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1999-01-3682

Homogeneous Charge Compression Ignition (HCCI): Benefits,


Compromises, and Future Engine Applications
Rudolf H. Stanglmaier and Charles E. Roberts
Southwest Research Institute

Copyright © 1999 Society of Automotive Engineers, Inc.

ABSTRACT
Homogeneous Charge Compression Ignition
Large reductions in low-load NOx emissions can (HCCI) has emerged as a technology with potential for
be obtained by replacing conventional Diesel or spark reducing engine-out emissions and significant research
ignited combustion by HCCI combustion in reciprocating efforts have been directed at understanding the
engines. Currently, HCCI combustion is limited to fundamental mechanisms of this combustion mode in
operating conditions with lean air/fuel ratios or large recent years. HCCI combustion of most fuels displays a
amounts of EGR. However, a numerical model shows peculiar two-stage heat release, as shown in Figure 1.
that, even if high equivalence ratio HCCI operation were The first stage of the heat release curve is associated
satisfactorily attained, the NOx reduction potential vs. DI- with low-temperature kinetic reactions (cool and/or blue
Diesel combustion would be much smaller. Thus, high- flames), and the time delay between the first and main
load HCCI operation may best be obtained through highly heat releases is attributed to the “Negative Temperature
boosted fuel-lean operation. Alternatively, HCCI Coefficient Regime” of these reactions (Furutani et al.,
combustion may be suited well for “dual mode” engine 1993, Pucher et al., 1996). Low-temperature kinetics
applications, in which spark ignition or conventional have been studied for some time, as this chemistry is
Diesel combustion is used to obtain full load. Avoiding responsible for knock in spark-ignition engines (e.g.
wall impingement with heavy fuels is critical for achieving Green et al., 1987, Addargarla et al., 1989). Research
good emissions and fuel consumption, and it appears that conducted with the use of optical diagnostics has shown
a large degree of mixture inhomogeneity can be tolerated that HCCI combustion initiates simultaneously at multiple
from a NOx benefit standpoint. sites within the combustion chamber and that there is no
discernable flame-propagation (e.g. Furutani et al., 1993;
INTRODUCTION Iida, 1994; Aoyama et al., 1996). It has been reported
that, despite the absence of a flame front, the HCCI heat
Homogeneous Charge Compression Ignition release rate is not controlled purely by chemical reaction
(HCCI) combustion is achieved when a mixture of air, fuel rates. One group has postulated that turbulent mixing
and recycled combustion products is compressed until it may play an important role in limiting the heat release rate
auto-ignites. This results in heat releasing reactions that (Kong et al., 1992), although this view is not embraced by
initiate simultaneously at multiple sites within the all researchers in the field. Since the combustion
combustion chamber and occur at the global equivalence reactions are not initiated by a spark and are not limited
ratio. Unlike Diesel (diffusion-controlled) combustion, by traditional flame-sheet physics, leaner mixtures can be
HCCI reactions are not necessarily limited by the mixing consumed by HCCI combustion than is possible through
rate at the interface between the fuel jet and oxidizer. other methods. In general, HCCI combustion consists of
HCCI combustion differs from spark-ignited combustion in distributed, fuel-lean reactions and is devoid of localized
that it has no discernible flame front and is devoid of a high-temperature regions or flame fronts.
localized high-temperature reaction region. Thus, HCCI
combustion is generally characterized by distributed, low-
temperature reactions that occur relatively fast.
HCCI engines have demonstrated very low
emissions of oxides of nitrogen (NOx) and particulate
matter (PM), as well as high thermal efficiency at part
load. However, there are some difficulties in applying
HCCI combustion to internal combustion engines. This
paper discusses the potential benefits of HCCI engines
and the obstacles that must be overcome to realize those
benefits.

