Heat Losses in the Exhaust Manifold of a 4-Stoke DI Diesel Engine Subjected to Pulsating Flow

This paper presents a study aiming to provide insight into the complex flow and heat transfer processes in the exhaust manifold of a four-stroke, compression ignition engine. An experimental system has been constructed capable of capturing temperature and heat flux high-frequency signals as they develop in the exhaust pipe wall during the engine cycle, under its steady-state operation. The values of the Heat Transfer Coefficient obtained by applying the classic convection relations have been correlated in the form of a Nusselt–Reynolds number relationship for local and spatially averaged steady-state heat transfer and compared with available experimental data obtained at the same position of the exhaust manifold. It has been shown that the use of conventional steady-state heat transfer relationships for fully developed steady-state turbulent flow in pipes underpredicts heat transfer rates when compared with those experimentally observed. Periodic flow of high frequency and geometrical effects at the exhaust entrance are expected to affect the validity of the application of the classic steady-state correlations for the exhaust manifold. To overcome this problem it is developed and presented a new correlation for the time-averaged heat transfer rates. To verify the heat transfer mechanism, the thermal field of the whole engine cylinder head, including the intake and exhaust manifolds, was analyzed using FEA (Finite Element Analysis), and the results are compared and verified with available experimental data.