Performance of an Al-Si-graphite particle composite piston in a diesel engine

Al-Si-graphite particle composite alloy pistons containing different percentages of about 80 μm uncoated graphite particles were successfully cast by foundry techniques. Tests with a 5 hp single-cylinder diesel engine show that Al-Si-graphite particle composite pistons can withstand an endurance test of 500 h without any apparent deterioration and do not seize during the running-in period. The use of the Al-Si-3% graphite particle composite piston also results in (a) up to 3% reduction in the specific fuel consumption, (b) considerable reduction in the wear of all four piston rings, (c) a reduction in piston wear, (d) a 9% reduction in the frictional horsepower losses of the engine as determined by the motoring test and (e) a slight increase in the exhaust gas temperature. These reductions (a)–(d) appear to be due to increased lubrication from the graphite particles which are smeared on the bearing surface, the higher damping capacity of the composite pistons and the reduced coefficient of thermal expansion of the composite pistons. Preliminary results indicate that aluminum-graphite particle composite alloy is a promising material for automotive pistons.

Velocity ratio-cum-transfer matrix method for the evaluation of a muffler with mean flow

The paper deals with a method for the evaluation of exhaust muffers with mean flow. A new set of variables, convective pressure and convective mass velocity, have been defined to replace the acoustic variables. An expression for attenuation (insertion loss) of a muffler has been proposed in terms of convective terminal impedances and a velocity ratio, on the lines of the one existing for acoustic filters. In order to evaluate the velocity ratio in terms of convective variables, transfer matrices for various muffler elements have been derived from the basic relations of energy, mass and momentum. Finally, the velocity ratiocum-transfer matrix method is illustrated for a typical straight-through muffler.

Running-in wear of a compression ignition engine: Factors influencing the conformance between cylinder liner and piston rings

The conformance between the liner and rings of an internal combustion engine depends mainly on their linear wear (dimensional loss) during running-in. Running-in wear studies, using the factorial design of experiments, on a compression ignition engine show that at certain dead centre locations of piston rings the linear wear of the cylinder liner increases with increase in the initial surface roughness of the liner. Rough surfaces wear rapidly without seizure during running-in to promote quick conformance, so an initial surface finish of the liner of 0.8 μm c.l.a. is recommended. The linear wear of the cast iron liner and rings decreases with increasing load but the mass wear increases with increasing load. This discrepancy is due to phase changes in the cast iron accompanied by dimensional growth at higher thermal loads. During running-in the growth of cast iron should be minimised by running the engine at an initial load for which the exhaust gas temperature is approximately 180 °C.

Hydrocarbon oxidation and three-way catalytic activity on a single step directly coated cordierite monolith: High catalytic activity of Ce0.98Pd0.02O2−δ

Catalytic activity of cordierite honeycomb by a completely new coating method for the oxidation of major hydrocarbons in exhaust gas is reported here. The new coating process consists of (a) dipping and growing γ-Al2O3 on cordierite by combustion of monolith dipped in the aqueous solution of Al(NO3)3 and oxalyldihydrazide (ODH) (or glycine) at 600 °C and active catalyst phase Ce0.98Pd0.02O2−δ on γ-Al2O3-coated cordierite again by combustion of monolith dipped in the aqueous solution of ceric ammonium nitrate, ODH and 1.2 × 10−3 M PdCl2 solution at 500 °C. Weight of active catalyst can be varied from 0.02 wt% to 2 wt% which is sufficient but can be loaded even up to 12 wt% by repeating dip dry combustion. Adhesion of catalyst to cordierite surface is via oxide growth, which is very strong. ‘HC’ oxidation over the monolith catalyst is carried out with a mixture having the composition, 470 ppm of both propene and propane and 870 ppm of both ethylene and acetylene with the varying amount of O2. Three-way catalytic test is done by putting hydrocarbon mixture along with CO (10 000 ppm), NO (2000 ppm) and O2 (15 000 ppm). Below 350 °C full conversion is achieved. In this method, handling of nano-material powder is avoided.

