Effect of Alcohol Fuels on Fuel-Line Materials of Gasoline Vehicles SAE TECHNICAL PAPER SERIES

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1 SAE TECHNICAL PAPER SERIES Effect of Alcohol Fuels on Fuel-Line Materials of Gasoline Vehicles Atsushi Kameoka, Keiichi Nagai, Gen Sugiyama and Toshiyuki Seko Japan Automobile Research Institute Powertrain & Fluid Systems Conference and Exhibition San Antonio, Texas USA October 24-27, Commonwealth Drive, Warrendale, PA U.S.A. Tel: (724) Fax: (724) Web:

2 By mandate of the Engineering Meetings Board, this paper has been approved for SAE publication upon completion of a peer review process by a minimum of three (3) industry experts under the supervision of the session organizer. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth Drive Warrendale, PA USA permissions@sae.org Fax: Tel: For multiple print copies contact: SAE Customer Service Tel: (in USA and Canada) Tel: (out USA) Fax: CustomerService@sae.org ISSN Copyright 2005 SAE International Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE. The author is solely responsible for the content of the paper. A process is available by which discussions will be printed with the paper if it is published in SAE Transactions. Persons wishing to submit papers to be conred for presentation or publication by SAE should send the manuscript or a 300 word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE. Printed in USA

3 Effect of Alcohol Fuels on Fuel-Line Materials of Gasoline Vehicles Atsushi Kameoka, Keiichi Nagai, Gen Sugiyama and Toshiyuki Seko Japan Automobile Research Institute Copyright 2005 SAE International ABSTRACT In 1999, some Japanese fuel suppliers sold highly concentrated alcohol fuels, which are mixtures of gasoline and oxygenates, such as alcohol or ether, in amounts of 50% or more. In August 2001, it was reported that some vehicle models using the highly concentrated alcohol fuels encountered fuel leakage and vehicle fires due to corrosion of the aluminum used for the fuel-system parts. The Ministry of Economy, Trade and Industry (METI) and the Ministry of Land, Infrastructure and Transport Government of Japan (MLIT) jointly established the committee on safety for highly concentrated alcohol fuels in September The committee consisted of automotive technology and metal corrosion experts knowledgeable about preventing such accidents and ensuring user safety. Immersion tests were conducted on metals and other materials used for the fuel-supply system parts to determine the corrosion resistance to each alcohol component contained in the highly concentrated alcohol fuels. It was confirmed that each alcohol component contained in the highly concentrated alcohol fuels currently on the market causes corrosion of the aluminum generally used for automotive fuel-system parts. INTRODUCTION A biomass alcohol for automotive fuels represents an important measure to reduce global warming. However, the use of fuels containing alcohol, such as ethanol, in vehicles originally designed to be fueled with gasoline may affect vehicle safety and exhaust emission due to incompatibility with the automotive-part materials and a difference in the air-fuel ratio. Some Japanese fuel suppliers sold highly concentrated alcohol fuels in 1999 (1). These fuels were mixtures of gasoline and oxygenates, such as alcohol or ether, in an amount of 50% or more. It was reported in August 2001 that some vehicle models using the highly concentrated alcohol fuels encountered fuel leakage and vehicle fires due to corrosion of the aluminum used for the fuel-system parts. The Ministry of Economy, Trade and Industry and the Ministry of Land, Infrastructure and Transport Government of Japan jointly established the committee on safety for highly concentrated alcohol fuels in September (1) This committee consisted of automotive technology and metal corrosion experts knowledgeable about preventing such accidents and ensuring user safety, and it conducted investigations for about one year. This paper focuses on corrosion of the aluminum materials used for automotive fuel-system parts from among the following technological investigations conducted by the committee. Fuel sampling from gas stations selling highly concentrated alcohol fuels and analyses of sampled fuels (Total of 226 samples from five suppliers) (1) Tests on the effects of highly concentrated alcohol fuels on materials (2)(3) Hearings with manufacturers of highly concentrated alcohol fuels Investigations concerning overseas high concentration alcohol fuels The committee sampled highly concentrated alcohol fuels from gas stations and domestic storage tanks and analyzed the fuel properties. They found that ethanol, n- propanol, i-propanol, n-butanol, and i-butanol were contained in the highly concentrated alcohol fuels currently on the market. METAL IMMERSION TEST OBJECTIVE OF THE METAL IMMERSION TEST The objective of the metal immersion test was to clarify the corrosion resistance of each component contained in highly concentrated alcohol fuels on the materials used for fuel-system parts in gasoline vehicles and the corrosion tendencies of the materials.

4 IMMERSION TEST METHOD A test piece was immersed in the alcohol or a mixture of the alcohol and gasoline and the presence or absence of corrosion of the metal material was observed. The test was conducted using an airtight container placed in an explosion-proof thermostatic chamber (4)(5)(6). Figures 1.1 to 1.3 show the shape of the test piece, the test piece holding method, and the immersion container. Table 1 shows the dimensions of the immersion container mm d 3.5mm Test piece Fig. 1.3 Immersion airtight container and inner glass container. Table 1 Dimensions of the immersion container. Immersion airtight container (SS316) Inner glass container Outer dimensions: 65 mm in diameter and 165 mm in height Inner dimensions: 45 mm in diameter and 130 mm in height Outer dimensions: 40 mm in diameter and 120 mm in height (capacity: 100 ml) Amount of immersion liquid: 80 ml Fig. 1.1 Shape of the test piece and test piece holder. Single-material corrosion test Galvanic (bimetallic) corrosion test Crevice corrosion test Test piece holder (Insulator) Spacer (Insulator) The test pieces are inserted into the test piece holder on either of a spacer used to prevent contact between them. A pair of test pieces made of different metals is inserted into the test piece. A spacer separates them from another pair of test pieces. A pair of test pieces made of a single metal is inserted into the test piece holder. A spacer separates them from another pair of test pieces. Fig. 1.2 Test piece holding method for each test. TEST ITEMS The tests were conducted under four conditions depending on the mixing mode of the alcohols contained in the highly concentrated alcohol fuels. Test of single alcohol fuel Test of two or three species of alcohol fuels Test of sour fuel Test of model samples and actual samples Sour fuel is oxidized fuel that has been stored for a long time. TEST MATERIAL Metal material used for the fuel systems of existing gasoline vehicles was provided (7). The test was conducted on each fuel for each corrosion form (singlematerial corrosion, bimetallic corrosion, and crevice corrosion). The effects on plated steel were determined by conducting the test on single-material test pieces made of nickel, zinc, or tin as the plating material and performing the bimetallic corrosion test using steel. MEASUREMENT ITEMS The test piece was weighed before and after the immersion test to determine the corrosion tendencies of the fuels. Corrosion behavior was observed by photographs and the pressure in the container was measured. A reduction in mass was judged to have occurred when a reduction in mass in an amount equal

