The current ongoing rise in environmental pollution is leading research efforts toward the adoption of propulsion systems powered by gaseous fuels like hydrogen, methane, e-fuels, etc. Although gaseous fuels have been used in several types of propulsion systems, there are still many aspects that can be improved and require further study. For this reason, we considered it important to provide a review of the latest research topics, with a particular focus on the injection process. In advanced engine systems, fuel supply is achieved via enhanced direct injection into the combustion chamber. The latter involves the presence of under-expanded jets. Under-expanded jets are a particular kind of compressible flow. For this reason, the review initially provides a brief physical explanation of them. Next, experimental and numerical CFD investigation techniques are discussed. The last section of this manuscript presents an analysis of the jet’s structure. The injection parameters commonly used are examined; next, the characteristics of the near-nozzle field are reviewed and finally, the far-field turbulent mixing, which strongly affects the air–fuel mixture formation process, is discussed.

The direct injection of a gaseous fuel in internal combustion engines involves under-expanded supersonic jets and complex air/fuel fluid-dynamics. Furthermore, with the high pressure ratios between the injector and the cylinder, the gaseous flow usually becomes choked even inside the injector. Knowledge of all these phenomena is essential to achieve a deeper understanding of the air–fuel mixing process that follows, influencing combustion and pollutant formation. In this framework, this study deals with the development and validation of a fully explicit, density-based solver for supersonic compressible flows, using the OpenFOAM library and featuring Runge–kutta fourth order time discretization and the Kurganov central flux splitting scheme. This methodology was applied to analyze the inner and the external flow of an innovative, multi-hole, high pressure injector for heavy-duty vehicle applications. The adoption of multi-hole patterned injectors in gaseous fuel combustion systems is believed to be an efficient way of achieving a better air/fuel mixture and, therefore, improving the combustion reaction. The present work aims to evaluate the reliability of the aforementioned mathematical approach for such kinds of complex flows and, especially, provide a comprehensive characterization of the multi-jet spray. It was found that shock waves in the internal-nozzle deeply modify the flow development and the external Mach disk as shock cells move the mixing activity on a lateral shear layer. It was also observed that a methane cloud grows downstream and, although flammable conditions are present, it later inhibits air recirculation toward the near nozzle zone.