Fuel Injector Holes

(Fabrication of Micro-Orifices for Fuel Injectors)

George Fenske, Nicholaos Demas,

and Robert Erck
Argonne National Laboratory
May 11th, 2011
PM003
pm003_fenske_2011_o
This presentation does not contain any proprietary, confidential, or otherwise restricted information
 Overview
Timeline Barriers
 Project start date FY04  Emissions – reduction of in-cylinder
 Project end date FY14 formation of particulates
 Efficiency – improved combustion and
 Percent complete 80% mitigation of after-treatment fuel
consumption

Budget Partners
 Total Project Funding ~$2 M  Imagineering Finishing Technologies
– DOE Share ~$1.5M  Fuel system OEMs
– Collaborator Share ~$0.25M  Engine OEM
 Small business - integration of
 FY10 $400 K electroless nickel (EN) process into
 FY11 $200 K (CR) nozzle production line
 U.S. EPA

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Project Objectives - Relevance

 Main objective/goal of the project is the development of fuel injector

manufacturing technology to reduce diesel emissions by reducing in-
cylinder production of particulates.
– Potential secondary benefits are higher fuel efficiency through improved fuel
atomization and combustion, and reduced use of fuel for regeneration of particulate
matter (PM) traps.
 Multiple paths are being pursued by DOE & industry to reduce emissions:
– After-treatment devices (NOx and PM traps)
– Alternative combustion cycles (homogeneous charge compression ignition and low
temperature combustion)
– Improved fuel injector designs – fuel atomization (in-cylinder reduction of
particulates)
 DOE Workshop “RESEARCH NEEDS RELATED TO FUEL INJECTION
SYSTEMS IN CIDI AND SIDI ENGINES” identified following needs:
– Manufacturing technologies that would be used for cost effectively producing ultra-
small holes and controlling dimensions with ultra precision
– Materials and coatings to resist fatigue, wear, and corrosion; sensors and controls;
non-traditional fuel injection; modeling and simulation, etc.
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Objective of Work
 Combustion studies have demonstrated that reducing the orifice diameter on an
injector decreases the amount of particulates formed during combustion.
 Objective of research is to develop technologies to fabricate 50-µm diameter (or
less) micro-orifices for high-pressure diesel injectors.
– Reduce in-cylinder production of particulates (lower emissions) with no fuel economy
penalty.
– Improve combustion of fuel (improved fuel efficiency).

125 to 200 µm 4
d H φ(H)

Optical Thickness- KL
(µm) (mm) 180 µm
3 180 21.8 5.0
100 18.3 3.4
71 18.0 2.4
2 50 18.1 1.6
100 µm

1
71 µm

50 µm
0
0 20 40 60 80
Axial distance from injector (mm)

Courtesy L. Pickett SNL-Livermore

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Project Milestones
 FY 2010
– Preparation of multi-sized (40/145 μm) micro-orifices on commercial nozzles for spray
visualization studies at the U.S. EPA (completed)
• EPA contact no longer involved in spray visualization studies, seeking alternative partner for
flow studies
– Establishment of collaborative agreements with engine and nozzle OEMs to accelerate
technology validation
• Separate agreements in place with international injector OEM and domestic engine OEM (FY
11); proposal with vehicle OEM developed and submitted to DOE (FY 11)
 FY 2011
– Demonstration of x-ray absorption imaging technique for nondestructive evaluation
(NDA) of internal coated orifice surfaces (completed)
– Evaluation of ASTM Method G32-09 to determine cavitation erosion performance of
plated nozzles (completed)
• Cavitation erosion studies (in progress)
– Preparation of 2nd generation multi-orifice nozzles (50/110 μm) for nozzle OEM
evaluation (in progress)
• Two collaborations in progress (engine OEM, injector OEM)

