Aluminum structures in sealed fuel systems into which dried, deaerated JP-10 had been introduced were found to have corroded after several years in storage. An investigation into the cause of corrosion revealed that the aluminum had been chemically attacked by the weakly acidic alcoholic hydrogen on the ethylene glycol monomethyl ether icing inhibitor additive in the fuel. Under dry, anaerobic conditions, the ethylene glycol monomethyl ether was found to attack each of several aluminum alloys that were tested, even in instances where they had been treated with a chromate conversion coating. Hydrogen gas and aluminum alkoxides have been identified as the primary byproducts of the corrosion reaction. Methane, methanol, ethanol, ethers, and ether alcohols were also observed. Water and oxygen in sufficient concentrations inhibited attack, probably by virtue of the protective aluminum oxide that is maintained in their presence.
Experimental SectionMaterials. Sheet aluminum alloys 7075, 2024, and 6061 treated with Alodine 1200 chromate conversion coating, bare alloys 7075 and 6061, and clad aluminum 7075 were chosen for exposure testing. Sheet A357 alloy was not available, so portions of an A357 casting were treated with Alodine 1200 and used instead. Exposure media were prepared from JP-10 fuel (Koch Chemical Co.), Fisher Certified EGME with a water content of 0.1% (Fisher Scientific), anhydrous 99.9+% EGME (Aldrich), BHT (Eastman Kodak), and Fisher Optima purified water.Exposure Testing. Those coupons that were to be tested without application of a protective chemical conversion coating
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