A study on the relationship between internal nozzle geometry and injected mass distribution of eight ECN Spray G nozzles

[EN] Gasoline direct injection (GDI) nozzles are manufactured to meet geometric specifications with length scales on the order of a few hundred microns. The machining tolerances of these nominal dimensions are not always known due to the difficulty in accurately measuring such small length scales in a nonintrusive fashion. To gain insight into the variability of the machined dimensions as well as any effects that this variability may have on the fuel spray behavior, a series of measurements of the internal geometry and fuel mass distribution were performed on a set of eight nominally duplicate GDI “Spray G” nozzles provided by the Engine Combustion Network. The key dimensions of each of the eight nozzle holes were measured with micron resolution using full spectrum x-ray tomographic imaging at the 7-BM beamline of the Advanced Photon Source at Argonne National Laboratory. Fuel density distributions at 2 mm downstream of the nozzle tips were obtained by performing x-ray radiography measurements for many lines of sight. The density measurements reveal nozzle-to-nozzle as well as hole-to-hole density variations. The combination of high-resolution geometry and fuel distribution datasets allows spray phenomena to be linked to specific geometric characteristics of the nozzle, such as variability in the hole lengths and counterbore diameters, and the hole inlet corner radii. This analysis provides important insight into which geometrical characteristics of the nozzles may have the greatest importance in the development of the injected sprays, and to what degree these geometric variations might account for the total spray variability. The goal of this work is then to further the understanding of the relationship between internal nozzle geometry and fuel injection, provide input to improve computational models, and ultimately aid in optimizing injector design for higher fuel efficiency and lower emissions engines.