Investigations of the scaling criteria for a mild combustion burner

In this paper, a new strategy for scaling burners based on "mild combustion" is evolved and adopted to scaling a burner from 3 to a 150 kW burner at a high heat release Late of 5 MW/m(3) Existing scaling methods (constant velocity, constant residence time, and Cole's procedure [Proc. Combust. Inst. 28 (2000) 1297]) are found to be inadequate for mild combustion burners. Constant velocity approach leads to reduced heat release rates at large sizes and constant residence time approach in unacceptable levels of pressure drop across the system. To achieve mild combustion at high heat release rates at all scales, a modified approach with high recirculation is adopted in the present studies. Major geometrical dimensions are scaled as D similar to Q(1/3) with an air injection velocity of similar to 100 m/s (Delta p similar to 600 mm water gauge). Using CFD support, the position of air injection holes is selected to enhance the recirculation rates. The precise role of secondary air is to increase the recirculation rates and burn LIP the residual CO in the downstream. Measurements of temperature and oxidizer concentrations inside 3 kW, 150 kW burner and a jet flame are used to distinguish the combustion process in these burners. The burner can be used for a wide range of fuels from LPG to producer gas as extremes. Up to 8 dB of noise level reduction is observed in comparison to the conventional combustion mode. Exhaust NO emissions below 26 and 3 ppm and temperatures 1710 and 1520 K were measured for LPG and producer gas when the burner is operated at stoichiometry. (c) 2004 The Combustion Institute. Published by Elsevier Inc. All rights reserved.

Gas turbine diagnostics using a soft computing approach

A fuzzy system is developed using a linearized performance model of the gas turbine engine for performing gas turbine fault isolation from noisy measurements. By using a priori information about measurement uncertainties and through design variable linking, the design of the fuzzy system is posed as an optimization problem with low number of design variables which can be solved using the genetic algorithm in considerably low amount of computer time. The faults modeled are module faults in five modules: fan, low pressure compressor, high pressure compressor, high pressure turbine and low pressure turbine. The measurements used are deviations in exhaust gas temperature, low rotor speed, high rotor speed and fuel flow from a base line 'good engine'. The genetic fuzzy system (GFS) allows rapid development of the rule base if the fault signatures and measurement uncertainties change which happens for different engines and airlines. In addition, the genetic fuzzy system reduces the human effort needed in the trial and error process used to design the fuzzy system and makes the development of such a system easier and faster. A radial basis function neural network (RBFNN) is also used to preprocess the measurements before fault isolation. The RBFNN shows significant noise reduction and when combined with the GFS leads to a diagnostic system that is highly robust to the presence of noise in data. Showing the advantage of using a soft computing approach for gas turbine diagnostics.

Correlation of Oxygen Storage Capacity and Structural Distortion in Transition-Metal-, Noble-Metal-, and Rare-Earth-Ion-Substituted CeO2 from First Principles Calculation

Oxygen storage/release (OSC) capacity is an important feature common to all three-way catalysts to combat harmful exhaust emissions. To understand the mechanism of improved OSC for doped CeO2, we undertook the structural investigation by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), H-2-TPR (temperature-programmed hydrogen reduction) and density functional theoretical (DFT) calculations of transition-metal-, noble-metal-, and rare-earth (RE)-ion-substituted ceria. In this report, we present the relationship between the OSC and structural changes induced by the dopant ion in CeO2. Transition metal and noble metal ion substitution in ceria greatly enhances the reducibility of Ce1-xMxO2-delta (M = Mn, Fe, Co, Ni, Cu, Pd, Pt, Ru), whereas rare-earth-ion-substituted Ce(1-x)A(x)O(2-delta) (A = La, Y) have very little effect in improving the OSC. Our simulated optimized structure shows deviation in cation oxygen bond length from ideal bond length of 2.34 angstrom (for CeO2). For example, our theoretical calculation for Ce28Mn4O62 structure shows that Mn-O bonds are in 4 + 2 coordination with average bond lengths of 2.0 and 3.06 angstrom respectively. Although the four short Mn-O bond lengths spans the bond distance region of Mn2O3, the other two Mn-O bonds are moved to longer distances. The dopant transition and noble metal ions also affects Ce coordination shell and results in the formation of longer Ce-O bonds as well. Thus longer cation oxygen bonds for both dopant and host ions results in enhanced synergistic reduction of the solid solution. With Pd ion substitution in Ce1-xMxO2-delta (M = Mn, Fe, Co, Ni, Cu) further enhancement in OSC is observed in H-2-TPR. This effect is reflected in our model calculations by the presence of still longer bonds compared to the model without Pd ion doping. The synergistic effect is therefore due to enhanced reducibility of both dopant and host ion induced due to structural distortion of fluorite lattice in presence of dopant ion. For RE ions (RE = Y, La), our calculations show very little deviation of bonds lengths from ideal fluorite structure. The absence of longer Y-O/La-O and Ce-O bonds make the structure much less susceptible to reduction.

