Corrosion Considerations in Design of Automotive Fuel Systems

Metals, plastics, and rubber components are used effectively in the fuel system. This paper presents some of the material limitations and corrective measures required to minimize corrosion or materials degradation. For example, the use of zinc chromate coating, petroleum base coating, and/or Polyurethane foam barriers may be required to minimize the effects of road de-icing salt and mud. Fuel tank electrical connections may require sealed connections and the use of water resistant grease. Zinc coated armor wire protection of the metal fuel lines and optimum material selection of the rubber components of the fuel lines are also discussed. New legislative proposals to add increasing amounts of alcohols to gasoline may dictate further materials design optimizations as suggested by a review of some selected references dealing with this subject.