Reliability Optimization of Piezoelectric Injectors for Methanol Compression-Ignition Engines

Methanol compression-ignition engines are vital for transport carbon neutrality, yet methanol’s low cetane number, corrosivity, low viscosity, and cavitation tendency compromised piezoelectric injector reliability. This study proposed systematic optimization strategies tailored to methanol’s fuel properties. A sealed thin-walled metal encapsulation, fabricated from precipitation-hardening martensitic stainless steel, was designed to isolate corrosive methanol media. The geometry of the tubular spring was optimized to meet the stiffness requirements for high-frequency injections. A monolithic nozzle without side pin holes, also upgraded to the same precipitation-hardening martensitic stainless steel, effectively suppressed stress corrosion cracking by leveraging the material’s combined high strength and excellent corrosion resistance. A dedicated return-line backpressure valve compensated for hydraulic leakage and improved fuel replenishment, and nozzle hole taper and inlet fillet radius were optimized to mitigate cavitation. Cold-motoring reliability tests showed the optimized injector maintained flow deviation within 3% after 100 million cycles, whereas the unoptimized prototype reached 8% deviation at 60 million cycles. The single-cycle injected fuel quantity coefficient of variation dropped from 4% to 1.3%. Spray characteristic comparison tests further confirmed that the optimized injector maintained stable flow consistency and atomization quality after prolonged cyclic operation. These optimizations effectively resolved corrosion, wear, and hydraulic instability caused by methanol, significantly enhancing flow consistency and durability over the service life. The results provided critical component-level technical support for advancing methanol compression-ignition engines from laboratory research to industrial application, addressing key reliability barriers that previously hindered engineering deployment of methanol-fueled powertrains.