Hydrogen Direct Injection and Intake Characteristics of an Internal Combustion Engine

Hydrogen internal combustion engines are a promising propulsion technology due to their zero-carbon emission potential and high efficiency. However, achieving stable mixture formation during direct hydrogen injection remains a key challenge affecting ignition stability and NOx emissions. Although numerous studies address the combustion characteristics of hydrogen, only a limited number have examined the transient behavior of hydrogen/air mixing during the intake stroke, particularly its interaction with in-cylinder flow structures prior to ignition. This lack of detailed insight into early mixture stratification and jet-driven turbulence represents a significant research gap that currently limits further optimization of DI-H2ICE systems. This study therefore deals with the numerical analysis of the process of mixing hydrogen with air in the combustion chamber of a direct hydrogen injection engine (DI-H2ICE). A 3D CFD model of a hydrogen direct-injection engine was used to evaluate in-cylinder mixing during the intake and early compression strokes. Unlike most existing publications that focus primarily on combustion or emission formation, this work examines the mixing process from the beginning of the intake stroke and provides a new evaluation of the evolution of the hydrogen jet and its interaction with the piston-induced swirl as the crankshaft angle changes. The simulation covers the section from the exhaust top dead center (TDC) to the early compression phase, during which hydrogen is injected at a high pressure. The results show that the shape of the combustion chamber and the interaction of the hydrogen jet with the piston significantly affect the distribution of the equivalent ratio and the intensity of the swirl. Quantitative evaluation showed that the mixture remained lean overall throughout the cycle: typical hydrogen mass fractions in the cylinder ranged from 0.01 to 0.05, corresponding to equivalence ratios of φ = 0.35–1.81 (λ = 2.85–0.55). Only the core of the jet reached an instantaneous local mass fraction of 0.96, representing undiluted hydrogen and not a combustible mixture. No persistent zones with φ > 1 were detected, confirming that the chosen injection strategy prevents the formation of locally rich pockets. This study confirmed that a suitably selected injection configuration and combustion chamber geometry can significantly contribute to a uniform mixture distribution, a more stable combustion process, and lower NOx production. The presented findings provide a methodological basis for improving mixture formation strategies in hydrogen engines and may support the development of efficient, zero-carbon powertrains in future mobility systems.