Fuels and Lubricants Research

in the U.S. Army TARDEC Fuels and Lubricants Research Facility at Southwest Research Institute

Southwest Research Institute has staffed and continuously operated the U.S. Army Tank-Automotive Research, Development, and Engineering Center (TARDEC) Fuels and Lubricants Research Facility (TFLRF) since the facility began operation on the Institute grounds in 1957. TFLRF functions as a dedicated "in-house" facility, an extension of the Army's Tank-automotive and Armaments Command (TACOM) at Warren, Michigan. TFLRF is surrounded and augmented as required by the Institute's diverse staff and modern facilities. Included among the Institute's 12 technical divisions are three with more than 40 years' experience in engine, fuels, and lubricants activities. The TFLRF research program provides the Army and Department of Defense with unique capabilities ranging from proof of concept to field validation testing and rapid response problem solving, particularly in the area of combat mobility fuels and lubricants. Other governmental agencies and contractors also use SwRI fuels and lubricants research capabilities through cooperative or independent arrangements.

The Institute assembles multidisciplinary teams capable of solving integrated fuels- and lubricants-related problems, specifically, how fuels, lubricants, engines, and systems interact.

TFLRF (SwRI) technology areas include:

• Characterization of fuel and lubricant (F&L) properties and compositions
  
• Prediction, analysis, and correlation of F&L properties with equipment performance
  
• Alternative F&L utilization criteria
  
• Development of bench and engine evaluation methodologies
  
• Friction studies and wear mapping for components and systems
  
• Fuel lubricity
  
• Fuel-lubricant-equipment interactions
  
• Diesel, turbine engine combustion and performance mapping analysis
  
• Fluid flammability and combustion
  
• Halon extinguishing alternatives
  
• Failure analysis
  
• Field and fleet evaluations

Lubricity Studies for Diesel Injection Systems

Southwest Research Institute works with the U.S. Army as well as the engine and pump industries, SAE, ISO, and CRC to develop fuel lubricity requirements for heavy-duty vehicles and equipment. Lubricity studies for diesel injection equipment require the Institute's expertise in using engine, component, and bench testing in an integrated problem-solving process.

TFLRF (SwRI) studies diesel fuel contamination by extracting contaminants from clean and dirty fuel filters from Army battle tanks. Possible sources of contamination range from products of fuel degradation to dirt or dust to microbiological growth, such as fungus or yeast.

Fuel Cleanliness, Deterioration, and Property Measurements

Institute scientists are experts in studies of fuel stability and cleanliness. SwRI staff members have improved methods for removing, isolating, and characterizing contaminants from plugged fuel filters and samples of contaminated fuel. SwRI develops special instrumentation and techniques to predict and diagnose fuel stability and cleanliness and provides services such as establishing fuel monitoring procedures, providing guidance on use of fuel additives, and conducting onsite fuel sampling and testing.

Fuels Kinetics Studies

The Institute measures fuels kinetics to establish a theoretical base and to develop methods of predicting future behavior of hydrocarbon fuels, such as the peroxidation potential of turbine fuels. SwRI generates highly repeatable and accurate fuels kinetics data by precisely controlling temperatures within stainless steel stirred pressure reactors equipped with liquid and gas phase sampling probes.

SwRI scientists have developed a new, accelerated test procedure to predict the storage stability of kerosene fuels by measuring rates of peroxidation. Developed for the U.S. Navy, the procedure also reliably evaluates the effectiveness of antioxidants in retarding autoxidation of turbine fuels.

High-Output Diesel Engine Lubrication

The Institute is working with the U.S. Army to define lubricant requirements for next-generation combat and tactical vehicles requiring low-heat rejection engines.

SwRI is also investigating requirements for an engine oil that will function in conventional as well as new reduced-emission heavy-duty diesel-powered Army equipment. Worldwide operation with available diesel fuels of varying composition is also required.

The Caterpillar 1N test research engine is used to evaluate the piston deposition characteristics of future high-performance fluids, including high-temperature lubricants, improved arctic engine oils, and emission-compliant lubricants.

Flammability Hazard Assessments

SwRI uses standard and specially designed tests to simulate fuels and fluids flammability hazards such as aircraft post-impact pool burning or high-pressure fluid leaks in engine compartments. For example, a dynamic mist flammability test is used to assess the hazards of fuels, lubricants, or high-pressure hydraulic fluids near or in contact with hot surfaces. An SwRI-developed test apparatus allows staff members to determine the fire-extinguishing agent effectiveness and decomposition product effects on system components, providing guidance for vehicular fire suppression systems development. Innovative research enables SwRI to provide leadership in technical and professional societies dealing with fluid hazards and formulation, such as the American Society for Testing and Materials and the Coordinating Research Council.

Dynamic mist flammability tests assess the hazards of high-pressure fluid leaks near hot surfaces, such as engine manifolds or broken lines.

Recent and Current TFLRF (SwRI) Accomplishments

• Developed a laboratory fuel lubricity evaluation procedure that correlates with a bench pump stand durability procedure to provide the Army the capability to specify fuel requirements to control wear in diesel injection pumps.
  
  
• Successfully completed a three-year technology demonstration at a U.S. Army base using aviation turbine fuel JP-8 in diesel-consuming combat, tactical, and administrative ground equipment; provided assistance in solving non-routine problems to enable worldwide adoption of a single kerosene-based fuel.
  
  
• TFLRF is using advanced analytical-instrumental chemometrics in a petroleum quality analysis system protocol that will allow rapid on-site military or civilian verification of fuel quality.
  
  
• Designed, fabricated, and field demonstrated a first generation fuel filtration additive injection unit (FAU) to provide the Army with an as-needed capability for using stabilizer, biocide, or orrosion-inhibitor antiwear additives or for cleaning vehicle fuel cells. The U.S. Army and Marine Corps have each used the FAU in successful field demonstrations.
  
  
• In concert with recent Clean Air Act and alternative fuels legislation, TFLRF (SwRI) identified military vehicles, equipment, and fleets to be evaluated for future use of cleaner burning, reformulated gasoline, M85, compressed natural gas, and biodiesel (methyl soyate) fuels.
  
  
• Developed high-temperature liquid lubricant and fuel thermal stability screening procedures for future Army battle tank low-heat rejection diesel engines. An all-climate, year-round lubricant candidate was also identified and is undergoing evaluation in Army high-output, lubricant-sensitive two-cycle diesel engines.
  
  
• TFLRF is conducting a cooperative program with industry to develop vehicle and equipment fuel filter evaluation methodologies that will provide industry and the Army with needed guidance in fuel system specifications and standardization.
  
  
• Provided rapid technical response capabilities for the U.S. Army in support of Operations Desert Shield and Desert Storm (ODS). This activity was highlighted by efforts in fuel deterioration, flammability, cleanliness, and filtration and failure analysis of diesel engine rotary-type fuel injection pumps. Selected Army and Marine Corps equipment deployed during ODS used earlier TFLRF-developed technology in fuel stability and alternative fuels applications, providing the military with timely information and contributing to high-level equipment readiness.
  

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