CHARACTERISTICS OF HCCI COMBUSTION


HCCI combustion is currently practical only at
0.12 low mixture equivalence ratios, as discussed elsewhere in
DF-2
this paper. Peak combustion temperatures within HCCI
Heat Release Rate (kJ/CAD)
0.10
engines are related directly to the engine load (if
0.08 controlled by stoichiometry), and NOx emissions from
HCCI combustion are known to increase considerably
0.06
with increasing engine load. A quasi-dimensional engine
0.04 Naphtha model (Alamo_Engine) was used to model the NOx
emissions from HCCI combustion of Diesel fuel in
0.02 comparison to conventional direct-injection Diesel
0.00 combustion. This model requires the crank-angle
resolved heat release as an input and uses the Zeldovich
-0.02 reaction set and a correlated contribution from prompt NO
135 150 165 180 195 210 225 kinetics to predict NOx (Dodge et al., 1998; Dickey et al.,
Crank Angle Degrees (CAD) 1999). Figure 2 shows the heat release rates used as
inputs to the model and the predicted NOx emissions
from HCCI combustion of Diesel fuel compared to a
Figure 1. Typical heat release curve from HCCI direct-injected Diesel engine (DI-Diesel) and DI-Diesel
combustion of DF-2 Diesel fuel and a Fischer-Tropsch with aggressive EGR levels. The compression ratio for
Naphtha. all cases was 16:1, and the prescribed heat-release curve
for HCCI represents a typical scenario at this
compression ratio. These results show that HCCI
HCCI combustion initiation is not sensitive to in-
combustion can result in large NOx reductions at part
cylinder fluid mechanics, and generally displays very low
engine load, but that the potential NOx advantage of
cyclic variability (e.g. Stockinger et al., 1992). However,
HCCI combustion vs. DI-Diesel diminishes at higher
under some conditions, bi-modal cylinder pressure
equivalence ratios.
distributions have been obtained (Ishibashi and Asai,
1996). This bi-modal, or irregular, combustion Normalized Heat Release Rate
8
characteristic is believed to be associated with the gas
exchange process and the retention of residual exhaust 7
HCCI
products from previous cycles (Ishibashi and Asai, 1996; 6
Green et al., 1987).
5
EMISSIONS BEHAVIOR 4
3
The main motivation for studying HCCI
2
combustion stems from its potential for significant DI Diesel
reductions in exhaust emissions in comparison to 1
conventional Diesel or spark-ignition combustion. A brief 0
overview of the emissions characteristics from HCCI 320 340 360 380 400 420
engines is provided in this section.
Crank Angle (deg)

Oxides of Nitrogen (NOx) 2.0


Perhaps the single largest attraction of HCCI ** Results Normalized to Diesel Baseline with A/F = 30/1
Normalized Specific NOx

combustion is that it can reduce NOx emissions by 90 –


98 % in comparison to conventional Diesel combustion 1.5 HCCI
(Gray and Ryan, 1997; Nakagome et al., 1997; DI Diesel
Aiyoshizawa et al., 1998, Hashizume et al., 1998; Mase
et al., 1998). The underlying mechanism responsible for 1.0
this reduction in NOx emissions is the absence of high- DI Diesel with EGR
temperature regions within the combustion chamber.
0.5
HCCI combustion reactions occur at the global air-fuel
ratio, which is typically quite lean, and at a temperature
significantly below those encountered within the reaction 0.0
zone in Diesel or spark-ignition engines. Several 0 25 50 75 100 125 150
numerical models of NOx emissions from HCCI
Load (%)
combustion have documented this effect (e.g., Najt and
Foster, 1983; Ishii et al., 1997; Christensen et al., 1997; Figure 2. Predicted NOx emissions vs. engine load
Gray et al., 1998). for typical HCCI and DI Diesel combustion.
The numerical model was also used to study the However, reduced fuel efficiencies (higher BSFC)
effects of combustion phasing on HCCI performance. It are reported for Diesel engines employing partial
was found that premature HCCI ignition at high loads fumigation (Osses et al., 1998), and for some direct-
causes dramatically increased BSFC and NOx levels. injected HCCI engines running on Diesel fuel (Suzuki et
However, at low to medium load conditions, premature al., 1997; Odaka et al., 1999). Difficulties in mixture
HCCI ignition increases BSFC without a large penalty in preparation, fuel impingement on the walls, and poor
NOx emissions. The model also predicts that optimizing combustion phasing are thought to be predominantly
the combustion phasing can extend the low-NOx region of responsible for these reduced efficiencies.
HCCI combustion to lower air/fuel ratios, but this has
been difficult to achieve in practice so far. HCCI CHALLENGES

