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Great Designs in Steel is Sponsored by:

ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,

Severstal North America, Inc. and United States Steel Corporation

Corrosion Resistance of Various

Steel Fuel Tank Systems in

Alcohol-Containing Fuels

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Alcohol-Containing Fuels

Peter Mould, Program ManagerStrategic Alliance for Steel Fuel Tanks (SASFT)

OUTLINEOUTLINEOUTLINEOUTLINE

• Introduction / Background

• Purpose and objective of the current study

• Experimental Procedures

– Fuels

– Steels/Test Cups

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– Steels/Test Cups

– Test Method

– Assessment criteria

• Results and Conclusions

• Further work

• Value of steel for fuel tanks

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

• SASFT:Organized by AISI to promote the application of steel fuel tanks

• Projects:– Market analysis/trends

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– Market analysis/trends– Technical development

• Corrosion durability• Design comparisons

– Communications

SASFT SASFT SASFT SASFT ---- MEMBERSMEMBERSMEMBERSMEMBERS

Americas Europe Asia

Fuel Tank

Manufacturers

Aethra Sistemas Automotivos

Fuel Systems, LLC

Harley Davidson

Martinrea International

Spectra Premium Inds.

Allgaier Automotive

Unipart Eberspacher

Dong Hee Ind.

Unipres

Equipment Soutec Soudronic

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Equipment

Suppliers

Soutec Soudronic

Steel Suppliers ArcelorMittal USA

ArcelorMittal Dofasco

No. American Stainless

Nucor Corporation

Severstal North America, Inc.

United States Steel Corp.

ThyssenKrupp Steel JFE Steel

Nippon Steel

Nisshin Steel

Posco

Sumitomo Metal

BACKGROUNDBACKGROUNDBACKGROUNDBACKGROUND

• Early focus for SASFT – Corrosion Durability

• Major Corrosion Studies conducted 2002-2004

– 10 different steel tank systems

– External Corrosion– Salt Spray tests (ASTM B117)

– Cyclic Corrosion tests (SAE J2334)

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Some corrosion occurred in some steels,

But no perforation in any steel.

– Internal Corrosion (Fuel)– CE10A/45 C/39weeks

No corrosion (staining only)

No pitting

• Concluded: Steel systems meet 15-year (150,000 miles) requirement of CARB

PURPOSE PURPOSE PURPOSE PURPOSE and and and and OBJECTIVESOBJECTIVESOBJECTIVESOBJECTIVES

Current Study

• Driver: Growing use of alternative fuels

• Purpose: Assess the corrosion performance of 10

steel fuel tank ‘systems’ in:

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steel fuel tank ‘systems’ in:

– Alcohol-containing fuels (PHASE 1)

subject of this presentation

– Bio-diesel fuels (PHASE 2)

in progress (not reported today)

EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL

PROCEDUREPROCEDUREPROCEDUREPROCEDURE

Fuels Selected for current study:

• 3 different alcohol contents – all aggressive─ CE 10A 10% ethanol

(Control)─ CE 22A 22% ethanol

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─ CE 85A 85% ethanol

• Aggressive ethanol contains (per SAE J1681)─ Water (Type II) ─ Sodium chloride─ Sulfuric acid─ Acetic acid

EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL

PROCEDUREPROCEDUREPROCEDUREPROCEDURESteel Systems• All supplied by SASFT member companies

• Commercially available for steel tank manufacturing

• Thickness: 0.8 to 1.1 mm

ID # Base Steel Metallic Coating Pre-paint*

1 Low carbon steel EG Zinc-Nickel Magni A36

2 Low carbon steel EG Zinc-Nickel Magni A35

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2 Low carbon steel EG Zinc-Nickel Magni A35

3 Low carbon steel Hot Dip Galvannealed Magni A36

4 Low carbon steel Hot Dip Galvannealed Magni A35

5 Low carbon steel Hot Dip Tin-Zinc None

6 Low carbon steel Hot Dip Aluminized None

7 Austenitic stainless (304L) None None

8 Ferritic stainless (443CT) None None

9 Ferritic stainless (430L) None None

10 Low carbon steel Hot dip Lead-Tin (Terne) None

*Magni pre-paints (about 10µ thickness) are proprietary epoxy coatings.

EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL

PROCEDUREPROCEDUREPROCEDUREPROCEDURE

Steel Cups (simulated fuel tanks)

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Test Method

Set up▪ Weigh cup and lid

▪ Add 30 ml. of fuel

▪ Assemble/torque to 10 pound-inch

▪ Shake assemblies twice/day at RT

▪ Hold 16 hours/day at 60°C

Temp º C

60

23 (RT)

EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL

PROCEDUREPROCEDUREPROCEDUREPROCEDURE

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▪ Hold 16 hours/day at 60°C

Each Week▪ Remove fuel

▪ Inspect cups/lids

▪ Change fuel every 4 weeks▪ Photograph/assess corrosion

• de-lamination of coatings

• extent of corrosion

Completion of tests• Expose for 26 weeks• Clean/air dry cups/lids

• Photograph

• Weigh cup/lid

• Assess corrosion

• Assess pitting

0 6 Time, hours 18 24

No Corrosion• No corrosion product

• No pitting

Corrosion Assessment Criteria – 4 rating categories

Light Corrosion• Some patches of corrosion

and/or pre-paint de-

lamination

EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL

PROCEDUREPROCEDUREPROCEDUREPROCEDURE

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lamination

• Minor pitting (infrequent

and depths < 10%

thickness)

