics and maximize after treatment effectiveness. A multi-cylinder engine was developed and calibrated over a steady-state map. Results fed vehicle simulations over the EPA city and highway test cycles to predict the fuel economy improvement and tailpipe emissions potential. Fuel economy improvements over the baseline vehicle were projected at 42% and 39% for active-urea and passive-ammonia SCR after treatment systems respectively. Controls complexity to achieve regulatory compliance and the cost of the lean after treatment system were identified as the primary challenges to commercial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1999

Simulation of Non-Acoustic Combustion Instability in a Hybrid Rocket Motor

A transient model of a hybrid motor was formulated to study the cause and elimination of non-acoustic combustion instability. The transient model was used to simulate four key tests out of a series of seventeen hybrid motor tests conducted by Thiokol, Rocketdyne and Martin Marietta at NASA/Marshall Space Flight Center (NASA/MSFC). These tests were performed under the Hybrid Propulsion Technology for Launch Vehicle Boosters (HPTLVB) program. The first test resulted in stable combustion. The second test resulted in large-amplitude, 6.5 Hz chamber pressure oscillations that gradually damped away by the end of the test. The third test resulted in large-amplitude, 7.5 Hz chamber pressure oscillations that were sustained throughout the test. The seventh test resulted in the elimination of combustion instability with the installation of an orifice immediately upstream of the injector. The formulation and implementation of the model are the scope of this presentation. The current model is an independent continuation of modeling presented previously by joint Thiokol-Rocketdyne collaborators Boardman, Hawkins, Wassom, and Claflin. The previous model simulated an unstable IR&D hybrid motor test performed by Thiokol. There was very good agreement between the model and the test data. Like the previous model, the current model was developed using Matrix-x simulation software. However, the tests performed at NASA/MSFC under the HPTLVB program were actually simulated. In the current model, the hybrid motor consisting of the liquid oxygen (LOX) injector, the multi-port solid fuel grain and the nozzle was simulated. Also, simulated in the model was the LOX feed system consisting of the tank, venturi, valve and feed lines. All components of the hybrid motor and LOX feed system are treated by a lumped-parameter approach. Agreement between the results of the transient model and the actual test data was very good. This agreement between simulated and actual test data indicated that the combustion instability in the hybrid motor was due to two causes. The first cause was a LOX feed system of insufficient stiffness. The second cause was a LOX injector with an impedance or pressure drop that was too low to provide damping against the feed system oscillations. Also, it was discovered that testing with a new grain of solid fuel sustained the combustion instability. However, testing with a used grain of solid fuel caused the combustion instability to gradually decay.

Rocker, Marvin↗
NASA NTRS1999

Simulation of Non-Acoustic Combustion Instability in a Hybrid Rocket Motor

A transient model of a hybrid motor was formulated to study the cause and elimination of non-acoustic combustion instability. The transient model was used to simulate four key tests out of a series of seventeen hybrid motor tests conducted by Thiokol, Rocketdyne and Martin Marietta at NASA/Marshall Space Flight Center (NASAIMSFC). These tests were performed under the Hybrid Propulsion Technology for Launch Vehicle Boosters (HPTLVB) program. The first test resulted in stable combustion. The second test resulted in large-amplitude, 6.5 Hz chamber pressure oscillations that gradually damped away by the end of the test. The third test resulted in large-amplitude, 7.5 Hz chamber pressure oscillations that were sustained throughout the test. The seventh test resulted in the elimination of combustion instability with the installation of an orifice immediately upstream of the injector. The formulation and implementation of the model are the scope of this presentation. The current model is an independent continuation of modeling presented previously by joint Thiokol-Rocketdyne collaborators Boardman, Hawkins, Wassom, and Claflin. The previous model simulated an unstable IR&D hybrid motor test performed by Thiokol. There was very good agreement between the model and the test data. Like the previous model, the current model was developed using Matrix-x simulation software. However, the tests performed at NASA/MSFC under the HPTLVB program were actually simulated. In the current model, the hybrid motor consisting of the liquid oxygen (LOX) injector, the multi-port solid fuel grain and the nozzle was simulated. Also, simulated in the model was the LOX feed system consisting of the tank, venturi, valve and feed lines. All components of the hybrid motor and LOX feed system are treated by a lumped-parameter approach. Agreement between the results of the transient model and the actual test data was very good. This agreement between simulated and actual test data indicated that the combustion instability in the hybrid motor was due to two causes. The first cause was a LOX feed system of insufficient stiffness. The second cause was a LOX injector with an impedance or pressure drop that was too low to provide damping against the feed system oscillations. Also, it was discovered that testing with a new grain of solid fuel sustained the combustion instability. However, testing with a used grain of solid fuel caused the combustion instability to gradually decay.