Particulate Matter (PM) There are a number of obstacles that must be


HCCI combustion has also been reported to overcome before the potential benefits of HCCI
produce low levels of smoke and PM emissions (Suzuki combustion can be fully realized in production
et al., 1997; Kimura et al., 1997 and 1998; Mase et al., applications. This section describes the main difficulties
1998). The mechanism for these smoke reductions is not with this technology.
as well documented, but it is thought that the absence of
diffusion-limited combustion and localized fuel-rich COMBUSTION PHASING AND CONTROL
regions discourages the formation of soot. One exception
to this can occur when poor mixture preparation leads to One of the principal challenges of HCCI combustion
liquid fuel deposition on the combustion chamber and is control of the combustion phasing. Unlike in spark-
localized fuel-rich regions of combustion. ignition or conventional Diesel engines, a direct method
for controlling the start of combustion is not available.
Hydrocarbons (HC) and Carbon Monoxide (CO) Instead, the start of combustion is established by the
In contrast to NOx and PM emissions, HCCI auto-ignition chemistry of the air-fuel mixture. Auto-
combustion typically results in higher HC and CO ignition of a fuel-oxidizer mixture is influenced by the
emissions than conventional Diesel combustion (Suzuki properties of the mixture and by the time-temperature
et al., 1997;Nakagome et al., 1997; Christensen and history to which it is exposed. Hence, combustion
Johansson, 1998). One factor that contributes to these phasing of HCCI engines is affected by:
observed levels of HC and CO emissions is the low in-


cylinder temperature due to the lean mixtures and/or high Auto-ignition properties of the fuel
levels of EGR which are necessary for satisfactory HCCI • Fuel concentration
operation. It is well known that reduced burned gas • Residual rate and, possibly, reactivity of the residual
temperatures lead to decreased post-combustion • Mixture homogeneity
oxidation rates within the cylinder (i.e. Roberts and • Compression ratio
Matthews, 1996) and increased levels of HC and CO in • Intake temperature, latent heat of vaporization of the
the exhaust. Mixture preparation is of great importance to fuel, and engine temperature
HC emissions for HCCI combustion of liquid fuels, for it is • Heat transfer to the engine
well known that liquid fuel deposition on combustion • Other engine-dependent parameters
chamber surfaces can result in dramatic increases in HC
emissions (Stanglmaier et al., 1999). This problem is Several approaches for controlling the
exacerbated for heavy fuels such as Diesel. combustion phasing have been attempted, but a
fundamental distinction can be made between those
EFFICIENCY methods attempting to control the time-temperature
history to which the mixture is exposed, and methods
aimed at altering the propensity for auto-ignition of the
HCCI combustion is generally characterized by
mixture, as illustrated on Figure 3. Methods for
high heat-release rates, which can approximate the ideal
controlling the time-temperature history of the mixture
Otto cycle when properly phased in relation to the engine
include: In-cylinder fuel injection timing, water injection,
cycle. The distributed low-temperature reactions and non-
intake air temperature modulation, variable compression
luminous combustion result in reduced heat rejection to
ratio, and variable valve timing.
the engine. Hence, HCCI combustion is, in itself,
The reactivity of the mixture can be altered by
conducive to high thermodynamic cycle efficiencies.
varying the properties of the fuel, the air-fuel ratio, or by
HCCI fuel efficiencies comparable to those of
exhaust gas recirculation (EGR). EGR can also be used
conventional Diesel combustion at part load have been
to modulate the mixture temperature. It has been
reported by several researchers (Aoyama et al., 1996;
suggested that active radical species in the exhaust play
Hashizume et al., 1997; Suzuki et al., 1997; Christensen
and important role in HCCI combustion (e.g. Ishibashi and
and Johansson, 1998; Harada et al., 1998).
Asai, 1996), but this view is not universally accepted. It

