Fuel temperature and injection pressure influence on the cold start GDI sprays

Cold start in gasoline direct injection engines (GDI) is a critical issue that significantly impacts fuel consumption and emissions. Therefore, it is essential to investigate and improve the spray and air-fuel mixing processes during cold starts. This study employed a complimentary set of optical diagnostic techniques, including line-of-sight(extinction, Schlieren, and long-distance microscopy) and 3D computed tomography (CT), to characterize and understand the cold-start spray dynamics under various fuel temperature and injection pressure conditions. The experiments were conducted in a constant volume spray vessel and the fuel temperature was varied using a coolant circulator, with temperatures reaching as low as -7°C to simulate cold-start conditions. The cold fuel exhibited longer liquid/vapor penetration lengths compared to hot fuel under low injection pressure conditions. This deterioration in spray characteristics was attributed to the attenuated fuel evaporation and reduced entrainment of ambient air. The 3D spray visualization obtained through the CT algorithm, particularly the cut plane images, revealed that plumes with low fuel temperatures had narrower individual plume widths, resulting in minimized plume-to-plume interaction. Microscopic imaging further confirmed this observation which showed separate plumes in the near-nozzle region for cold fuel conditions. Meanwhile, hot fuel under high injection pressure conditions exhibited complete plume collapsing, leading to a significant amount of liquid fuel remaining in the spray core. The liquid penetration reached 70mm during the injection period, potentially can cause wall wetting on the piston top or cylinder wall. Based on the experimental findings, this study suggests the application of multiple injections with a moderate level of injection pressure for optimized engine performance and reduced emissions during cold starts.