Corrosion behavioral study of Sintered materials with Ethanol-Blended Fuels - E20 and E85

The increasing adoption of ethanol-blended fuels, such as E20 (20% ethanol and 80% gasoline) and E85 (85% ethanol and 15% gasoline), necessitates a comprehensive understanding of their compatibility with automotive engine components to ensure durability and operational reliability. Fuel compatibility is particularly critical for components in direct contact with ethanol-rich fuels, as improper material selection or insufficient testing can lead to corrosion, material degradation, and compromised engine performance. This study focuses on evaluating the behaviour of sintered materials extracted from potential fuel-contact parts of automotive engines when exposed to E20 and E85 fuels. Testing was conducted in accordance with the SAE J1747 standard, which provides a systematic approach for assessing corrosion resistance and material degradation in fuel environments. Following the exposure tests, post-test evaluations included visual inspection to identify surface changes and Scanning Electron Microscopy (SEM) examination to characterize corrosion mechanisms at the microscopic level. Results showed significantly higher corrosion rates, highlighting their susceptibility to ethanol-induced degradation. The study provides valuable insights into the corrosion behavior of sintered materials and underscores the importance of rigorous material selection and testing protocols to ensure engine compatibility with advanced ethanol-blended fuels. These findings can guide the development of more durable and efficient engine systems for future fuel applications. Key words: Ethanol blende fuels, Corrosion, Sintered materials, Compatibility