FORD FLTM BL 102-2-2001 ENGINE TEST FOR COOLANTS IN ALUMINUM SYSTEMS (Replaces FLTM BL 002-02).pdf

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1、FORD LABORATORY TEST METHOD BL 102-02 Date Action ENGINE TEST FOR COOLANTS IN ALUMINUM SYSTEMS Revisions Application 2001 0820 Revised Editorial - no technical change A. Cockman 1997 10 02 This test is used to determine the suitability of coolants for use in automotive cooling systems with aluminum

2、components. This procedure is intended as a qualification test for new formulations and is based on evaluation of corrosion and erosion protection, inhibitor life and solution stability. It is usually run after the candidate coolant has passed other laboratory screening tests. Apparatus Required Eng

3、ine Ford 1.6 L OHC four cylinder engine with aluminum cylinder head and coolant pump. If a suitable 1.6, 1.9, 2.0 L Escort engine is not available then a 4.6 L 2 valve truck engine may be used. Induction Dynamometer or equivalent With suitable controls, indicators, and recorders to operate and contr

4、ol the test. Radiator An aluminum radiator (brazed or mechanically assembled design) of appropriate size. The radiator should be pretested for heat rejection by the QCBTU method. Refer to Step 13 of the Procedure. Mechanically Assembled Heater Core Use an aluminum core. Test Coupons Cleaned and weig

5、hed metal corrosion test coupons per ASTM D 1384. Full Flow Capsule To hold 2 sets of corrosion test coupons. Refer to ASTM D 2758 for capsule description. Cooling Tank for the Radiator The tank shall be deep enough to submerge the entire radiator in the cooling water. The flow of cooling water shal

6、l be baffled to prevent recirculation through the radiator. “Squirrel Cage“ Fan To cool the heater core, 180 mm diameter, 1 O0 mm wide; driv en at 1725 rpm Copynght02001, Ford Global Technologies, Inc FORD LABORATORY TEST METHOD BL 102-02 Overflow System To recover coolant lost from the system, and

7、return it to the system as required. Materials Required Acetone Reagent grade. Caution: Low flash point. Chelator-Type Engine Cleaner Use Dearborn 1 151 Heavy Duty Diesel Cooling System Treatment, Neutral pH Cleaner or equivalent. Is available in 5 gallon pails. Source: Betz Dearborn 2350 East Devon

8、 Avenue Libertyville, Illinois 60048-0383 Phone: (847) 367-5034 Fax: (847) 367-5034 Conditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 OC and 50 +/- 5 % relative humidity for not less than 24 h prior to testing a

9、nd tested under the same conditions unless otherwise specified. Procedure The engine shall be cleaned before each test by the following procedure: 1. Remove the thermostat and reinstall the housing. 2. Reverse flush the engine with water until the water runs clean (as perceived visually) 3. Install

10、a chelator-type engine cleaner per manufacturers instructions. DO NOT use an acid or an alkaline flush in order to avoid damage to the aluminum components. DO NOT use any cleaner in the test radiator; use a spare radiator to provide a closed system during engine cleaning. 4. Run the engine without l

11、oad at about 80 OC for 112 to 1 h. 5. Drain the cleaner from system and flush with water until the water runs clean. Thoroughly drain the system. Page 2 of 5 Copynght02001, Ford Global Technologies, Inc FORD LABORATORY TEST METHOD BL 102-02 6. 7. 8. 9. 1 o. 11. Replace thermostat and gasket. Install

12、 new radiator and heater hoses before each test. Assemble the cooling system as shown in Figure 1. Fill the cooling system with a mixture of 45 YO coolant to 55 YO corrosive test water by volume per ASTM D 1384, Section 6. Pressure test for leaks. The engine shall be run at the following conditions:

13、 Escort 2400 +/- 25 rpm 83 N.m torque 4.6 L 2i Truck 2400 +/- 25 rpm 264 N.m torque Speed output Coolant Temperature: Radiator Inlet (TCI) 107 +/- 3 “C 20 +/- 3 “C T Across Radiator (TCI-TC2) (Adjust flow through bypass to maintain these conditions.) Cycle 16 h on - 8 h off for 42 operating days (67

14、2 h on). The test may be interrupted on weekends. 1 set every 96 operating h (6 days). 1 set for duration of test. Clean per ASTM D 1384, Section 9.1.8 - 10.2. Coupon Change Interval Coolant Sample Interval Zero hour (60 mL) 1 operating hour. 96 operating hours. Each 96 operating hours thereafter. T

15、he inlet and outlet temperature of the radiator and the heater core shall be recorded at regular intervals (about once per hour). Page 3 of 5 Copynght02001, Ford Global Technologies, Inc FORD LABORATORY TEST METHOD BL 102-02 Evaluation of Results: 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. At the end o

16、f the test, remove the test radiator. Test for heat rejection by the QCBTU method or equivalent method and calculate the percent loss in heat transfer. (The QCBTU method is included in the Ford Dynamometer Operations Test Manual). Section the radiator and evaluate the core, headers and end tanks for

17、 corrosion and erosion damage. Carefully cut the heater core apart (see Attachment i). Determine the weight of the deposits in the tube. Evaluate the core and end tanks for corrosion and erosion damage. Evaluate the coolant pump for cavitation, erosion and corrosion. (Use rating system from FLTM BL

18、103-02.) Clean and weigh the corrosion test coupons per ASTM D 1384, Section 9.1.8 - 10.2. Report the weight loss and the presence/absence of pitting. Test the coolant samples for inhibitor concentration (B40i2, Poi3, TT, MBT, NO;, NO;, Si0;and other applicable inhibitors) and specific gravity. Chem

19、icals, materials, parts, and equipment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities. Page 4 of 5 Copynght02001, Ford Global Technologies, Inc FORD LABORATORY TEST METHOD BL 102-02 ENGINE TEST FOR CO

20、OLANTS IN ALUMINUM SYSTEMS COOLING SYSTEM Figure 1 COOLING TANK TC =THERMOCOUPLE ATTACHMENT I Tube Removal From Mechanically Assembled Copper or Aluminum Tube Heater Cores 1. Cut end tanks from heater core assembly just inside header plate with band saw. Retain end tanks for further examination. 2.

21、To remove tubes, cut through fins on either side of tubes with band saw. To aid in removal of fins from tubes, slit fins along length of tube (and down to tube) with a very sharp knife. Fins are then easy to remove with long-nosed pliers or heavy duty tweezers. Determination of Tube Weight 1. Carefu

22、lly remove burrs from ends of tubes and rinse all shavings and loose debris from interior of tubes with water. Rinse with methanol or acetone and dry in an oven with tubes standing on end. Weigh tubes after cooling. 2. Clean tube interior with a long, small diameter laboratory bristle-ended brush ro

23、tated with a small electric drill. Cleanliness can be judged by looking through tube at a light source. If deposits are not removed with mild soap and water, then use a very mild abrasive cleanser. Rinse, dry and reweigh. Measure inside surface area and record results in mg/cm2. Page 5 of 5 Copynght02001, Ford Global Technologies, Inc