California Mechanic's Tests Show G100UL Paint, Nitrile O Ring Damage Under Some Circumstances

G100UL unleaded fuel appears to damage aircraft paint under specific circumstances according to a California A and P who conducted his own compatibility tests on it and 100LL. Michael Luvara also said new nitrile O rings swelled beyond certified limits when submerged in the unleaded fuel for five to six days. GAMI recommends replacing nitrile components with those made of silicone or fluoropolymer elastomers.


This is a companion discussion topic for the original entry at https://www.avweb.com/aviation-news/california-mechanics-tests-show-g100ul-paint-nitrile-o-ring-damage-under-some-circumstances

TNSTAAFL - no doubt there will be negative side effects of any new unleaded fuel. We just have to ā€œman upā€ and deal with them, or we’re going be put out of business. We’ve had 50 years and have done basically nothing - time to get moving, ladies and gents.

They should point out the damages done by running E85. I’ve never replaced so many fuel pumps, sending units, and injectors, in my life, until that garbage fuel hit the marketplace.

I did similar studies when a hangar neighbor expert asserted I was wasting my time testing fuel purchases for alcohol. The claim: ā€˜a little won’t hurt.’ I took pure mogas and nearly pure ethanol from the local lab (99.2%) with a lot certificate.
I diluted stock 91 octane mogas 0%, 1%, 2%, 5%, 10%, 15% and 20%. I submerged new nitrile o-rings, fuel line snips, and pieces of an old fuel bladder removed from service. These were submerged in covered dishes individually for 1 hour, 8 hours, 24 hours and 72 hours. There was no measurable swelling and minimal softening in pure gasoline (unanalyzed) from the pump, in the 1% solution there was mild softening, and minor swelling which resolved on immersion in pure gas. The 5% showed substantial swelling, and the 20% rendered the o-rings and fuel line diameters unserviceable and did not return to their nominal sizes after re-imersion in pure gas after 24 hours. The bladder specimens significantly discolored the 20% gasohol, but I didn’t have the equipment to analyze the breakdown components, which could have been old fuel or dirt from the tank. I no longer have the original notes, and this study came when Jennifer Granholm was governor of Michigan and removed the ethanol labeling requirement from the gas station pumps. It does not surprise me that these problems will occur. Perhaps George could comment on what chemical reactions between nitrile and G100UL might be happening? Which brings another question: How stable are the bladder tanks and tank sealants with prolonged immersion? Gasoline we know. Mr. Luvara has demonstrated a potential risk of using fuels in older airplanes. Replacing nitrile components is a big and expensive job. The visible ones (gas caps) get replaced frequently, the others at annual or when there’s a problem. It might be interesting to retry this experiment using Swift 94 which I believe is the unleaded base stock of avgas. I wish I had also done it with 80 which was available then.

I agree and the path ahead is through unleaded fuel. I don’t have to like it (I don’t), but if we want to continue to fly our aircraft legally I don’t think we’ll have a choice. We can argue that the GA tetra-ethyl lead contribution is negligible all we want. Unfortunately, the arguments will also be negligible in the grand scheme of things. I want to continue to fly as long as I can. I’ll suck it up and play by the new rules when they take effect (making sheep noises).

I must have missed what type of paint he was testing. I believe he said the Aeronca was painted with some type of enamel, but I didn’t pick up what he said about the Cessna’s paint. I wonder if polyurethane was included in his test, and whether it responds in the same way as enamel?

Certainly an interesting analysis, and emphasizes the importance of cleaning any fuel spill immediately.

"When replacing seals or O-rings in the fuel systems of aircraft or engines operating on
G100UL Avgas replace Buna N or nitrile fuel system components with components
made of silicone or fluoropolymer elastomers (such as Viton) where practical."
GAMI Report 06-6460002, Rev C, September 1, 2022.
There are generic areas in aircraft and engine systems where this elastomer change can be made. Unfortunately, there are far more assemblies and sub-assemblies currently using nitrile for which a silicone or Viton is not commercially available, let alone approved. But that stumbling block could be overcome and specific requirements for the use of unleaded 100 octane fuel could be generated-there is no argument this needs to be done. It just should not be done in the field by persons unaware of the risk they are assuming when they top off with a reformulated unleaded fuel.

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I find it curious that there is no mention of stained paint caused by unaddressed leakage of 100LL. I’ve certainly witnessed it and expended no small amount of energy in trying to remove the blue stains.

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The blue staining of 100LL is caused by an added dye which makes it distinguishable from the other 100 octane fuels that used to exist (green, red). The G100UL staining is, to my knowledge, not caused by a dye but rather a chemical reaction with the paint or the metal.

Staining is ugly, but the O-ring swelling is a bigger problem.

Steve,
The FAA required us to conduct an extensive ā€œfunctionalā€ test of O-rings, gaskets, three different generations of fuel bladders, operating continental and Lycoming fuel pumps, fuel selectors, fuel spiders, carbs, and other engine related fuel wetted components.

That was one of the first ā€œmaterial compatibilityā€ issues we addressed. That test was extended over a period of eight months. That was done with a ā€œrig test.ā€

The FAA personally witnessed that operational testing at repeated intervals during the test run. All of the data and operating fuel temperatures were logged in real time. The FAA sent their senior engineers to GAMI to evaluate all of the components at the conclusion of the testing.

The FAA approved the results of that testing, without any exceptions.

That data was all presented to the ASTM about 9 years ago. The PAFI representative present at that ASTM meeting liked the rig test and asked if PAFI could have the test plan in order to incorporate that model into some of their testing. We provided them the test plan and the design of the rig-up modules used for the functional ā€œrig-test.ā€

We have offered both Lycoming and Continental the opportunity to review that data. They have each declined to avail themselves of that good faith opportunity.