† Although related to the auto-ignition properties of a fuel,


the “octane” and “cetane” ratings are avoided in this
discussion. These ratings are obtained from standardized
tests significantly different from HCCI combustion, and
can be misleading.
is perhaps more likely that stable, intermediate products clear solution to this challenge.
of combustion from a prior cycle, which can be much
more reactive than the parent fuel (e.g. Addargarla et al., POWER OUTPUT
1989), may influence the overall mixture reactivity. This
may be particularly true for HCCI combustion, given the A current drawback of HCCI combustion is that it
elevated concentrations of unburned and partially-burned is presently limited in power output. Stable HCCI
hydrocarbons in the exhaust stream, and the high EGR combustion can generally be achieved for lean A/F ratios
levels typically employed. Mixture reactivity can be used and/or large amounts of EGR. However, as the A/F ratio
to control HCCI combustion initiation effectively. A approaches stoichiometric values (without EGR dilution),
method for controlling the combustion phasing by the combustion stability degrades, heat release rates
blending two different fuels has been demonstrated in a increase, knock-like oscillations in the cylinder pressure
laboratory environment by Furutani et al. (1998) and appear, and the emissions benefits vanish (e.g.
Akagawa et al. (1999). Stockinger et al., 1992; Aoyama et al., 1996, Christensen
et al., 1997; Gray and Ryan, 1997). Fuels with inherently
Methods for Controlling HCCI lower heat release rates, like methane, can be combusted
Combustion Phasing at lower A/F ratios and achieve higher specific engine
outputs (Christensen et al., 1997).
Given this apparent limitation in A/F ratio for
HCCI combustion, power increases can be obtained by
augmenting the air flow through the engine.
Supercharging has proven to be effective in this respect,
ALTER and it also has a beneficial influence on reducing the heat
ALTER MIXTURE release rate (Aoyama et al., 1996; Christensen et al.,
TIME-TEMPERATURE
REACTIVITY 1998a; Iwabuchi et al., 1999). Christensen and coworkers
HISTORY OF MIXTURE
(1998a) have achieved HCCI operation up to an IMEP of
14 bar, using an externally boosted engine fueled with
methane. Increasing the engine speed may also be an
•Modulate intake temp. effective method of increasing HCCI power output and
•Blend 2 or more fuels reducing the heat release rate in crank-angle space, but
•In-Cyl. injection timing
•Fuel additives this approach is not well documented. A high-speed,
•Water injection
•Fuel pre-conditioning supercharged engine may be the most viable
•Variable CR
•EGR ? configuration for lean HCCI combustion.
•Variable valve timing
Another approach to overcome the limitations in
•EGR power output has been to pursue the development of
“dual-mode” engines that employ HCCI combustion at low
Figure 3. Methods for Controlling HCCI Combustion loads and Diesel combustion or spark-ignition at high
Phasing. loads. Although attractive, HCCI/spark-ignition engines
In laboratory experiments, the most popular have not been discussed much in the literature.
method for controlling the start of reaction is by HCCI/Diesel engines are being pursued by a number of
modulating the intake air temperature. Higher intake researchers.
temperatures advance the start of combustion and vice-
versa, but the range of crank-angles over which the HOMOGENEOUS MIXTURE PREPARATION
combustion phasing can be controlled is quite limited and
a large penalty in volumetric efficiency accompanies high Effective mixture preparation, and avoiding fuel-
intake temperatures. Moreover, this method is generally wall interactions is crucial for achieving high fuel
deemed impractical for mobile applications. Fuel-injection efficiency, reducing HC and PM emissions, and
timing (in direct injected applications) has proven to be an preventing oil dilution. Impingement of fuel on the
ineffective method for controlling the combustion phasing surfaces of the combustion chamber has been proven
(Takeda et al., 1996; Nakagome et al., 1997), as the fuel detrimental to HC emissions even for moderately volatile
vaporization process significantly affects the time- fuels such as gasoline (Stanglmaier et al., 1999). Mixture
temperature history of the mixture. Water injection has homogeneity has an effect on the auto-ignition reactions
been attempted as a method for delaying the start of that control the HCCI combustion phasing (Harada et al.,
reaction, but this approach was also found to be largely 1998; Christensen et al., 1999), but there is significant
inadequate (Christensen et al., 1999). Variable evidence that low NOx emissions can be produced even
compression ratio or valve timing appear promising, but with a large degree of mixture inhomogeneity within the
are associated with additional costs in engine hardware. combustion chamber (Kimura et al., 1997 and 1998;
These approaches are not commonly discussed in the Aiyoshizawa et al. 1998; Mase et al., 1998).