5 to or greater than 0.3% of the mass of the test piece was observed by comparing mass measurements taken before and after immersion. This level allows any change in mass to be reliably determined through specifications of the electronic balance used for the measurements. IMMERSION TEST CONDITIONS The maximum temperature of the fuel-system parts during normal use conditions was 70 o C for the body system parts, 80 o C for the parts in the engine chamber, and 100 o C for the fuel delivery pipe. The temperature conditions for the immersion tests were set at 100 o C based on these amounts. The immersion duration was set at 480 hours. TEST FUEL Ethanol, i-propanol, n-propanol, i-butanol, and n-butanol, which are contained in the highly concentrated alcohol fuels, were evaluated. Naphtha was provided as a reference. IMMERSION MODE The immersion tests were conducted in the following three modes to examine the corrosion mechanism. The test piece was individually immersed in the fuel in the single-material test. Aluminum, steel, copper, nickel, zinc, and tin were used in the single-material test. Test pieces made of different metals were immersed while in contact with each other for the bimetallic corrosion test. The combinations of metals were A1050/Fe, A1050/Cu, A1050/Ni, A1050/Zn, A1050/Sn, Fe/Cu, Fe/Ni, and Fe/Zn. Test pieces made of a single metal were immersed while in contact with each other for the crevice corrosion test. Eight metals, the same as those used in the single-material test, were subjected to the crevice corrosion test. PROCEDURE OF THE METAL MATERIAL IMMERSION TEST Table 2 shows the procedure of the metal material immersion test. Table 2 Procedure of the metal material immersion test. (3) Installation of the metal test piece (4) Start of the immersion test (5) Visual observations (6) Completion of the immersion test SINGLE ALCOHOL FUEL The test piece is installed in the test piece holder. The test piece installed in the holder is placed in the inner glass container. The inner glass container is placed in the immersion airtight container. The airtight container containing the test piece and the test solution is installed in the explosion-proof thermostatic chamber, and recording of data on pressure and temperature commences. The surface of the metal test piece is observed with the naked eye once a week. The test piece is removed, photographed, and weighed when a corrosion product is observed on the surface. Test pieces for which no changes in surface appearance are observed with the naked eye are continuously subjected to the test. The test is conducted again when an increase in pressure of 1 MPa or more occurs or a large amount of corrosion products is observed in the immersion liquid. The corroded test piece is removed before the test is conducted again. The metal test piece is removed after 480 hours of immersion and is photographed and weighed. Immersion tests were conducted on materials used for fuel supply system parts to determine the corrosion resistance of the metal to each alcohol component contained in the highly concentrated alcohol fuels. The alcohol concentration was varied within a range of 0 to 100% to determine the effects of the alcohol concentration. The test was conducted while varying the water content as the parameter since water content is an important factor that influences metal corrosion. Table 3 provides the test conditions using a single alcohol fuel. Table 3 Test conditions using a single alcohol fuel. Alcohol concentration 35%, 50%, 100% (1) Initial measurement (2) Grinding of the test piece The test piece is weighed. The water content in the fuel is measured to adjust the water content. - The surface of the test piece is ground (#400) and washed with the immersion fuel. Water content Temperature Time 150, 500, 2000, ppm (alcohol concentration: 50%) 100degC 480 hours