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Approach Electrodischarge (current process), plating
 Identify potential micro-orifice fabrication (aqueous, CVD/PVD), laser processing, LIGA, …
techniques
– No technology exists to economically Electroless Nickel
produce robust 50 µm orifices (EN) – autocatalytic
 Down select – 50 µm, maturity, cost, scale-up deposition of Ni from
 Demonstrate feasibility (lab) aqueous solution
 Identify and resolve technical barriers
– Uniformity, adhesion, deposit formation,
hardness, fatigue, reduced flow, etc.
 Treat prototypic components (Tech Transfer) USEPA
NVFEL
 Conduct spray visualization studies (EPA)
– Single-size orifices (50 µm)
 Prepare multi-sized orifices (e.g., 40 µm and
145 µm) on the same nozzle to maintain fuel 50 µm Ø
flow capability and improve combustion
– Detailed microstructural analysis
 Conduct NDE of multi-size orifices (x-ray 100 µm Ø
imaging)
 Manufacturing optimization (re-grind)
 Pop-testing (QA – prior to spray studies)
 Cavitation erosion studies
 Engine emission and efficiency studies
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Accomplishment – Demonstrated feasibility to coat
interior surfaces of small injector orifices using EN.

 Autocatalytic EN process generates hydrogen bubbles that adhere to surface and

prevent uniform coverage.
 Multiple mechanical techniques are being pursued to mitigate adhesion of H2
bubbles.

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Accomplishment: Addressed and resolved Accomplishment: Transferred
early issues related to coating adhesion. concept/technology to industrial
plater/coater.
 Initial adhesion issues were addressed  Lab-scale process transferred to
and resolved with proper control of commercial size operation.
precleaning/etching, control of
solution chemistry, and post-
deposition annealing.

Poor Adhesion

– Reduced small-batch chemistry

Inside the tip of
the orifice
variations.
Good Adhesion – Standardized cleaning and post-
Outside of deposition treatments.
Injector
– Access to knowledge base.
Progress/Accomplishment: Flow Visualization - Demonstrated enhanced flow
characteristics in single-size orifices (100, 75, and 50 μm) at 3000 bar.
Argonne Nozzle: 7x0.05x157 Argonne Nozzle: 7x0.075x157 Ann Arbor Nozzle: 7X0.10mmx160

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Courtesy – Ron Schaefer, USEPA/NVFEL
Accomplishment – Demonstrated feasibility of 3-D x-ray
imaging to examine the uniformity of EN coatings applied
to commercial fuel injectors (multi-size orifice).
 Potential of a high- Coated
resolution (< 2 μm) x-ray Uncoated
orifice
absorption technique was orifice
investigated to image the
internal volume of the
orifices after plating.
– Original expectation was to
image the void regions
only.

 Imaging capabilities exceed

original expectations.
– In addition to imaging the
void region, the technique
was able to delineate the
coating (Ni-P alloy) from
the ferrous injector alloy. X-ray absorption image of commercial nozzle
containing coated and uncoated orifices
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3-D x-ray movie of coated injector (illustrating EN
coating on interior orifices)

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3D imaging of plated nozzle with needle

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Accomplishment – Recent trials to mask critical regions
show promise to eliminate additional manufacturing
step to regrind barrel after EN.
 Current protocols to fabricate
micro-orifices require a Mini-sac
separate re-grind step to
remove EN plating from the EN-plating
nozzle bore.
 Recent efforts were initiated to
explore application of masks to
eliminate EN plating in critical Smooth
regions. interface
 Initial results suggest coating in
seat area is sufficiently smooth Needle
and may not require re-
grinding. Slice from 3D CAT scan of EN-plated nozzle
showing the mini-sac region with needle.
– Additional analysis at higher
Note smooth cross section of plating
resolution planned to examine
adjacent to needle in the seat.
surface finish at needle/seat
interface.
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 Accomplishment – Initial trials to mask critical regions
show promise to eliminate additional manufacturing
step to regrind barrel after EN.
 Current protocols to fabricate micro-orifices require a separate re-grind step to remove EN
plating from the nozzle bore.
 Recent efforts initiated to explore application of masks to eliminate EN plating in critical regions.
 Initial results suggest coating in seat area is sufficiently smooth and may not require re-grinding.
– Additional analysis at higher resolution planned to examine surface finish at needle/seat
interface.

