Flow-Based Corrosion Analysis of NBR-PVC Fuel Hoses in Ethanol-Gasoline Blends

The integration of ethanol into gasoline presents compatibility challenges for automotive fuel system materials. This study examines the degradation of NBR-PVC fuel hoses exposed to ethanol-gasoline blends (E30, E50, E70, and E100) under dynamic flow conditions. A custom-designed test rig simulates real-time fuel circulation for 1,200 hours. Analysis using FESEM, ATR-FTIR, and elemental mapping identifies ethanol-induced degradation, including dehydrochlorination, plasticizer leaching, and filler detachment. Among the blends, E30 exhibits the least material degradation, while E100 shows significant surface damage and chemical alteration. The study recommends multilayered fuel hose structures with ethanol-resistant inner linings for enhanced durability.