6 CORROSION RESISTANCE ON ALUMINUM Table 4 presents the immersion test results using a single alcohol fuel. Figures 2.1 and 2.2 contain photographs of the aluminum materials before and after immersion. Ethanol, n-propanol, i-propanol, n-butanol, and i-butanol exhibited characteristics that cause corrosion of the aluminum. The aluminum was conrably corroded, to the extent that it was completely dissolved or reduced in mass. Neither complete nor any reduction in mass was observed during immersion in 100% naphtha containing no alcohol. The aluminum was corroded at an alcohol concentration of 35% or more, and the degree of reduction in mass increased as the alcohol concentration was increased. These results prove that ethanol, n-propanol, i-propanol, n-butanol, and i-butanol have characteristics that corrode aluminum. Test material : A6061 After Naphtha E50 np50 ip50 nb50 ib50 Fig. 2.2 Photographs of the aluminum materials (A6061) before and after immersion. Table 4 Immersion test results using a single alcohol fuel. Tests Single-material corrosion test Crevice corrosion test Bimetallic corrosion test Material Test material : A1050 Naphtha 100% Alcohol:50%, water:150ppm E50 np50 ip50 nb50 ib50 A1050 OK * * * * * * * * * * * * * * A6061 OK * * * * * * * * * * * * * ADC12 OK * * * * * * * * * * Steel * OK OK OK OK OK Copper * * * * * * Nickel OK OK OK OK OK OK Zinc OK * * OK OK OK Tin OK * OK OK OK OK A1050/A1050 OK * * * * * * * * * * * * * * * Steel/Steel * OK OK OK OK OK Copper/Copper * * * * * * Nickel/Nickel OK OK OK OK OK OK Zinc/Zinc * * * OK OK OK Tin/Tin OK * OK OK OK OK A1050/Steel OK/ * *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Copper OK/ * *** / * *** /OK *** / * *** /OK OK/ * A1050/Nickel OK/OK *** /OK *** /OK *** /OK *** /OK OK/OK A1050/Zinc OK/OK *** / ** *** / ** *** /OK *** /OK OK/OK A1050/Tin OK/OK *** /OK *** /OK *** /OK *** /OK * / OK Steel/Copper * / * OK/ * OK/ * OK/ * OK/ * OK/ * Steel/Nickel OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Steel/Zinc OK/OK * / * OK/OK OK/OK OK/OK OK/OK Steel/Tin OK/OK * / * * / OK OK/OK * / OK OK/OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution After Naphtha E50 np50 MECHANISM OF REACTION BETWEEN ALUMINUM AND ALCOHOL Pressure in the container in the immersion test. The pressure in the immersion container was significantly increased in proportion to the corrosion of the aluminum. Figure 3.1 presents an example of the pressure history during the immersion test. The pressure of the vapor of alcohol, naphtha, and air increased due to an increase in the temperature of the immersion container sealed at room temperature. The pressure was increased by about 0.3 to 0.5 MPa immediately after immersion. Naphtha does not react with aluminum, and thus the pressure was not changed. In contrast, the pressure rapidly increased with i- propanol after 200 hours. Pressure (MPa) Criterion of Pressure rise is 0.6MPa i-propanol 50% Duration of Pressure rise Starting Combination of material A1050/A1050, A1050/Steel A6061, ADC12 Naptha ip50 nb50 ib Time (h) Fig. 3.1 Example of the pressure history during the immersion test. Fig. 2.1 Photographs of the aluminum materials (A1050) before and after immersion. Mechanism of reaction between aluminum and alcohol. A gas chromatography analysis of the gas components when the pressure was increased revealed 91 vol% of hydrogen. Table 5.1 lists the analysis conditions. Figure

7 3.2 presents the chromatogram of gas products in the immersion test. These results confirm that hydrogen was the major gas component that caused the pressure increase. Equipment Column 1 Column 2 Detector Table 5.1 Hydrogen analysis conditions. GC323 Porapak T50/80(2m) MOLECULAR SIEVE 5A 60/80 3m TCD Detector Temp. 80 Oven Temp. 50 Current 70 Carrier gas Volts H 2 Fig. 3.2 Gas chromatogram of the gas generated in the immersion test. The major component of the gas product was hydrogen; therefore, it was conred that the alcohol reacted with the aluminum to produce an alkoxide and hydrogen. N2 3ROH + Al Al(OR) 3 + 3/2H 2 H 2 standard gas(99.99%) Minutes Volts 0.10 H 2 The generated gas in immersion test Minutes The pressure at which aluminum will have completely reacted can be estimated based on this reaction formula. Table 5.2 gives the estimated values of increases in pressure due to hydrogen and the test results. The maximum value of an observed increase in pressure roughly coincided with the increase in pressure due to generation of hydrogen estimated from the above reaction formula. It increased as the number of aluminum test pieces was increased. These results confirm that the estimated reaction mechanism between the alcohol and aluminum is appropriate. Table 5.2 Estimated values of increases in pressure due to hydrogen and the test results. Number of aluminum test pieces Pressure increase estimated value (MPa) Pressure increase Pressure caused by increase a factor caused by Total other than hydrogen hydrogen generation generation Peak pressure observed in the immersion test (MPa) CORROSION TENDENCY OF ALUMINUM DUE TO ALCOHOL The degrees of of aluminum and the mass reduction in ethanol, n-propanol, and n-butanol were greater than with i-butanol and i-propanol. The initial time of pressure increase under respective conditions were compared to examine the corrosion tendency of aluminum caused by alcohol. An increase in pressure exceeding 0.6 MPa was observed under conditions in which the aluminum was dissolved; thus, the initial time of pressure rise was defined as the period from the commencement of immersion to the time at which the pressure exceeded 0.6 MPa. Figure 3.3 depicts the effects of the alcohol species on the time when the pressure began to rise. The pressure rise starting time was the shortest with ethanol, and it increased as the number of carbon atoms was increased. The starting time of the pressure rise was reduced for normal alcohol with the same number of carbon atoms compared with branched alcohol. These results suggest that alcohol with fewer carbon atoms exhibits less corrosion resistance on aluminum and that normal alcohol with the same number of carbon atoms exhibits less corrosion resistance. Pressure rise starting time (h) Water content 500ppm Ethanol 50% n-propanol 50% i-propanol 50% n-butanol 50% Combination of material A1050/A1050, A1050/Steel A6061, ADC12 i-butanol 50% Fig. 3.3 Effects of alcohol species on the pressure rise starting time.

