CRC AVFL-15 ProjectE20 Durability StudyFuel System ComponentsMid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010Presented by: Dominic DiCicco, Ford Motor CompanyProject Co-leads: Sean Torres, Ford Motor CompanyMike Foster, BPKeith Knoll, NRELPanel: CRC AVFL Member CompaniesSlide 2Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Scope•Initial investigation to evaluate the durability impacts of wetted fuelcomponents when exposed to E20.•Program limited to one piece evaluations due to resource constraintsTechnical Approach•Query OEMS for candidate fuel system applications relevant to the concern.•Perform specific durability protocols to expose andage components usingmid-level ethanol.•Conduct component functionality testing using E0 asthe test fluid baseline.Status:Pilot phase completed December 2008Fuel Injector testing completed E20Atesting Dec. 2009Fuel System Rigs completed aging February 2010Fuel Pump testing to complete (E10 Endurance) May 2010Finalizing setup of Fuel Level Sensor and Fuel Damper testingPost Mortem in progress or to be conducted for various componentsAVFL-15 Project SummarySlide 3Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Vehicle Design Selection•1996-2007MY(attempting to represent model years found in the fleet)Fuel-System Related Components Included in Program•Fuel pump•Fuel injector•Fuel level senders•Fuel damper•Fuel system rig assembly (from fuel rail to fuel tank and components inbetween)Vehicle Design & ComponentsSlide 4Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15•Base Gasoline (E0)–used for functional testing–Conventional Fuel with 38-40% aromatics–Instead of isooctane-toluene blend•E10–durability fuel–blended from the base gasoline•Aggressive E20 (E20A)–durability fuel–SAE J1681 – with agreed modifications–Chlorides – 10ppm max from ASTM 4806 (2ppm for E20)–Sulfates – 4ppm max on denatured ethanol (~1ppm forE20)–pHe – unable to achieve using acetic acid; replacedsulfuric acid with nitricacid (~2.8 as found in SAE J1681)•Fuels pre-blended and stored at testing facilityTest FuelsSlide 5Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15•Soak fuel pumps in E20Ato determine change in pumpperformance•Soak aging of 10 designs (up to 12 weeks)–Soak pump in E20Aat 60oC (140oF), non-vented container–Pump on time using 13.5 VDC, pump flow and pressureper specifications–Fuel changed weekly for first 8 weeks, then changedat week 10 and week 12•Flow testing–Weekly using SAE/USCAR-13 for first 8 weeks, thenfinal test at week 12–E0 used for all flow testing•Follow-up testing–Selected Pump designs impacted by E20Arepeated the soak test with E10•Pumps completing testing are to undergo tear down analysisFuel Pump: Soak Durability TestSlide 6Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Sample 1: Fuel Pump FlowFuel Pump Soak Durability - Pump Example 1Pump Flow vs. Soak TimeTest Time

% Change in FlowE20aPump Soak Conditions:- 60°C (140°F)- E20a (aggressive) test fuel- E10 (nominal) test fuelFlow Test Conditions:- E0 test fuel (retail gasoline)- 12 volt supply- OEM spec. pressureNOTE:1. This is an example of a fuel pump whichexperienced very little flow change.2. % change in flow does not include increasedvehicle flow demand due to lower energy contentfrom ethanol.Slide 7Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel Pump Soak Durability - Pump Example 2Pump Flow vs. Soak TimeTest Time

% Change in FlowE20aE10Pump Soak Conditions:- 60°C (140°F)- E20a (aggressive) test fuel- E10 (nominal) test fuelFlow Test Conditions:- E0 test fuel (retail gasoline)- 12 volt supply- OEM spec. pressureSample 2: Fuel Pump FlowNOTE:1. Data shown here is the largest difference between E20a andE10 of the pumps tested to date. Statistical robustness to bedetermined by additional testing.2. % change in flow does not include increased vehicle flowdemand due to lower energy content from ethanol.Test TimeSlide 8Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel Pump: Endurance Testing•Operate fuel pumps in E20Ato determine change in pumpperformance from nearly continuous operation•8 designs tested