Page 1
w w w . a u t o s t e e l . o r g
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
Great Designs in Steel is Sponsored by:
ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,
Severstal North America, Inc. and United States Steel Corporation
Page 2
Corrosion Resistance of Various
Steel Fuel Tank Systems in
Alcohol-Containing Fuels
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
Alcohol-Containing Fuels
Peter Mould, Program ManagerStrategic Alliance for Steel Fuel Tanks (SASFT)
Page 3
OUTLINEOUTLINEOUTLINEOUTLINE
• Introduction / Background
• Purpose and objective of the current study
• Experimental Procedures
– Fuels
– Steels/Test Cups
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
– Steels/Test Cups
– Test Method
– Assessment criteria
• Results and Conclusions
• Further work
• Value of steel for fuel tanks
Page 4
INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION
• SASFT:Organized by AISI to promote the application of steel fuel tanks
• Projects:– Market analysis/trends
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
– Market analysis/trends– Technical development
• Corrosion durability• Design comparisons
– Communications
Page 5
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
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
Page 6
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)
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
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
Page 7
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:
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
steel fuel tank ‘systems’ in:
– Alcohol-containing fuels (PHASE 1)
subject of this presentation
– Bio-diesel fuels (PHASE 2)
in progress (not reported today)
Page 8
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
─ CE 85A 85% ethanol
• Aggressive ethanol contains (per SAE J1681)─ Water (Type II) ─ Sodium chloride─ Sulfuric acid─ Acetic acid
Page 9
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
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.
Page 10
EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL EXPERIMENTAL
PROCEDUREPROCEDUREPROCEDUREPROCEDURE
Steel Cups (simulated fuel tanks)
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
Page 11
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
▪ 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
Page 12
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
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
Page 13
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
contamination of fuels even
for Hot-dip Aluminized and
Terne
2 steel systems
─ Hot-dip Aluminized ─ CE22A and CE85A─ Terne (control) ─ CE85A
Page 14
Visual Observations ─ #6 Hot-dip AluminizedNo Exposure CE10A – 26 weeks
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE22A – 26 weeks CE85A – 26 weeks
Page 15
Visual Observations ─ #10 Terne (control)No Exposure CE10A – 26 weeks
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE22A – 26 weeks CE85A – 26 weeks
Page 16
Visual Observations ─ #1 EG Zn-Ni Pre-paintCE10A – 26 weeksNo Exposure
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE85A – 26 weeksCE22A – 26 weeks
Page 17
Visual Observations ─ #5 Hot-dip Tin-ZincNo Exposure CE10A – 26 weeks
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE22A – 26 weeks CE85A – 26 weeks
Page 18
Visual Observations ─ #7 Austenitic Stainless (304L)CE10A – 26 weeksNo Exposure
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE85A – 26 weeksCE22A – 26 weeks
Page 19
Visual Observations ─ #9 Ferritic Stainless (430L)No Exposure CE10A – 26 weeks
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
CE22A – 26 weeks CE85A – 26 weeks
Page 20
Quantitative Measurements (after 26 weeks)
None ─ all steel systems─ all fuels
Weight Change
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
─ all fuels
No pits deeper than 0.001 inch– all steel systems
Pitting
Page 21
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
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
Page 22
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
���� 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.
Page 23
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
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
─ 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
Page 24
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:
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
• 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
Page 25
FOR MORE INFORMATIONFOR MORE INFORMATIONFOR MORE INFORMATIONFOR MORE INFORMATION
Contact:Peter [email protected]
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
810.225.8250
Visit:www.sasft.org
Page 26
w w w . a u t o s t e e l . o r g
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
Great Designs in Steel is Sponsored by:
ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,
Severstal North America, Inc. and United States Steel Corporation
Page 27
Back Up Slides
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
Page 28
SEM - #6 HDAℓ (CE85A)
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
� Corrosion product:: Aℓ oxide/hydroxide
(white rust)���� ~ 70% of Aℓ coating corroded
Page 29
SEM - #10 Terne (CE85A)
RESULTSRESULTSRESULTSRESULTS
w w w . s a s f t . o r g w w w . a u t o s t e e l . o r g
� Corrosion product:: Pb-Sn oxides
� No red rusting