literature. Perhaps the most successful phasing control Homogeneous mixture preparation is most difficult for
demonstrated to date is fuel-blending. Combustion fuels with reduced volatility such as Diesel, which require
control over a significant range has been achieved with elevated intake air temperatures for low-smoke operation
this method, but its feasibility for production is when port-injected (Gray and Ryan, 1997).
questionable. At this time, no single method for
controlling HCCI combustion phasing has emerged as a HCCI ENGINE CONFIGURATIONS
A number of promising engine concepts using
HCCI combustion are being developed, including free HCCI Engine
piston designs (Van Blarigan et al., 1998), and two-stroke Configuration
engines (e.g. Ishibashi and Asai, 1996). In this
discussion, only conventional 4-stroke engine designs
suitable for over the road applications are included.
Dedicated
Figure 4 shows a schematic breakdown of HCCI engine Dual Mode
HCCI
configurations. The first distinction in this illustration is
for full-time HCCI engines vs. dual combustion mode
engines. Full-time HCCI engines have the largest benefit
potential. Highly boosted, fuel-lean, dedicated HCCI HCCI- HCCI-
engines may be attractive for some stationary or marine Diesel Spark Ignition
applications. Future development of HCCI-specific fuels
and combustion phasing control may also expand the
air/fuel ratio operating range. HCCI Fuel
An alternative way of obtaining full power output, Introduction
at the expense of additional benefits, is to operate an
engine on HCCI combustion at low and part loads and on
either spark-ignition or conventional Diesel combustion at
full load. Obviously, this approach is only attractive for Port In-Cylinder
applications that experience significant part load engine Injection Injection
operation and would benefit from emissions reductions
over this operating range. Dual-mode spark-ignition/HCCI
engines have not been discussed much in the literature, Late Early
but appear attractive for light-duty vehicle applications. In-Cylinder In-Cylinder
Dual-mode Diesel/HCCI engines, on the other hand, are Injection Injection
being pursued by several research groups around the
world. Figure 4. HCCI Engine Configurations.
The next level of classification for HCCI engines
is comprised by the method of fueling. This represents EARLY IN-CYLINDER INJECTION
an important distinction because it has a profound effect
on the engine characteristics and confines the Another method of promoting a homogeneous
combustion control methods that can be employed. fuel-air mixture within the cylinder is through early (well in
Three fueling methods will be described in more detail: advance of TDC) in-cylinder injection of a portion or all of
port-injection, early in-cylinder injection, and late in- the fuel. This can be done through the same nozzles
cylinder injection. used for Diesel combustion (e.g., Yokota et al., 1997), or
through separate direct-injectors (e.g. Miyamoto et al.,
PORT-INJECTION OR FUMIGATION 1998). Interestingly, this method provides ineffective
control of the reaction phasing by varying the fuel
The simplest way of promoting a homogenous in- introduction time. This occurs because the fuel
cylinder mixture is by introducing fuel upstream of the vaporization process significantly affects the time-
intake valves, and inducting the mixture into the cylinder temperature history to which the mixture is exposed and
during the intake stroke. This method takes advantage of limits the range over which control can be attained.
the turbulence generated as the intake flow rushes past HCCI operation with in-cylinder injection is only
the intake valves to promote mixing. However, the fuel- reported in the literature for Diesel fuel. However, fuel wall
air mixture is exposed to the entire time-temperature impingement is a severe problem when injecting heavy
history of the cylinder, and thus injection timing cannot be fuels into the low-density air charge. Some researchers
used to control the start of reaction. Port-injection or have expended significant effort in minimizing wall
fumigation is the most common configuration used in impingement by developing low-penetration fuel injectors
HCCI engines, and a number of researchers have used it (Harada et al., 1998; Iwabuchi et al., 1999), and have
with varying degrees of success (e.g., Stockinger et al., obtained significant improvements. However, wall
1992; Aoyama et al., 1996; Christensen et al., 1997 and impingement is likely to remain a problem for in-cylinder
1998; Ryan and Callahan, 1996; Osses et al., 1998; injection of Diesel fuel into low-density environments. In-
Suzuki et al., 1997 and 1998; Ogawa et al., 1998; cylinder fuel injection is likely to become the preferred
Furutani et al., 1998). method for fueling HCCI engines in the future as better
Port-injection or fumigation of heavy fuels can mixture preparation techniques are developed.
result in high HC and CO emissions, and in increased fuel
consumption and oil dilution. Most of these problems can LATE IN-CYLINDER INJECTION
be attributed directly to poor fuel vaporization and fuel-