8 Figure 3.4 illustrates the effects of water content on the pressure rise starting time. The pressure was not increased at a water content of 2000 ppm due to the absence of corrosion. The pressure rise starting time was reduced at a water content of 150 ppm compared with a water content of 500 ppm. Table 5.3 presents the effects of water content on the in mass for n- propanol and n-butanol. The degrees of of aluminum and in mass tended to increase as water content increased. These results suggest that water tends to suppress the reaction between the alcohol and aluminum. Pressure rise starting time (h) i-propanol 50% Combination of material A1050/A1050, A1050/Steel A6061, ADC12 No Change Water content (ppm) Fig. 3.4 Effects of water content on the pressure rise starting time. Table 5.3 Effects of the water content on the in mass. Tests Single-material corrosion test Bimetallic corrosion test Material Alcohol:50%, water:150ppm Alcohol:50%, water:500ppm Alcohol:50%, water:2000ppm np50 nb50 np50 nb50 np50 nb50 np50 nb50 A1050 *** *** *** *** *** *** OK OK A6061 *** 76.2 *** 80.7 *** 85.1 OK OK ADC *** *** *** *** OK OK A1050/Zinc ***/0.3 *** /OK ***/1.1 *** /OK ***/2.5 *** /OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution CORROSION RESISTANCE ON OTHER METALS Alcohol:50%, water:1% Figure 3.5 contains photographs of steel, copper, nickel, zinc, and tin before and after the immersion tests. Steel, copper, nickel, and tin were reduced in mass but not completely dissolved. Some samples of the test piece that were not completely dissolved or reduced in mass exhibited changes in surface color or metal glossiness during the immersion tests. No differences between immersion in the fuel containing alcohol and immersion in naphtha were observed. However, the mass of zinc was d at a water content of 150 ppm or more, and the mass reduction rate increased as the water content was increased, as indicated in Table 5.3. Test material : Fe After Naphtha E50 np50 Test material : Cu After Naphtha E50 np50 Test material : Ni After Naphtha E50 np50 Test material : Zn After Naphtha E50 np50 Test material : Sn After Naphtha E50 np50 Fig. 3.5 Photographs of steel, copper, nickel, zinc, and tin before and after the immersion tests. MIXED FUEL OF TWO OR THREE ALCOHOLS The immersion tests were conducted using mixtures of alcohol species contained in the highly concentrated alcohol fuels to determine the effects of mixing two or more alcohol species. TEST CONDITIONS Ten fuels were selected by combining two or three species of alcohol, and these fuels were subjected to the test. Table 6 shows the test conditions using two or three species of alcohol fuel. Table 6 Test conditions using two or three species of alcohol fuels. Alcohol concentration 50% Water content 150 ppm (alcohol mixed liquid) 28 ppm (water content in naphtha) Temperature 100 o C Time 480 hours

9 TEST RESULTS Table 7 provides the immersion test results using two or three species of alcohol fuel. Figure 4 presents photographs of the aluminum before and after the immersion tests using two or three species of alcohol. The aluminum was corroded by the alcohols in the tests using an immersion liquid prepared by mixing two or three species of ethanol, n-propanol, i-propanol, n- butanol, and i-butanol. No reduction effect on the corrosion of aluminum was observed even when two or more alcohol species were mixed. Table 7 Immersion test results using two or three species of alcohol fuels. Tests Single-material corrosion test Material E25 np25 Mixture of two species of alcohol E25 nb50 np25 ip25 ip25 ib25 nb25 ib25 E17 np17 ip17 E17 np17 nb17 E17 nb17 ib17 np17 ip17 ib17 ip17 nb17 ib17 A1050 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * A6061 * * * * * * * * * OK * * * * * * * * * * * * * * * * ADC12 * * * * * * * * * OK * * * * * * * * * * * * * * * * Steel OK OK OK OK OK OK OK OK OK OK Copper * * * * * * * * * * Nickel OK OK OK OK OK OK OK OK OK OK Zinc OK * OK OK OK * * * OK OK Tin OK OK OK OK OK OK OK OK OK OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution Test material : A1050 After Test material : A6061 ip25+ib25 Mixture of three species of alcohol ip17+nb17+ib17 After ip25+ib25 ip17+nb17+ib17 SOUR FUEL TEST METHOD Immersion tests were conducted using sour fuel prepared with an alcohol concentration of 50% to determine the effects under conditions in which the fuel is oxidized during long-term storage. Cumene hydroperoxide was used as a peroxide; the peroxide number (8) was adjusted to 160 mg/kg. This peroxide number generally corresponds to the conditions under which gasoline is oxidized to the maximum extent. Table 8 presents the test conditions using the sour fuel. Table 8 Test conditions using sour fuel. Alcohol concentration Water content Temperature Time TEST RESULTS 50% (naphtha 50% + i-propanol 50%) 150 ppm (alcohol mixed liquid) 28 ppm (water content in naphtha) 100 o C 480 hours Table 9 shows the immersion test results using the sour fuel. Figure 5 contains photographs of aluminum with steel before and after the bimetallic corrosion tests using sour fuel. Neither complete nor any reduction in mass was observed under conditions in which the sour fuel was prepared by mixing the peroxide into naphtha. The aluminum and aluminum alloys were completely dissolved or reduced in mass under all the conditions when the immersion test was conducted using a solution prepared by mixing the peroxide into a mixed solution of naphtha and i-propanol. The alcohol displayed no corrosion resistance on aluminum even under conditions in which sour fuel was used; however, no significant difference in corrosion resistance was observed. Some metals other than aluminum exhibited changes in surface color or metal glossiness before and after the immersion tests. However, no significant difference due to sour fuel was observed. Test material : ADC12 After ip25+ib25 ip17+nb17+ib17 Fig. 4 Photographs of the aluminum before and after immersion tests using two or three species of alcohols.