Catalytic hydrogen combustion for treatment of combustible gases from fuel cell processors

Catalytic combustion of H-2 was carried out over combustion synthesized noble metal (Pd or Pt) ion-substituted CeO2 based catalysts using a feed stream that simulated exhaust gases from a fuel cell processor The catalysts showed a high activity for H-2-combustion and complete conversion was achieved below 200 C over all the catalysts when O-2 was used in a stoichiometric amount With higher amounts of O-2 the reaction rates Increased and complete conversions were possible below 100 C The reaction was also carried out over Pd-impregnated CeO2 The conversions of H-2 with stoichiometric amount of O-2 were found to be higher over Pd-substituted compound The mechanism of the reaction over noble metal-substituted compounds was proposed on the basis of X-ray photoelectron spectroscopy studies The redox couples between Ce and metal ions were established and a dual site redox mechanism was pi posed for the reaction (C) 2010 Elsevier B V All rights reserved

Flow-Acoustic Performance of Perforated Element Mufflers With Application to Design

A fairly comprehensive computer program incorporating explicit expressions for the four-pole parameters of concentric-tube resonators, plug mufflers, and three-duct cross-flow perforated elements has been used for parametric studies. The parameters considered are hole diameter, the center-to-center distance between consecutive holes (which decides porosity), the incoming mean flow Mach number, the area expansion ratio, the number of partitions of chambers within a given overall shell length, and the relative lengths of these partitions or chambers, all normalized with respect to the exhaust pipe diameter. Transmission loss has been plotted as a function of a normalized frequency parameter. Additionally, the effect of the tail pipe length on insertion loss for an anechoic source has also been studied. These studies have been supplemented by empirical expressions for the normalized static pressure drop for different types of perforated-element mufflers developed from experimental observations.

Transverse plane wave analysis of short elliptical chamber mufflers: An analytical approach

Short elliptical chamber mufflers are used often in the modern day automotive exhaust systems. The acoustic analysis of such short chamber mufflers is facilitated by considering a transverse plane wave propagation model along the major axis up to the low frequency limit. The one dimensional differential equation governing the transverse plane wave propagation in such short chambers is solved using the segmentation approaches which are inherently numerical schemes, wherein the transfer matrix relating the upstream state variables to the downstream variables is obtained. Analytical solution of the transverse plane wave model used to analyze such short chambers has not been reported in the literature so far. This present work is thus an attempt to fill up this lacuna, whereby Frobenius solution of the differential equation governing the transverse plane wave propagation is obtained. By taking a sufficient number of terms of the infinite series, an approximate analytical solution so obtained shows good convergence up to about 1300 Hz and also covers most of the range of muffler dimensions used in practice. The transmission loss (TL) performance of the muffler configurations computed by this analytical approach agrees excellently with that computed by the Matrizant approach used earlier by the authors, thereby offering a faster and more elegant alternate method to analyze short elliptical muffler configurations. (C) 2010 Elsevier Ltd. All rights reserved.

Potential of bio-DME as a transportation fuel for India

This article discusses the potential of bio-dimethyl ether (DME) as a promising fuel for India in the transportation sector where a majority of imported petroleum in the form of diesel is used. Specifically, the suitability of DME in terms of its properties vis-a-vis those of diesel, ability to liquefy DME at low pressures similar to liquefied petroleum gas (LPG), and ease of production from renewable feedstock (biomass), and most importantly, very low emissions including near-zero soot levels are some of the features that make it an attractive option. A detailed review presents the state-of-the-art on various aspects such as estimates of potential bio-DME production, methods of synthesis of bio-DME, important physicochemical properties, fuel-injection system-related concerns (both conventional and common-rail system), fuel spray characteristics which have a direct bearing on the engine performance, and finally, exhaust emissions. Future research directions covering all aspects from production to utilization are summarized (C) 2010 American Institute of Physics. doi:10.1063/1.3489529]