Rocker, Marvin↗
DOE OSTI2026

Design of a SMART Valve Testbed for Nuclear Thermal Dispatch

By the year 2050, the United States aims to achieve net-zero carbon emissions. To achieve this target, the licensing of the Light Water Reactor (LWR) fleet has been extended for 20 more years. To stay economically competitive with other power sources such as renewable and fossil-fuel power plants, the U.S. Department of Energy has introduced a plan to modernize the existing LWR fleet and diversify the revenue stream. One of the plans is to dispatch thermal energy to endothermic industrial processes. SMART valves will play an important role in this initiative by efficiently balancing the load by regulating valves in a coordinated manner while monitoring the thermal-hydraulic systems to enhance safety and maintain the integrity of the power plant. This research aims to develop a facility to test the coordinated control algorithm and produce various test results for training the monitoring system. The constructed facility is capable of simulating various operational and accidental scenarios by coordinating all the valves (positions) and pump (flowrate). The facility is developed with an Internet of Things (IoT)-based custom system and a python-based valve position control and coordination mechanism. It has achieved stable sensor outputs, pump control, and coordinated valve regulation in all three valves with minimum obstruction in the system.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2013

Project Profile: Hydrogen Fuel Cell Mobile Lighting Tower (HFCML)

NASA is committed to finding innovative solutions that improve the operational performance of ground support equipment while providing environment and cost benefits, as well. Through the Hydrogen Fuel Cell Mobile Lighting Tower (HFCML) project, NASA gained operational exposure to a novel application of high efficiency technologies. Traditionally, outdoor lighting and auxiliary power at security gates, launch viewing sites, fallback areas, outage support, and special events is provided by diesel generators with metal halide lights. Diesel generators inherently contribute to C02, NOx, particulate emissions, and are very noisy. In 2010, engineers from NASA's Technology Evaluation for Environmental Risk Mitigation Principal Center (TEERM) introduced KSC operations to a novel technology for outdoor lighting needs. Developed by a team led by Sandia National Laboratory (SNL), the technology pairs a 5kW hydrogen fuel cell with robust high efficiency plasma lights in a towable trailer. Increased efficiency, in both the fuel cell power source and lighting load, yields longer run times between fueling operations while providing greater auxiliary power. Because of the unit's quiet operation and no exhaust fumes, it is capable of being used indoors and in emergency situations, and meets the needs of all other operational roles for metal halide/diesel generators. The only discharge is some water and warm air. Environmental benefits include elimination of diesel particulate emissions and estimated 73% greenhouse gas emissions savings when the hydrogen source is natural gas (per GREET model). As the technology matures the costs could become competitive for the fuel cell units which are approximately 5 times diesel units. Initial operational . concerns included the hydrogen storage tanks and valves, lightning safety/grounding, and required operating and refueling procedures. TEERM facilitated technical information exchange (design drawings, technical standards, and operations manuals) necessary for KSC hydrogen system experts to approve use of the HFCML unit, including initiating the environmental checklist (i.e. exterior lighting waiver due to sea turtles), and development of operations and maintenance instructions. TEERM worked with SNL to establish a bailment agreement for KSC to utilize a Beta unit as part of normal Center Operations for a period of twelve months.

McLaughlin, Russell↗
DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗
NASA NTRS1930

Effect of Orifice Length-Diameter Ratio on Spray Characteristics

The effect of variations of orifice length to diameter ratio on spray characteristics was determined for a 0.014-inch and a 0.040-inch orifice for ratio of 0.5 to 4.0. The nozzles containing the orifices were mounted in an injection valve and tested with a plan stem and with a helically grooved stem. The injection pressure was varied from 4000 to 8000 pounds per square inch. The air density into which the fuel was sprayed was varied from the density obtained with a pressure of 60 pounds per square inch to the density obtained with a pressure of 250 pounds per square inch at room temperature. The tests showed that increasing the orifice length to diameter ratio with a plain stem in the injection valve causes the spray tip penetration first to decrease, reaching a minimum between a ratio of 1.5 and 2.5, and then to increase, reaching a maximum at a ratio greater than 3.5. The spray cone angle showed little change with variation of the ratio. With a helically grooved stem and small ratio of orifice area to groove area, the penetration at first shows little tendency towards a minimum; but as the time of injection is increased to 0.004 second, the penetration becomes a minimum at a ratio between 0.5 and 2.0.

Gellales, A G↗
NASA NTRS1974

Linear Test Bed. Volume 2: Test Bed No. 2

Test bed No. 2 consists of 10 combustors welded in banks of 5 to 2 symmetrical tubular nozzle assemblies, an upper stationary thrust frame, a lower thrust frame which can be hinged, a power package, a triaxial combustion wave ignition system, a pneumatic control system, pneumatically actuated propellant valves, a purge and drain system, and an electrical control system. The power package consists of the Mark 29-F fuel turbopump, the Mark 29-0 oxidizer turbopump, a gas generator assembly, and propellant ducting. The system, designated as a linear aerospike system, was designed to demonstrate the feasibility of the concept and to explore technology related to thrust vector control, thrust vector optimization, improved sequencing and control, and advanced ignition systems. The propellants are liquid oxygen/liquid hydrogen. The system was designed to operate at 1200-psia chamber pressure at an engine mixture ratio of 5.5. With 10 combustors, the sea level thrust is 95,000 pounds.

Source record↗
NASA NTRS1938

Discharge characteristics of a simulated unit injection system

Rate-of-discharge curves that show the discharge characteristics of an injection system having a very short fuel passage are presented. The rate of discharge closely follows the rate of displacement of the injection-pump plunger for open nozzles in which the maximum calculated pressures at the orifice do not exceed a certain value, which is dependent on the particular injection pump. With small orifices and high pump speeds, the rate of discharge does not follow the rate of plunger displacement because the higher discharge pressure results in increased leakage with corresponding decrease in discharge rate. The rate of discharge is not directly related to the rate of plunger displacement with automatic injection valves having closed nozzles. The types of pump check valve tested did not control the rate of cut-off or the discharge rate but they did affect the injection lag. Use of the short fuel passage eliminated the formation of secondary discharges.

Marsh, Edred T↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part I

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

33 ADVANCED PROPULSION SYSTEMS↗