10 Table 9 Immersion test results using sour fuel. Tests Single-material corrosion test Crevice corrosion test Material Sour fuel Tests Material Naptha ip50 Naptha ip50 A1050 OK ** A1050/Steel OK/ * *** /OK A6061 OK *** A1050/Copper OK/ * *** /OK ADC12 OK *** A1050/Nickel OK/OK *** /OK Steel * OK A1050/Zinc OK/ * *** /OK Copper * * A1050/Tin OK/OK *** /OK Nickel OK OK Steel/Copper * / * * /OK Zinc OK OK Steel/Nickel * /OK OK Tin OK OK Steel/Zinc * / * OK A1050/A1050 OK *** Steel/Tin * /OK OK Steel/Steel * OK OK : No Change Copper/Copper * * * : Change in Surface without Reduction Bimetallic corrosion test Nickel/Nickel OK OK in Mass Zinc/Zinc OK OK ** : Reduction in Mass Tin/Tin OK OK *** : Dissolution Test material : A1050 ip50 No Sour Sour fuel ip50 Sour fuel immersion test conditions using the model samples and the actual samples. Table 11 lists the compositions of the model fuels and the actual samples with the average alcohol concentration of the highly concentrated alcohol fuels currently on the market, as determined from the sampling analysis results. Table 10 Immersion test conditions using the model samples and the actual samples. Model sample Actual sample The immersion test was conducted using fuels prepared with a sample composition (alcohol, MTBE, and water content) of the minimum alcohol concentration and a sample with an almost average alcohol concentration of the highly concentrated alcohol fuels currently on the market from each of the five suppliers, as determined from the sampling analysis results. The immersion test was conducted using a sample with the minimum alcohol concentration and a sample with an almost average alcohol concentration of the highly concentrated alcohol fuels currently on the market from each of the five suppliers. Table 11 samples. Composition of model fuels and actual Test material : Fe Outer Contact ip50 No Sour ip50 Sour fuel Minimum content of individual products Averagecontent of individual products Sample Composition of model fuel Total Water MTBE i-butanol i-propanol n-butanol Alcohol ppm vol.% vol.% vol.% vol.% vol.% A B C D E A B C D E Fig. 5 Photographs of aluminum with steel before and after the bimetallic corrosion tests using sour fuel. COMPARISON WITH MODEL SAMPLES TEST METHOD Samples with the same composition and content as those of the actual fuels of each of the five suppliers were prepared based on the composition obtained by a sampling analysis to investigate corrosiveness on aluminum by the highly concentrated alcohol fuels currently on the market. Immersion tests were conducted using the samples. Table 10 presents the The test was also conducted using the highly concentrated alcohol fuels currently on the market. The test was conducted under conditions in which the oxide film was damaged and conditions in which the oxide film was completely formed. Automotive parts subjected to a temperature change, such as the fuel-system parts, may be damaged when the oxide film on the surface of the metal is subjected to thermal stress. The surface of the test piece was ground immediately before immersion and scratched using a diamond pen in the immersion liquid (damaged oxide film conditions) to simulate conditions under which the oxide film on the material surface is damaged. The test was also conducted under conditions in which the test piece was allowed to stand for one week after the surface was ground and was then

11 immersed (oxide film formation conditions) to examine corrosion resistance when the oxide film is sufficiently formed on the surface of the metal. TEST RESULTS Tables 12.1 and 12.2 provide the immersion test results for the model fuels prepared with the average composition (alcohol, MTBE, and water content) of the highly concentrated alcohol fuels currently on the market, and the actual samples with minimum and average total alcohol concentrations. Figures 6.1 and 6.2 illustrate the immersion test results for the model fuels and the actual samples. The aluminum was completely dissolved or reduced in mass for all the fuels in the immersion tests using the model samples. The samples were not corroded under the single-material corrosion and oxide film formation conditions using the actual samples. However, the aluminum was corroded by all the samples under the damaged oxide film conditions. These results confirm that the highly concentrated alcohol fuels currently on the market corroded the aluminum material even when a sample with the minimum alcohol concentration was used. Different results were obtained depending on the immersion conditions, such as the corrosion form, including single-material corrosion and bimetallic corrosion, and the state of the oxide film. This suggests that it is important to manage the state of the oxide film on the material surface before immersion when evaluating a material using the immersion test and to include the bimetallic corrosion mode in conration of the conditions under which the material is used for the actual automotive parts. The corrosion tendencies differed between the damaged oxide film conditions and oxide film formation conditions. Therefore, it is important to manage the initial state of the oxide film on the material surface when evaluating corrosion resistance using the immersion test. Automotive parts subjected to a temperature change, such as the fuel-system parts, may be damaged when the oxide film on the surface of the metal material is subjected to thermal stress. Therefore, it is necessary, for example, to scratch the surface of the test piece in the immersion liquid with a diamond pen. Table 12.1 Immersion test results for the model fuels prepared to have the minimum and average compositions (alcohol, MTBE, and water content) of the highly concentrated alcohol fuels on the market. Minimum content of individual products Averagecontent of individual products Sample A1050 / Cu A1050 / Ni A1050 / Zn A1050 / Sn A1 ** /OK *** /OK ** /OK ** /OK B1 ** /OK *** /OK *** /OK ** /OK C1 ** /OK ** /OK ** /OK ** /OK D1 ** /OK *** /OK *** /OK ** /OK E1 ** /OK *** /OK *** /OK ** /OK A2 *** /OK *** /OK *** /OK ** /OK B2 ** /OK *** /OK *** /OK ** /OK C2 ** /OK *** /OK *** /OK *** /OK D2 ** /OK *** /OK *** /OK ** /OK E2 ** /OK *** /OK *** /OK *** /OK OK : No Change ** : Reduction in Mass *** : Dissolution Table 12.2 Immersion test results for the actual samples with the minimum and average total alcohol concentrations. Test Singlematerial test Bimetallic corrosion test Test Singlematerial test Bimetallic corrosion test Condition Oxidation film Material A B A1 A2 B1 B2 Minimum Average Alcohol Alcohol Concentration Concentration Minimum Alcohol Concentration Average Alcohol Concentration Formed A1050 OK OK OK OK Broken Condition Oxidation film A1050/Cu *** /OK *** /OK *** /OK ** /OK A1050/Ni *** /OK *** /OK ** /OK *** /OK A1050/Zn *** /OK *** /OK *** /OK *** /OK A1050/Sn ** /OK ** /OK ** /OK ** /OK Material C D C1 C2 D1 D2 Minimum Average Alcohol Alcohol Concentration Concentration Minimum Alcohol Concentration Average Alcohol Concentration Formed A1050 OK OK OK OK Broken A1050/Cu ** /OK ** /OK ** /OK ** /OK A1050/Ni *** /OK ** /OK *** /OK *** /OK A1050/Zn *** /OK *** /OK *** /OK *** /OK A1050/Sn *** /OK ** /OK ** /OK ** /OK Test Condition Oxidation film Material E E1 E2 Minimum Average Alcohol Alcohol Concentration Concentration Singlematerial test Bimetallic corrosion test Formed A1050 OK OK Broken A1050/Cu ** /OK ** /OK A1050/Ni *** /OK *** /OK A1050/Zn ** /OK *** /OK A1050/Sn *** /OK *** /OK OK : No Change ** : Reduction in Mass *** : ly Dissolution