Moderate Corrosion• Moderate and widespread

corrosion and/or pre-paint

de-lamination

• Significant weight loss

• High pitting frequency

• Intensive pitting

Failure• Heavy and extensive

corrosion

• Perforation

RESULTSRESULTSRESULTSRESULTS

Visual Observations

Fuels

• Clear after 4 week periods

• No evidence of solid

contamination of fuels even

Cups and Lids

• No corrosion in 8 steel

systems

• Light-moderate corrosion in

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contamination of fuels even

for Hot-dip Aluminized and

Terne

2 steel systems

─ Hot-dip Aluminized ─ CE22A and CE85A─ Terne (control) ─ CE85A

Visual Observations ─ #6 Hot-dip AluminizedNo Exposure CE10A – 26 weeks

RESULTSRESULTSRESULTSRESULTS

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CE22A – 26 weeks CE85A – 26 weeks

Visual Observations ─ #10 Terne (control)No Exposure CE10A – 26 weeks

RESULTSRESULTSRESULTSRESULTS

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CE22A – 26 weeks CE85A – 26 weeks

Visual Observations ─ #1 EG Zn-Ni Pre-paintCE10A – 26 weeksNo Exposure

RESULTSRESULTSRESULTSRESULTS

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CE85A – 26 weeksCE22A – 26 weeks

Visual Observations ─ #5 Hot-dip Tin-ZincNo Exposure CE10A – 26 weeks

RESULTSRESULTSRESULTSRESULTS

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CE22A – 26 weeks CE85A – 26 weeks

Visual Observations ─ #7 Austenitic Stainless (304L)CE10A – 26 weeksNo Exposure

RESULTSRESULTSRESULTSRESULTS

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CE85A – 26 weeksCE22A – 26 weeks

Visual Observations ─ #9 Ferritic Stainless (430L)No Exposure CE10A – 26 weeks

RESULTSRESULTSRESULTSRESULTS

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CE22A – 26 weeks CE85A – 26 weeks

Quantitative Measurements (after 26 weeks)

None ─ all steel systems─ all fuels

Weight Change

RESULTSRESULTSRESULTSRESULTS

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─ all fuels

No pits deeper than 0.001 inch– all steel systems

Pitting

ID Steel System CE10A CE22A CE85A1 LCS EG Zn-Ni pre-paint (A36) None

Corrosion Assessment Category Visible

Corrosion

Product in Fuel

EXTENT OF CORROSION

None Light Moderate Failure

RESULTSRESULTSRESULTSRESULTS

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1 LCS EG Zn-Ni pre-paint (A36) None

2 LCS EG Zn-Ni pre-paint (A35) None

3 LCS HD Galvannealed pre-paint (A35) None

4 LCS HD Galvannealed pre-paint (A36) None

5 LCS HD Sn-Zn None

6 LCS HD Aluminized None

7 Austenitic Stainless (304L) None

8 Ferritic Stainless (443CT) None

9 Ferritic Stainless (430L) None

10 (control) LCS Terne None

CONCLUSIONSCONCLUSIONSCONCLUSIONSCONCLUSIONS

26-week exposure tests of 10 different steel systems in 3 aggressive alcohol fuels at 60°C has shown:

� No corrosion for 8 steel systems / all fuels

���� Light corrosion in CE22A for:─ Hot-dip Aluminized steel

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���� Light to moderate corrosion in CE85A for:

─ Hot-dip Aluminized steel

─ Terne steel (control)

���� No visual indication of contamination of fuels─ Supported by zero weight loss

Results demonstrate the corrosion durability of

most steel systems in aggressive ethanol fuels.

FURTHER WORKFURTHER WORKFURTHER WORKFURTHER WORK

Phase 2 Durability Tests in Alternative Fuels are underway � 3 Bio-diesel feed-stocks

─ RME / SME / AFME

���� 4 Bio-diesel fuel blends (with water)─ B10 “European” Blend (80% RME + 20% SME)

─ B20 SME

─ B20 AFME

─ B90 SME

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─ B90 SME

���� Characterize the stability of feed-stocks

���� Characterize the degradation of blends

���� Expose in steel cups at 90ºC for 10 weeks

���� Assess extent of corrosion

Results expected

in Q2 2009

VALUE VALUE VALUE VALUE ---- STEEL FOR STEEL FOR STEEL FOR STEEL FOR

FUEL TANKSFUEL TANKSFUEL TANKSFUEL TANKS

• SASFT tests confirm the corrosion durability of steel systems to:

- Road salt environments (prior tests)- Gasoline-ethanol fuels (current tests)

• Additional attributes of steel tanks:

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• Additional attributes of steel tanks:- Cost competitive- Good design flexibility- High rigidity for shape stability- Mass can be competitive with plastic- Environmentally friendly- Ideal for high pressure hybrid systems

FOR MORE INFORMATIONFOR MORE INFORMATIONFOR MORE INFORMATIONFOR MORE INFORMATION

Contact:Peter Mouldprmould@comcast.net810.225.8250

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810.225.8250

Visit:www.sasft.org

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Great Designs in Steel is Sponsored by:

ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,

Severstal North America, Inc. and United States Steel Corporation

Back Up Slides

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SEM - #6 HDAℓ (CE85A)

RESULTSRESULTSRESULTSRESULTS

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� Corrosion product:: Aℓ oxide/hydroxide

(white rust)���� ~ 70% of Aℓ coating corroded

SEM - #10 Terne (CE85A)

RESULTSRESULTSRESULTSRESULTS

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� Corrosion product:: Pb-Sn oxides

� No red rusting