wall interactions within the combustion chamber. Port- Perhaps the newest approach to homogeneous
injection may be attractive for gaseous and high volatility Diesel combustion is that used in the Nissan MK system
fuels, but is more problematic for Diesel fuel. during low-load operation (Aiyoshizawa et al., 1998; Mase
et al., 1998). In this concept, fuel is injected directly into engines as fuel-wall wetting negatively impacts HC,
the combustion chamber near or after TDC, but the CO, and PM emissions, as well as BSFC and oil
ignition delay is extended through the use of large dilution. Mixture preparation of heavy fuels in HCCI
amounts of cooled EGR, a reduction in the engine engines often represents a compromise between
compression ratio, and vigorous swirl. The net result is mixture homogeneity and reduced wall impingement.
that the combustion reactions begin well after the end of • It appears that some degree of mixture inhomogeneity
injection, and a diffusion-limited combustion jet is not is tolerable for realizing HCCI NOx benefits. Thus, it
established. Despite the significant mixture may be possible to trade-off mixture homogeneity for
inhomogeneity that exists within the cylinder, low NOx combustion phasing control and/or HC emissions
emissions are obtained. Late in-cylinder injection of benefits, with some injection strategies.
Diesel appears to avoid most of the problems associated • HCCI combustion has been shown to produce very low
with fuel wall impingement and provides some control of levels of NOx at low loads, but computational models
the combustion phasing, but the short ignition delay of predict that NOx levels would equal or exceed DI-Diesel
Diesel limits this approach to low engine loads. Further levels at comparable full load if the combustion phasing
developments of the late in-cylinder injection approach can not be optimized.
are likely to be applied to other classes of Diesel engines • Intake charge boosting can increase power output from
in the near future. fuel-lean HCCI engines. Alternatively, HCCI
combustion may be used in “dual-mode” engine
FUTURE ENGINE APPLICATIONS OF HCCI applications, which operate on DI-Diesel or spark-
ignition at high load.
There are a number of obstacles which must be
overcome in order to realize a fuel-efficient, low- ACKNOWLEDGMENTS
emissions HCCI engine. A full-time HCCI engine appears
desirable, but its ability to produce power comparable to We sincerely thank Mr. Lee Dodge of Southwest
conventional Diesel or stoichiometric engines is still in Research Institute for his assistance using the
question. Computational and experimental results Alamo_Engine code.
suggest that, even if stoichiometric air-fuel ratios were
possible under HCCI combustion, there would be no NOx CONTACT
benefit over spark ignited combustion. Highly boosted,
fuel-lean HCCI engines appear to be a promising option
Rudolf H. Stanglmaier, Ph.D.
for producing full power output in stationary and marine
Dept. of Engine Research
applications. Future development of HCCI-specific fuels
Southwest Research Institute
and improvements in combustion phasing control may
(210) 522-5505 Phone
enable Diesel-like air/fuel ratios and power output. For
(210) 522-2019 Fax
near-term mobile applications, however, HCCI combustion
e-mail: rstanglmaier@swri.edu
may be best suited to “dual-mode” engines, which take
advantage of HCCI benefits at low loads and operate on
either spark-ignition or conventional Diesel combustion at
full load. An attainable goal may be to operate on HCCI
mode up to ~75% of the peak load. Accordingly, the
nearest-term application of HCCI combustion is likely to
be in those engine applications which experience
substantial low and part load operation during their useful
life.
HCCI combustion has received most attention for
Diesel engine applications, because future NOx
reductions due to pending emissions legislation is more
severe for these engines. However, HCCI combustion
may be an attractive method for reducing low-load NOx
emissions from spark-ignited engines. Full-time HCCI
engines are not limited to Diesel or gasoline, and may
require HCCI-specific fuels or additives.

SUMMARY

• Two fundamentally different approaches to controlling


HCCI combustion phasing are possible: i) altering the
mixture propensity for auto-ignition, and ii) altering the
time-temperature history to which the mixture is
exposed. A viable method of controlling the
combustion phasing in production applications has not
yet been identified.
• The method of fuel introduction is critical for HCCI
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Fumigation Partial Premixing for Reduced Particulate Soot
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Pucher, G. R., D. P. Gardiner, M. F. Bardon, and V. Battista


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Roberts C. E., and R. D. Matthews (1996), “Development and


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Ryan III, T. W., and T. J. Callahan (1996), “Homogeneous


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