Sonochemical reaction engineering

Ultrasound has been widely used by chemists to enhance yields as well as rates of homogeneous as well as heterogeneous chemical reactions. The effect of ultrasound on the course of chemical reactions is mediated through cavitation bubbles it generates. High temperatures and pressures are attained inside the cavitating bubbles when they collapse. The extreme conditions so generated lead to the formation of reactive intermediates, e.g., free radiacls, inside the bubbles, which cause chemical reactions to occur when they enter the surrounding liquid. This is the mechanism through which ultrasound influences the path of homogeneous reactions. The cavitation bubbles collapse asymmetrically in the vicinity of solids, e.g., catalyst particles. Asymmetric collapse lead to formation of high speed microjets. The microjets can enhance transport rates, the increase surface area through pitting as well as particle fragmentation through collisions. Both can alter the rates of heterogeneous reaction rates. It however appears that these effects do not exhaust the scope of the influence of ultrasound on heterogeneous reactions. Modelling and quantitative prediction of the effect of ultrasound on chemical reactions is however at a stage of infancy as the phenomena are complex. Only a few examples of modelling exist in literature. Apart from this, reactor design and scaleup pose significant problems. Thus sonochemical reaction engineering offers large scope for research and development efforts.

Three- and Seven-Point Optimally Weighted Recursive Median Filters for Gas Turbine Diagnostics

Measured health signals incorporate significant details about any malfunction in a gas turbine. The attenuation of noise and removal of outliers from these health signals while preserving important features is an important problem in gas turbine diagnostics. The measured health signals are a time series of sensor measurements such as the low rotor speed, high rotor speed, fuel flow, and exhaust gas temperature in a gas turbine. In this article, a comparative study is done by varying the window length of acausal and unsymmetrical weighted recursive median filters and numerical results for error minimization are obtained. It is found that optimal filters exist, which can be used for engines where data are available slowly (three-point filter) and rapidly (seven-point filter). These smoothing filters are proposed as preprocessors of measurement delta signals before subjecting them to fault detection and isolation algorithms.

Fuzzy logic intelligent system for gas turbine module and system fault isolation

A fuzzy logic intelligent system is developed for gas-turbine fault isolation. The gas path measurements used for fault isolation are exhaust gas temperature, low and high rotor speed, and fuel flow. These four measurements are also called the cockpit parameters and are typically found in almost all older and newer jet engines. The fuzzy logic system uses rules developed from a model of performance influence coefficients to isolate engine faults while accounting for uncertainty in gas path measurements. It automates the reasoning process of an experienced powerplant engineer. Tests with simulated data show that the fuzzy system isolates faults with an accuracy of 89% with only the four cockpit measurements. However, if additional pressure and temperature probes between the compressors and before the burner, which are often found in newer jet engines, are considered, the fault isolation accuracy rises to as high as 98%. In addition, the additional sensors are useful in keeping the fault isolation system robust as quality of the measured data deteriorates.

Noise and outlier removal from jet engine health signals using weighted FIR median hybrid filters

The removal of noise and outliers from measurement signals is a major problem in jet engine health monitoring. Topical measurement signals found in most jet engines include low rotor speed, high rotor speed. fuel flow and exhaust gas temperature. Deviations in these measurements from a baseline 'good' engine are often called measurement deltas and the health signals used for fault detection, isolation, trending and data mining. Linear filters such as the FIR moving average filter and IIR exponential average filter are used in the industry to remove noise and outliers from the jet engine measurement deltas. However, the use of linear filters can lead to loss of critical features in the signal that can contain information about maintenance and repair events that could be used by fault isolation algorithms to determine engine condition or by data mining algorithms to learn valuable patterns in the data, Non-linear filters such as the median and weighted median hybrid filters offer the opportunity to remove noise and gross outliers from signals while preserving features. In this study. a comparison of traditional linear filters popular in the jet engine industry is made with the median filter and the subfilter weighted FIR median hybrid (SWFMH) filter. Results using simulated data with implanted faults shows that the SWFMH filter results in a noise reduction of over 60 per cent compared to only 20 per cent for FIR filters and 30 per cent for IIR filters. Preprocessing jet engine health signals using the SWFMH filter would greatly improve the accuracy of diagnostic systems. (C) 2002 Published by Elsevier Science Ltd.