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Accomplishment – Masking nozzle barrel and “pop” test validation of
injector performance
 Similar to previous discussion on
masking critical areas to
mitigate need to re-grind the
nozzle, efforts to mask the
barrel region showed promise.
 Several nozzles were plated with
a special mask that covered the
barrel region. Subsequent tests
indicated the original needle
(fitted to a tolerance of several
microns) was able to be re-
inserted into the plated nozzle
without re-grinding the barrel. Pop-test images of injector spray
 Subsequent pop-tests (at 3-5 Left: unplated nozzle
ksi) on plated nozzles Right: EN-plated nozzle, no re-grind
demonstrate micro-orifices are
open (after mechanical agitation
to remove plating salts).

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Cavitation Erosion – Demonstrated mechanical
sonication can induce cavitation erosion in fuel
injector coupons.
 Efforts continued to define
technique to simulate
cavitation with ASTM G 32-09
lab-scale technique.
 Initial tests with low-grade Cavitation erosion on
steel demonstrated fast Cavitation at low-grade steel
erosion (within tens of tip of horn
minutes).
 Tests with coupons machined Cavitation erosion on
from commercial nozzles also nozzle coupon
demonstrated erosion, but at
a much lower rate (hours).
 Custom fabrication of coupons
from high-grade tool steel to
simulate nozzle alloy is being
investigated.

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Collaborations/Coordination with Other Institutions
 Development of processes to fabricate micro-orifices on commercial nozzles
involves coordination of different manufacturing steps:
– Injector OEMs – providing nozzles for development efforts
– Electrodischarge machining (EDM) of orifices on existing commercial nozzles (either
nozzle blanks or nozzles with pre-existing orifices) [LEER (industry)]
– High-pressure abrasive honing of EDM orifices to increase flow characteristics [Extrude
Hone (industry)]
– Electroless nickel plating of nozzles [Imagineering (industry)]
– Tooling firm to re-grind nozzles [C&A Tooling]

 During FY11 several collaborative efforts were initiated, including*:

– Nondisclosure agreement established with international fuel injector OEM
– Work-for-others contract negotiations with an engine OEM
– Development of a proposal for DOE with an integral team consisting of a vehicle OEM,
engine OEM, injector designer/manufacturer, and plater.

 Collaborations with U.S. EPA being pursued on potential emission studies (subject
to availability of funding)
* Names withheld subject to nondisclosure agreements.

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Proposed Future Work

 Near Future (FY11/12)

– Flow visualization studies by U.S. EPA
– Preparation of single and multi-sized orifice nozzles for evaluation by OEMs
– Cavitation erosion studies
– Development of 3-D x-ray imaging for in-situ characterization of orifice surfaces and
cavitation erosion

 Longer Term (parallel) Activity (FY 11/15)

– Combustion studies on instrumented single-cylinder rigs (national labs or industry)
– Engine emission studies
• National labs
• Engine OEM
– Integration of overall fabrication processes
• Nozzle and/or engine OEM

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 Summary
 Based on studies that demonstrated significant reductions in soot production with decreasing
orifice diameter, initiated efforts to identify and develop processes to fabricate micro-orifices on
commercial nozzles.
– Improved fuel atomization reduces soot/particulate formation and improves air entrainment, thereby
improving combustion efficiency.
 Examined multiple orifice fabrication approaches early in the project, selecting the EN process.
 Demonstrated the EN process for fabricating micro-orifices on commercial fuel injectors.
 Worked with industry: technical barriers were identified and resolved (uniformity, adhesion, and
hardness).
 Completed spray visualization studies in collaboration with the U.S. EPA :
– Smaller orifices resulted in shorter liquid penetration length and an appreciably shorter spray core
length.
– Smaller orifices enhanced atomization.
 Successfully demonstrated ability to fabricate multi-size orifices (6 @ 40 μm + 6 @ 145 μm).
 Demonstrated 3-D x-ray NDE technique to image orifice and coating on treated nozzles.
 Established multiple collaborations with industry to accelerate introduction of micro-orifice
technology.
 Efforts in FY11/12 will focus on spray visualization studies of multi-sized orifices and
performance evaluation with nozzle OEM.
 Future efforts will focus on engine emission studies.