Over a decade ago, we sent several drums of G100UL Avgas to Continental at their request for testing. Two years later, they reported that they had not ā€œhad timeā€ to do any testing. We had them send the drums back so we could do some long term storage stability analysis, which was nominal in its results.

We offered fuel to Lycoming for Lycoming to test. Lycoming wanted to charge us a large five figure sum of $$$ to conduct that testing. Since we have a significantly more capable engine test facility than does Lycoming (or Continental) we declined Lycoming’s peculiar offer.

Recently, we asked Textron to send one of their turbocharged Cessna on the long 50 minute trip from Wichita down to GAMI to let us fill the tanks with G100UL Avgas and work with Cessna for them to conduct a thorough evaluation of G100UL Avgas.

Cessna declined to avail itself of that opportunity.

I would extend an invitation to any legitimate group of California pilots to send a ā€œdelegationā€ to GAMI to review the complete FAA approved certification file, and observe, in person, some of the means and methods (including engine test stand runs) by which we conducted the certification of G100UL Avgas.

No other fuel candidate sponsor has been anywhere nearly as transparent and open about the testing and the results as has been GAMI.

I would note that the recent attacks (by major OEM industry participants) on the thoroughness and comprehensive testing and evaluation of G100UL conducted by the FAA could be interpreted by any number of conscientious FAA engineers and managers as a direct and unfounded attack on their competency.

Regards,
George Braly
Head of Engineering
GAMI

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Fool designers at Chrysler did not use latest common seal material in high pressure fuel lines of 3.6L V6 of early 90s.
So eventually leaks began. Additives like injector cleaners were a suspect.
It did then sell a kit to encompass each joint in rubber clamped over it.

(High pressure in that engine system is less than 200 psig at maximum engine demand.)

These findings illustrate a danger I’ve been discussing. The experimental community uses parts from swap meets and other sources that will be used in a conglomerate vehicle. There’s no telling which parts in your experimental might be sensitive to UL100 that aren’t sensitive to 100LL.

All the focus is on fleet impact, but there’s a huge vulnerability in the experimental category.

Not to mention rubber bladders and wet wing seals.
I fear that the adoption of UL will slow now due to lack of supportive data, and there are so many airports (Reid-Hillview in San Jose), Torrance in Los Angeles and Whiteman in Los Angeles) which agitators want to close due to the war cry of (belching lead over the community and causing retardation in our children. The best argument to keep these airports open is to stop using fuel with any lead component since the morons in county management feel that any lead is bad!

This story gives us one more reason to commit to UL 94 as the replacement fuel.

As a mechanic, I’m a big fan of getting the lead out of our fuels, but, testing a new fuel includes testing it for the complete aircraft, not just the engine’s ability to burn it. It’s been my observation that aeromatics that damage the paint and cause O-ring swelling, typically are also not compatible with composites. So, what are we do do with some of the AA series of Grummans that have composite spars that double as fuel tanks? is this fuel going to cause the spars to start delaminating? The Cherokee 235 and Cherokee 6 used polyester resin composite tip tanks. is this fuel likely to damage these tanks as well? A number of aircraft have sloshed fuel tanks. Is this fuel going to be causing the slosh compounds to degrade and slough/disolve? What about fuel bladders? I own an aircraft that had the fuel tanks delaminate due to the aeromatics (not alcohol) added to Mogas. After that failure, my testing showed that same fuel caused significant degradation to most composite resins and O-ring swelling. What kind of damage will this fuel do should there be a leak or seep inside a fabric wing? If it dissolves the dope, this is a serious safety issue. The same Mogas that damaged my composite tanks also caused significant damage to the nitrate/butyrate dopes on my plane as well. Will this fuel do the same?

The quick test I devised to test for this stuff in Mogas was to drop a fitting with pipe dope in the threads into a jar of the fuel. Swish the jar and the pipe dope would immediately dissolve. It would not do so in the clean Mogas I had bought (but can’t get anymore) or 100LL.

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The story about the California Mechanic’s Tests - - was just circulating as I was leaving town for Europe before Christmas. That trip included some meetings to try to work out a plan for deployment of G100UL in Europe.

But just before I left, I met with our fuel team at GAMI and we set up the test that is documented in the attachment.

That test documents the fact that neither G100UL Avgas (nor 100LL nor even 100LL with additional toluene) adversely affects the paint form ~ 20 year old aircraft painted parts - - when soaked in G100UL Avgas for more than a week.

Please review the attachment and if you have any questions or any concerns about the validity of the testing, please feel free to contact me or John-Paul Townsend at GAMI.

George ( gwbraly@gami.com )

We have done extensive fiberglass fuel tank testing.

Cirrus did a lot of that early in the 2011-12 time frame using their fiberglass production fuel tanks and using the same protocol they used to qualify those tanks for use of 100LL. Cirrus did the testing using a specially blended (very high aromatic content) G100UL avgas.

Cirrus then wrote the reports and submitted them to the FAA which accepted them as FAA approved data for the G100UL certification file.

We did further testing on the fiberglass fuel tank chemistry used in the Glasairs.

We kept G100UL Avgas in one tank for about 12 years. No deterioration.

Based on that previous testing, I think it is rather unlikely that any fuel tank fiberglass composition that tolerates toluene based 100LL will have any kind of issue with G100UL Avgas.

Regards, George

Cheap airframe manufacturers.

I admire your plugging away with facts. Good luck making money you’ve earned.

Clarify ā€˜clean mogas’.

Hard to find it without ethyl alcohol of course.