12 Test material : A1050 Outer Naphtha Model Fuel (C1) Model Fuel (E1) activity of each component contained in highly concentrated alcohol fuels on materials used for gasoline vehicles and the corrosion resistance of the materials used for the fuel supply system parts. Contact Mass Ethanol, n-propanol, i-propanol, n-butanol, and i-butanol corrode aluminum. The corrosion resistance d as the concentration increased. Test material : Zn Outer Contact Naphtha Mass Model Fuel (C1) Model Fuel (E1) Alcohol with fewer carbon atoms exhibited lower corrosion resistance on aluminum. The corrosion resistance of normal alcohols with the same number of carbon atoms was less than that for branched alcohols. Water tended to suppress the reaction between the alcohol and aluminum. However, the mass reduction rate of zinc increased as the water content was increased to a water content of 150 ppm or more. It was confirmed that the highly concentrated alcohol fuels currently on the market corrode aluminum even when fuel with the minimum alcohol concentration is used. Fig. 6.1 Immersion test results for the model fuels prepared with the average composition (alcohol, MTBE, and water content) of the highly concentrated alcohol fuels on the market. It is important to manage the initial state of the oxide film on the material surface when evaluating a material using the immersion test and to include the bimetallic corrosion mode in the testing conditions, taking into conration the conditions under which the material is used for actual automotive parts. Test material : A1050 Outer Contact Naphtha 100% Actual Fuel (C1) Actual Fuel (E1) Mass ACKNOWLEDGMENTS This study was contracted from the Agency for Natural Resources and Energy of the Ministry of Economy, Trade and Industry of Japan. The test method and test results were discussed and confirmed by the committee on the safety of highly concentrated alcohol fuels. We greatly appreciate their assistance. Test material : Zn Outer Contact Fig. 6.2 Immersion test results for the actual samples with the minimum total alcohol concentration. CONCLUSION Mass Naphtha 100% Actual Fuel (C1) Actual Fuel (E1) Immersion tests were conducted on the materials used for fuel-supply system parts to clarify the corrosion REFERENCES T. Ishida, et. Al., Effect of high concentration alcohol fuel on high polymer materials (I) - The effect on rubber materials -, Annual conference of the Society of Rubber Industry, Japan, T. Ishida, et. Al., Effect of high concentration alcohol fuel on high polymer materials (II) - The effect on resin materials -, Annual conference of the Society of Rubber Industry, Japan, R. C. Tupa et. al., Gasoline and Diesel Fuel Additives for Performance/Distribution Quality II, SAE , E. J. Owens, et. al., Effects of Alcohol Fuels on Engine Wear, SAE , R. M. King et. al. ; Hardware Effects on the Wear of Methanol-Fueled Engines, SAE , D. W. Naegeli, et. al., Surface Corrosion in ethanol Fuel Pumps, SAE , Standard Test Method for Peroxide Number of Aviation Turbine Fuels, ASTM D3703, 1992.

13 APPENDIX FINAL SAFETY ASSESSMENT OF HIGHLY CONCENTRATED ALCOHOL FUELS FOR GASOLINE-FUELED VEHICLES In addition to the above-described metal corrosion tests, the committee conducted an immersion test on the rubber and resins used for automotive fuel-system parts, held hearings with manufacturers of highly concentrated alcohol fuel, and investigated the use of highly concentrated alcohol fuels in other countries. The investigation results and the conclusions derived from each of those results are presented below as the final assessment. It was confirmed that each alcohol component contained in the highly concentrated alcohol fuels on the market corrodes the aluminum generally used for automotive fuel-system parts. The highly concentrated alcohol fuels on the market corroded the aluminum material even when a sample with the minimum alcohol concentration was used. The alcohol component contained in the highly concentrated alcohol fuels degrades the rubber and resins, such as by causing swelling, and s the functionality of the rubber parts. Therefore, the fuel resistance and other factors may be d compared to the effects of (2) (3) using gasoline. The manufacturers and importers of highly concentrated alcohol fuels did not provide acceptable explanations regarding the safety of using the highly concentrated alcohol fuels for gasoline-fueled vehicles. Some countries have approved the mixing of alcohol at a low concentration as the gasoline standard. However, no countries have approved an alcohol concentration level as high as that of the highly concentrated alcohol fuel sold in Japan. The committee reported their final assessment based on these investigation results and stated that the use of highly concentrated alcohol fuels for gasoline vehicles designed to be fueled with only gasoline poses safety problems, since highly concentrated alcohol fuels may cause corrosion and deterioration of the automotive fuelsystem parts. The fuel policy subcommittee of the advisory committee for natural resources and energy surveys conducted examinations upon receiving the above report. They concluded that it is necessary to regulate the quality of alcohol fuels from the standpoint of ensuring consumer safety. The Diet passed a bill in April and May 2003 to amend the law concerning the quality of gasoline. Selling of highly concentrated alcohol fuels was prohibited on August 28, At present, methanol must not be detected in fuel, the ethanol content is limited to 3%, and other oxygenates are limited to an oxygen content of 1.3% when mixing any alcohol into gasoline.