with E20Ainitially; repeat with E10 as necessary•Endurance aging:–3,000 hours (10 minutes on, 6 seconds off)–Aging temperatures included 105oF and 140oF–Fuel pressure is specific to design–Fuel change twice per week•Test stand functionality as defined in SAE/USCAR-13–Test every 1,000 hours (and before/after hot temp operation)Status:E20Atesting completeE10 testing underway (4 designs), near completionTear down in progressSlide 9Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel Injector Testing•Operate fuel injectors with E20Ato determine change in spraypattern, dynamic flow, static flow, and if leakageoccurs due tooperation in E20A•3 designs tested with E20Ainitially; repeat with E10 as necessary•Aging–600 MM cycles (approx. 6 weeks), Test every 100 MM cycles–Pulse Width of 2.5 ms with Period of 5.0 ms–Fuel change at Test points–Use aftermarket fuel pump and pressure regulator; pressure set perapplication•Injector testing (SAE J1832)–Static and Dynamic Flow–Spray quality degradation (via photograph)–Leakage•Status–Completed E20Atesting Dec. 2009Slide 10Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel Level Sensor•Operate fuel level sensor in E20Ato determine performance•Fuel Resistance (1000 hr test)–250,000 cycles (powered), 1 week soak (no power) for 1 million cycles–Total duration at 1 Hz: Approximately 40 days•Full Sweep–5,000,000 cycles (58 days at 1 Hz)•Evaluation to consist of:–Sensor Accuracy–Continuity and Noise–Resistance Stability–Visual InspectionStatus:Endurance aging fuel pumps to be used for design selectionActuation method approved, setup finalizingTesting scheduled to begin in MaySlide 11Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel Damper•Soak fuel dampers in E20Atoassess damping change•High Temperature Soak /Permeation Test–100 psig fluid pressure @ 120oC for 120 hrs•Pulse Attenuation (“water hammer” setup) using fastactingvalve–10 Hz to 200 Hz injector frequency at 20oC•External Leakage–72 psig air test while submerged in test fluidStatus:Setup finalizing (relatively short test)Testing scheduled to begin in MaySlide 12Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel System Rig Testing•Expose fuel system components to E20Aand E10•13 rigs: 6 designs (1 rig for each fuel) & one additional rig from•CRC Project E-65 (on E20A)–Rigs to mimic vehicle fuel system (using new parts)•14 month soak at 105oF (40.6oC)•Fuel circulation for 10 min every weekday to wet components•Fuel replaced weekly, then every 2nd week, then every 3rd weekduring each subsequent 14 week period•Conduct Tear Down and Post Mortem Analysis–Capture fuel samples to assess material degradation–Analyze fuel system materials at the end of the soak•StatusAging completed February 2010Fuel sample analysis underwayRig teardownSlide 13Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Fuel System Rig ExampleSlide 14Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Post-Mortem Testing•Fuel Pump–Flow Test–Teardown (e.g. brush, commutator, impeller)•Fuel System Rig–Leak Test–Disassemble–Component teardowns (e.g. corrosion, contamination,seal degradation)•Fuel Level Sensor: TBD•Fuel Damper: TBD•Fuel Injector: Not Planned PresentlySlide 15Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15Testing Status / Timeline•Currently Planned / Budgeted Testing•Initial aging & testing only–Does not include post-mortem, data analysis, reporting period, etc.•Any additional testing will progress beyond June 2010Slide 16Mid-Level Ethanol BlendsResearch Coordination GroupMay 5th, 2010AVFL-15What’s Next?•AVFL-15 was a scoping study•Performance differences in some fuel pumps were found•Post Mortem and Tear Downs in progress•All testing will not complete by end of Summer 2010Panel Recommendation is that “Further work is needed todetermine the significance of changes in pump performancefound in some models” :1. To investigate root causes2. To provide some statistical robustnessCurrent study involves single sample testing3. To assess inclusion of additional ethanol fuel types and concentrations4. To evaluate additional testing/functional protocols