Analysis of Thermomechanical Stress of High-Temperature Ignition Surface Caused by Drop–Wall Interaction at Engine Conditions

Abstract

Abstract Drop–wall interaction is a complex phenomenon encountered in diverse industrial applications. An important example is fuel droplets impinging on a high-temperature ignition plug in a direct-injection compression-ignition engine. The ignition plug, comprised of heat-resistant materials, will experience thermal shock due to abrupt temperature changes. The ensuing temperature fluctuation in the solid wall induces thermal stress, and if this stress surpasses the material's strength in that mode, failure can occur. Therefore, it is imperative to analyze the temperature dynamics on the high-temperature surface to enhance material durability. This study focuses on drop–wall interactions in the engine environment. Utilizing the Smoothed Particle Hydrodynamics (SPH) method, this research simulates fuel droplet impingement on an ignition plug with various materials to characterize heat transfer, thermal penetration, and temperature distributions in the heated wall. The investigation also delves into the behavior of ceramic material, specifically silicon nitride, assessing its thermomechanical stress and durability based on the stress–number of cycles (S-N) curve. Thermal stress is computed by considering temperature gradients and material properties, while mechanical stress is evaluated based on the bending momentum and momentum flux induced by the spray. A parametric study explores diverse materials such as tungsten carbide, iron, stainless steel, carbon steel, and aluminum. Results indicate that thermal stress outweighs bending and spray-induced stress. Moreover, the analysis reveals that silicon nitride exhibits the lowest thermal stress distribution and superior durability, potentially capable of operating for infinite cycles under engine-relevant conditions.