Effect of thermodynamic modeling and design variations on cavitation erosion in high-pressure fuel injectors
Preprint, 2025

The influence of thermodynamic modeling and needle design variations on cavitation erosion in high- pressure fuel injectors was investigated. Two thermodynamic frameworks—a barotropic Tait equation of state with incompressible vapor (Tait&IV) and a real-fluid PC-SAFT model with compressible vapor (PC-SAFT&CV)—were assessed. The modeling approach was validated against experimental erosion data obtained from a single-hole injector operating under industrial conditions. Cavitation behavior and erosion risk were evaluated using a unified indicator based on the squared material derivative of pressure. Following validation, three different needle-tip geometries (Base, NV-01, and NV-02) were studied using the PC-SAFT&CV model. The results showed that both thermodynamic assumptions and geometric features strongly influenced vapor collapse patterns, erosion location, and thermal gradients. The PC-SAFT&CV model provided improved agreement with experimental erosion locations and predicted smaller, more localized vapor structures. Among the designs, NV-02 yielded the most balanced erosion profile and reduced vapor volume by 85%. These findings demonstrate the importance of combining advanced thermodynamic models with design optimization to improve erosion prediction and enhance injector durability under realistic conditions.

Cavitation erosion

Thermodynamics effects

Design variations

Författare

Mehmet Özgünoglu

Chalmers, Mekanik och maritima vetenskaper, Marin teknik

Marilia Vaz

City University

Ioannis Karathanasis

City University

Rickard Everyd Bensow

Chalmers, Mekanik och maritima vetenskaper, Marin teknik

Michael Oevermann

Chalmers, Mekanik och maritima vetenskaper, Energiomvandling och framdrivningssystem

Gerard Mouokue

Woodward L'orange GmbH

Manolis Gavaises

City University

Experimentally Validated DNS and LES Approaches for Fuel Injection, Mixing and Combustion of Dual-Fuel Engines (EDEM)

Europeiska kommissionen (EU) (EC/H2020/861002), 2019-09-01 -- 2023-08-31.

Drivkrafter

Hållbar utveckling

Styrkeområden

Transport

Energi

Ämneskategorier (SSIF 2025)

Strömningsmekanik

Infrastruktur

Chalmers e-Commons (inkl. C3SE, 2020-)

Mer information

Senast uppdaterat

2025-05-10