Efforts to improve diesel fuel sprays have led to a significant increase in fuel injection pressures and a reduction in nozzle-hole diameters. Under these conditions, the likelihood for the internal nozzle flow to cavitate is increased, which potentially affects spray breakup and atomisation, but also increases the risk of causing cavitation damage to the injector. This thesis describes the study of cavitating flow phenomena in various single and multi-hole optical nozzle geometries. It includes the design and development of a high-pressure optical fuel injector test facility with which the cavitating flows were observed. Experiments were undertaken using real-scale optical diesel injector nozzles at fuel injection pressures up to 2050 bar, observing for the first time the characteristics of the internal nozzle-flow under realistic fuel injection conditions. High-speed video and high resolution photography, using laser illumination sources, were used to capture the cavitating flow in the nozzle-holes and sac volume of the optical nozzles, which contained holes ranging in size from 110 micrometers to 300 micrometers. Geometric cavitation in the nozzle-holes and string cavitation formation in the nozzle-holes and sac volume were both observed using transient and steady-state injection conditions; injecting into gaseous and liquid back pressures up to 150 bar. Results obtained have shown that cavitation strings observed at realistic fuel injection pressures exhibit the same physical characteristics as those observed at lower pressures. The formation of string cavitation was observed in the 300 micrometers multi-hole nozzle geometries, exhibiting a mutual dependence on nozzle flow-rate and the geometry of the nozzle-holes. Pressure changes, caused by localised turbulent perturbations in the sac volume and transient fuel injection characteristics, independently affected the geometric and string cavitation formation in each of the holes. String cavitation formation of was shown to occur when free-stream vapour was entrained into the low pressure core of a sufficiently intense coherent vortex. Hole diameters less than or equal to 160 micrometers were found to suppress string cavitation formation, with this effect a result of the reduced nozzle flow rate and vortex intensity. Using different hole spacing geometries, it was demonstrated that the formation of cavitation strings in a particular geometry became independent of fuel injection and back pressure once a threshold pressure drop across the nozzle had been reached.

An experimental apparatus was designed and built to study the thermal autoxidative carbon deposition, or coking, in the fuel injection nozzles of small gas turbine engines. The apparatus is a simplified representation of an aircraft fuel system, consisting of a preheating section and a test section, which is a passage that simulates the geometry, temperatures, pressures and flow rates seen by the fuel injection nozzles. Preliminary experiments were performed to verify the functionality of the apparatus. Pressure drop across the test section was measured throughout the experiments to monitor deposit buildup, and an effective reduction in test section diameter due to deposit blockage was calculated. The preliminary experiments showed that the pressure drop increased more significantly for higher test section temperatures, and that pressure drop measurement is an effective method of monitoring and quantifying deposit buildup.

An experimental apparatus was designed and built to study the thermal autoxidative carbon deposition, or coking, in the fuel injection nozzles of small gas turbine engines. The apparatus is a simplified representation of an aircraft fuel system, consisting of a preheating section and a test section, which is a passage that simulates the geometry, temperatures, pressures and flow rates seen by the fuel injection nozzles. Preliminary experiments were performed to verify the functionality of the apparatus. Pressure drop across the test section was measured throughout the experiments to monitor deposit buildup, and an effective reduction in test section diameter due to deposit blockage was calculated. The preliminary experiments showed that the pressure drop increased more significantly for higher test section temperatures, and that pressure drop measurement is an effective method of monitoring and quantifying deposit buildup.