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The Characterization of an Externally Cooled Exhaust Manifold

Cartwright, Justin W
http://rave.ohiolink.edu/etdc/view?acc_num=osu1385982535

Abstract Details

2013, Master of Science, Ohio State University, Mechanical Engineering.
The performance of a liquid cooled exhaust manifold installed on a Ford 2011 3.5L V6 EcoBoost engine is quantified experimentally. An external cooling circuit was constructed to control the manifold coolant flow rate V_WCM, inlet temperature, and outlet pressure. The manifold has a jacket that is located near the exhaust outlet and cooled with a water/ethylene-glycol mixture from the external cooling circuit to reduce skin temperatures. The manifold is characterized in terms of: heat rejection rates, skin temperatures, and cooling jacket boiling. Results were obtained by sweeping V_WCM from 0.2 to 2.0 gpm while maintaining a nominal manifold inlet temperature and outlet pressure of 85 degC and 13 psig, respectively. For each V_WCM sweep, the engine operation was held constant. These sweeps were completed at a total of 12 engine operating points. Nine of these points were from experiments at a constant speed of 2000 rpm with BMEP ranging from 1 to 16 bar. The remaining 3 operating points were acquired at a constant nominal load of 16 bar and speeds of 2500, 3000, and 3500 rpm. The measurements include engine exhaust flow rate and exhaust gas temperature at the outlet of the manifold. Manifold coolant temperatures were measured at the jacket inlet and outlet. Manifold coolant flow rate was measured with a turbine flow meter installed upstream. Moreover, a dynamic pressure transducer was installed inside the cooling jacket to capture hydraulically and thermally induced pressure fluctuations. Finally, manifold outer skin temperatures were obtained at 12 different locations. The manifold coolant heat rejection rate was found to depend primarily on engine operation. Due to high heat transfer resistance on the exhaust gas side, only slight sensitivity to V_WCM was observed for power levels above 122 hp. The peak manifold heat rejection rate found was 3.2 kW for engine operation at 3500 rpm and 16 bar. When normalized by engine brake power, the manifold heat rejection rate showed an asymptotic decay to 0.02 with increasing engine brake power. Metal surface temperatures were found to peak in the center of the manifold, away from the cooling jacket and near Cylinder 2 of the engine. The maximum skin temperature observed was 662 degC, which is below the lower transformation temperature (750 degC) of iron-carbon materials. Except for locations on or adjacent to the cooling jacket, skin temperatures showed little sensitivity to changes in V_WCM. Subcooled flow boiling was found to occur in the form of partially developed and fully developed boiling. Above 45 hp, partially developed boiling was observed for all coolant sweeps. At every engine power level, the detection of fully developed boiling was found to begin in the proximity of 1.0 gpm as V_WCM was decreased. Saturated flow boiling was observed at the minimum V_WCM of 0.2 gpm above an engine output of 154 hp.
Ahmet Selamet (Advisor)
Xiaodong Sun (Committee Member)
152 p.
Automotive Engineering; Mechanical Engineering
exhaust manifold; cooling system; boiling detection

Recommended Citations

Citations

  • Cartwright, J. W. (2013). The Characterization of an Externally Cooled Exhaust Manifold [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1385982535

    APA Style (7th edition)

  • Cartwright, Justin. The Characterization of an Externally Cooled Exhaust Manifold. 2013. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1385982535.

    MLA Style (8th edition)

  • Cartwright, Justin. "The Characterization of an Externally Cooled Exhaust Manifold." Master's thesis, Ohio State University, 2013. http://rave.ohiolink.edu/etdc/view?acc_num=osu1385982535

    Chicago Manual of Style (17th edition)

osu1385982535
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© 2013, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.