14 APPENDIX Appendix 1.1 The immersion test results using a single alcohol fuel. (Alcohol content : 50%, Water content : 150ppm). Tests Material Naphtha 100% Alcohol:50%, water:150ppm Alcohol:50%, water:500ppm Alcohol:50%, water:2000ppm Alcohol:50%, water:1% E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 A1050 OK * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * OK OK OK OK OK A6061 OK * * * * * * * * * * * * * * * * * * * * * * * * * * OK * * * OK * * OK OK OK OK OK OK ADC12 OK * * * * * * * * * * * * * * * * * * * * * * * OK * * * * * * * * OK OK OK OK * OK Steel * OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK * OK OK OK OK Copper * * * * * * * * * * * * * * * * * * * * * Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc OK * * OK OK OK * * OK OK OK OK * OK OK * * * * * OK Tin OK * OK OK OK OK * OK OK OK OK * OK OK OK OK OK OK OK OK OK A1050/A1050 OK * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * OK * * * OK * * * OK Steel/Steel * OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper/Copper * * * * * * * * * * * * * * * * Nickel/Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc/Zinc * * * OK OK OK * * OK OK OK * * OK OK OK Tin/Tin OK * OK OK OK OK * OK OK OK OK * * OK OK OK A1050/Steel OK/ * *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK OK/ * *** /OK OK/OK *** /OK OK/OK A1050/Copper OK/ * *** / * *** /OK *** / * *** /OK OK/ * *** /OK *** /OK *** /OK *** /OK OK/ * *** /OK *** /OK *** /OK *** /OK OK/ * A1050/Nickel OK/OK *** /OK *** /OK *** /OK *** /OK OK/OK *** /OK *** /OK *** /OK *** /OK OK/OK *** /OK *** /OK *** /OK *** /OK OK/OK A1050/Zinc OK/OK *** / ** *** / ** *** /OK *** /OK OK/OK *** / ** *** / ** *** /OK *** /OK OK/OK *** / ** *** / ** *** /OK *** /OK OK/OK A1050/Tin OK/OK *** /OK *** /OK *** /OK *** /OK * / OK *** /OK *** /OK *** /OK *** /OK * / OK *** /OK *** /OK *** /OK *** /OK OK/OK Steel/Copper * / * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * Steel/Nickel OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Steel/Zinc OK/OK * / * OK/OK OK/OK OK/OK OK/OK OK/ * OK/OK OK/OK OK/OK OK/OK OK/ * OK/OK OK/OK OK/OK OK/OK Bimetallic corrosion test Crevice corrosion test Single-material corrosion test Steel/Tin OK/OK * / * * / OK OK/OK * / OK OK/OK * / * * / OK OK/OK OK/OK OK/OK * / OK * / OK OK/OK * / OK OK/OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution

15 Appendix 1.2 The in mass of immersion test results using a single alcohol fuel. (Alcohol content : 50%, Water content : 50ppm). Tests Material Naphth a 100% Alcohol:50%, water:150ppm Alcohol:50%, water:500ppm Alcohol:50%, water:2000ppm Alcohol:50%, water:1% E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 E50 np50 ip50 nb50 ib50 A1050 OK *** *** *** *** 0.4 *** *** *** *** *** *** *** OK *** 0.4 OK OK OK OK OK A6061 OK *** *** *** *** *** *** OK *** OK 85.1 OK OK OK OK OK OK ADC12 OK *** *** *** 59.2 OK *** 0.5 OK OK OK OK OK OK Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/A1050 OK *** *** *** *** *** *** *** *** *** *** OK *** OK *** OK Steel/Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper/Copper OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Nickel/Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc/Zinc OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Tin/Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/Steel OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK OK *** /OK OK *** /OK OK A1050/Copper OK *** / * *** /OK *** / * *** /OK OK *** /OK *** /OK *** /OK *** /OK OK *** /OK *** /OK *** /OK *** /OK OK A1050/Nickel OK *** /OK *** /OK *** /OK *** /OK OK *** /OK *** /OK *** /OK *** /OK OK *** /OK *** /OK *** /OK *** /OK OK A1050/Zinc OK ***/0.7 ***/0.3 *** /OK *** /OK OK ***/0.7 ***/1.1 *** /OK *** /OK OK ***/5.6 ***/2.5 *** /OK *** /OK OK A1050/Tin OK *** /OK *** /OK *** /OK *** /OK OK *** /OK *** /OK *** /OK *** /OK OK *** /OK *** /OK *** /OK *** /OK OK Steel/Copper OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Steel/Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Steel/Zinc OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Bimetallic corrosion test Crevice corrosion test Single-material corrosion test Steel/Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution

16 Tests Appendix 2.1 The immersion test results using a single alcohol fuel (35%) and two or three species of alcohol mixtures (Alcohol content : 35%, 50%, Water content : 150ppm). Material Alcohol:100% Alcohol:35% E100 np100 ip100 nb100 ib100 E35 np35 ip35 nb35 ib35 E25 np25 Mixture of two types of alcohol E25 nb50 np25 ip25 ip25 ib25 nb25 ib25 E17 np17 ip17 Mixture of three types of alcohol E17 np17 nb17 E17 nb17 ib17 np17 ip17 ib17 ip17 nb17 ib17 A1050 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * A6061 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * OK * * * * * * * * * * * * * * * * ADC12 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * OK * * * * * * * * * * * * * * * * Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper * * * * * * * * * * * * * * * * * * * * Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc OK OK OK OK OK OK OK OK OK OK OK * OK OK OK * * * OK OK Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/A1050 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * OK * * * * * * * * * * * * * * * * * * Steel/Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper/Copper * * * * * * * * * * * * * * * * * * * * Nickel/Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc/Zinc OK OK OK OK OK * OK OK OK OK * * OK OK * * * * OK OK Tin/Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/Steel ** /OK *** /OK *** /OK *** /OK *** /OK ** /OK *** /OK ** /OK ** /OK ** /OK *** /OK *** /OK *** /OK OK/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Copper ** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK ** /OK ** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Nickel ** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK ** /OK ** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Zinc ** / ** *** / ** *** / ** *** / ** *** /OK *** / ** *** /OK ** /OK *** /OK *** /OK *** / ** *** / ** *** /OK *** /OK *** /OK *** / ** *** / ** *** / ** *** /OK *** /OK A1050/Tin ** /OK *** /OK *** /OK *** / ** *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK Steel/Copper OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * * / * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * OK/ * Steel/Nickel OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Steel/Zinc * / * OK/OK OK/OK OK/OK OK/OK OK/ * OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/ * OK/OK OK/OK OK/OK OK/OK Steel/Tin OK/OK OK/OK * / OK * / OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK * / OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK * / OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution Bimetallic corrosion test Crevice corrosion test Single-material corrosion test

