Optimization of a Heavy-Duty Hydrogen-Fueled Internal Combustion Engine Injector for Optimum Performance and Emission Level

Hydrogen is a promising zero-carbon fuel for internal combustion engines; however, the geometric optimization of injectors for low-pressure direct-injection (LPDI) systems under lean-burn conditions remains underexplored. This study presents a high-fidelity optimization framework that couples a validated computational fluid dynamics (CFD) combustion model with a surrogate-assisted multi-objective genetic algorithm (MOGA). The CFD model was validated using particle image velocimetry (PIV) data from non-reacting flow experiments conducted in an optically accessible research engine developed by Sandia National Laboratories, ensuring accurate prediction of in-cylinder flow structures. The optimization focused on two critical geometric parameters: injector hole count and injection angle. Partial indicated mean effective pressure (pIMEP) and in-cylinder NOx emissions were selected as conflicting objectives to balance performance and emissions. Adaptive mesh refinement (AMR) was employed to resolve transient in-cylinder flow and combustion dynamics with high spatial accuracy. Among 22 evaluated configurations including both capped and uncapped designs, the injector featuring three holes at a 15.24° injection angle outperformed the baseline, delivering improved mixture uniformity, reduced knock tendency, and lower NOx emissions. These results demonstrate the potential of geometry-based optimization for advancing hydrogen-fueled LPDI engines toward cleaner and more efficient combustion strategies.