17 Appendix 2.2 The in mass of immersion test results using a single alcohol fuel (35%) and two or three species of alcohol mixtures (Alcohol content : 35%, 50%, Water content : 150ppm). Alcohol:100% Alcohol:35% Mixture of two types of alcohol Mixture of three types of alcohol Tests Material E100 np100 ip100 nb100 ib100 E35 np35 ip35 nb35 ib35 E25 np25 E25 nb50 np25 ip25 ip25 ib25 nb25 ib25 E17 np17 ip17 E17 np17 nb17 E17 nb17 ib17 np17 ip17 ib17 ip17 nb17 ib17 A1050 *** *** *** *** *** *** *** *** *** *** *** *** *** *** *** *** *** *** A *** *** *** *** *** *** *** *** OK 75.7 *** *** *** *** 87.8 ADC12 *** *** *** *** *** *** *** *** *** OK 76.4 *** *** *** 55.5 *** Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/A /41.8 *** *** *** *** *** *** *** 94.9/87.0 *** *** *** *** OK *** *** *** *** *** *** Steel/Steel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Copper/Copper OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Nickel/Nickel OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Zinc/Zinc OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Tin/Tin OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK A1050/Steel 41.2/OK *** /OK *** /OK *** /OK *** /OK 68.9/OK *** /OK 87.5/OK 70.3/OK 46.1/OK *** /OK *** /OK *** /OK OK/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Copper 64.0/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK 46.5/OK 37.2/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Nickel 61.7/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK 79.1/OK 85.0/OK 72.5/OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK A1050/Zinc 81.9/29.4 *** /11.5 *** /3.7 *** /2.6 *** /OK *** /0.8 *** /OK *** /OK *** /OK *** /OK *** /1.8 *** /1.6 *** /OK *** /OK *** /OK *** /8.3 *** /3.2 *** /1.1 *** /OK *** /OK A1050/Tin 61.8/OK *** /OK *** /OK *** /0.4 *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK *** /OK Steel/Copper OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Steel/Nickel OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Steel/Zinc OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK Bimetallic corrosion test Crevice corrosion test Single-material corrosion test Steel/Tin OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK/OK OK : No Change * : Change in Surface without Reduction in Mass ** : Reduction in Mass *** : Dissolution

18 Test material : A1050 After Naphtha E50 np50 ip50 nb50 ib50 Test material : A6061 After Naphtha E50 np50 ip50 nb50 ib50 Test material : ADC12 After Naphtha E50 np50 ip50 nb50 ib50 Appendix 3.1 Photographs of the immersion test results using a single alcohol fuel. (Alcohol content : 50%, Water content : 150ppm).

19 Test material : Fe After Naphtha E50 np50 ip50 nb50 ib50 Test material : Cu After naphtha E50 np50 ip50 nb50 ib50 Test material : Ni After Naphtha E50 np50 ip50 nb50 ib50 Appendix 3.2 Photographs of the immersion test results using a single alcohol fuel. (Alcohol content : 50%, Water content : 150ppm).

20 Test material : Zn After Naphtha E50 np50 ip50 nb50 ib50 Test material : Sn After Naphtha E50 np50 ip50 nb50 ib50 Appendix 3.3 Photographs of the immersion test results using a single alcohol fuel. (Alcohol content : 50%, Water content : 150ppm).

21 Test material : A1050 After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Test material : A6061 After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Test material : ADC12 After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Appendix 4.1 Photographs of the immersion test results using a single alcohol fuel (35%) and two or three species of alcohol mixtures (Alcohol content : 35%, 50%, Water content : 150ppm).

22 Test material : Fe After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Test material : Cu After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Test material : Ni After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Appendix 4.2 Photographs of the immersion test results using a single alcohol fuel (35%) and two or three species of alcohol mixtures (Alcohol content : 35%, 50%, Water content : 150ppm).

23 Test material : Zn After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Test material : Tin After Naphtha ip35 nb35 ib35 ip25+ib25 ip17+nb17+ib17 Appendix 4.3 Photographs of the immersion test results using a single alcohol fuel (35%) and two or three species of alcohol mixtures (Alcohol content : 35%, 50%, Water content : 150ppm).

24 Test material : A1050 Outer Contact Test material : Zn Outer Contact Naphtha Model Fuel (A1) Model Fuel (B1 Model Fuel (C1 Model Fuel (D1) Model Fuel (E1 Mass Mass Mass Mass Naphtha Model Fuel (A1) Model Fuel (B1 Model Fuel (C1 Model Fuel (D1) Model Fuel (E1 Appendix 5.1 The immersion test results for the model samples of average composition (alcohol, MTBE, and water content) of the high concentration alcohol fuels on the market.

25 Test material : A1050 Naphtha Actual Fuel (A1) Actual Fuel (B1) Actual Fuel (C1) Actual Fuel (D1) Actual Fuel (E1) Outer Mass Contact Mass Test material : Zn Naphtha Actual Fuel (A1) Actual Fuel (B1) Actual Fuel (C1) Actual Fuel (D1) Actual Fuel (E1) Outer Contact Appendix 5.2 The immersion test results for the actual samples of the minimum total alcohol concentration.

26 Test material : A1050 Naphtha Actual Fuel (A2) Actual Fuel (B2) Actual Fuel (C2) Actual Fuel (D2) Actual Fuel (E2) Outer Contact Test material : Zn Naphtha Actual Fuel (A2) Actual Fuel (B2) Actual Fuel (C2) Actual Fuel (D2) Actual Fuel (E2) Outer Contact Appendix 5.3 The immersion test results for the actual samples of the average total alcohol concentration.