Welcome to QMI

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Welcome to QMI

• Engine Deposit Problems and Solutions
• Evidence of deposit problems
• SAE Paper documentation

• SAE Paper publication process
• Submit abstract

• Submit Draft Manuscript

• Re-submit corrected draft

• Submit Final Paper

• SAE Papers considered automotive authority

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SAE Deposit Documentation

• How much documentation?
• SAE Papers published 1998 to 2003 containing
  all the words
• Intake manifold deposits .. 1246
• Fuel injector deposits 1091
• Intake valve deposits 1866
• Combustion chamber deposits 498
• Crankcase deposits .. 443

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Engine Component Manufacturers
SAE Papers by

• BMW

• Chrysler

• Ford

• General Motors

• Grand Marque

• Mazda

• Mercedes-Benz

• Mitsubishi

• Nissan

• Orbital

• Siemens

• Toyota

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Petroleum Chemical Producers

• SAE Papers by Agip Petroli, Amoco, BASF,
  Chevron, Denso, Esso, Ethyl, Exxon, ExxonMobile,
  Infinuem, Lubrizol, Mitsubishi Oil Co., Mobile,
  Nippon Soken, Oronite, Phillips, Shell,
  Synerject, Texaco

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Testing Research Institutions

• SAE Papers by Additive Manufacturers Assn., Air
  Improvement Resource, Auchland Institute of
  Technology, Automotive Fuels Consultants,
  Automotive Testing Labs, CRC Deposit Group,
  Chalmers University of Technology, EGG
  Automotive Research, FEV Motorentechnik,
  Institute for Technical Chemicals and
  Petrochemicals, Institute of Applied
  Thermodynamics

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Testing Research Institutions

• SAE Papers by Japan Automobile Manufacturers
  Association, MIT, OACIS Deposit Workshop,
  Pennsylvania State University, Petroleum
  Association of Japan, Princeton University, RWTH
  Aachen, Rutgers University, Sandia National
  Laboratory, Southwest Research Institute, State
  University of New Jersey, University of Kansas,
  University of Utah, Wayne State University

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Deposit Forming Mechanism

• Running engine cooled
• Intake air flow, evaporating fuel

• Engine stops, fuel residues remain
• No cool air, no evaporating fuel
• Heat rises, highest temp. after 15-30 minutes

• Light fuel molecules evaporate
• Heavy olefins, aromatics (sticky, waxy
  substances) remain, oxidize and polymerize
• Forms sticky coating gums, varnish, resins

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Repeat Hot Soak Produces Deposits

• Each engine stoppage produces hot soak

• Sticky coatings build up
• Repeat hot soak accumulation
• Bakes into hard carbon deposits

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US Driving Conditions

• Recent study shows
• 80 cars start at least three times per day
• 63 trips under 20 miles / 32 km
• 57 driving in stop-and-go traffic

• Typical drivingproduces repeathot soak deposit
  forming conditions

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Engine Design Problem

• Deposits most critical engine design problem
• Adverse effect driveability, emissions, fuel
  economy
• How?
• Deposits interfere with air/fuel ratio, heat
  transfer, combustion, emissions, operation
  mechanical components
• Deposit design changes time consuming
• Longer for engine modifications than addition
  of detergents to gasoline

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Emission Controls Increase Deposits

• PCV routes oily crankcase vapors into intake air

• EGR adds exhaust heat and carbon particles
• Oily vapors combine with carbon particles and
  heat
• Condense and layer over sticky coating
• Bake into larger hard, crusty carbon deposits

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Fast-Burn High-Swirl Engines

• Intake geometry creates air swirl
• Calibrated for specific rate of combustion
• Deposits interfere with swirl pattern
• Affects all aspects of operation
• 15 restriction can cause 50 power loss

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Close Tolerances

• Fuel injector openings 0.002 inch / 0.05 mm

• Size of human hair
• Produces fine mist,cone shaped spray

• 5 restriction bad influence on driveability

• Reduced evaporation and combustion, less power,
  increased fuel consumption, increased
  emissions, etc.

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Squish Area

• Clearance 0.03 in. / 0.7 mm
• Thin as paper clip
• Piston deposits carbon rapping on cylinder head
• Causes CCDI
• Combustion Chamber Deposit Interference

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Engine Control Modules

• Calibrated close to lean limit
• Deposits interfere
• Upset calibration
• Cylinder-to-cylinder deposits vary
• Affect performance, driveablity, emissions, fuel
  economy
• Feedback system controls cannot correct imbalance
  between cylinders

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Fuel Variables Increase Deposits

• Crude oil selection limited
• Compromises quality
• Fuel additives lack thermal stability
• Beyond temperature range become deposit
  forming
• Catalytic cracking

• Heavy fractions, sulfur, aromatics
• Mandated oxygenated/alcohols
• Gums form during storage

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Throttle Body Intake Manifold

• Throttle body deposit mechanism

• Raw fuel blow back
• Vapor purge gases
• PCV oily crankcase vapors
• EGR exhaust carbon particles and heat speeds
  deposit build up
• Fuel detergents cannot control

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Injector Deposits

• Deposits inherent in design
• Capillary action causes weeping at tip
• Deposit forms during hot soak
• No injector totally immune
• Tiny deposits cause streamers

• Additive concentrate can clean-up in one tankful

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Intake Valve Deposits

• Restrict air flow
• Sponge effect
• Absorbs and releases intake fuel
• Causes hesitation, surge
• Insulation effect
• Insulates fuel from hot valve surfaces
• Reduces combustion efficiency

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Intake Valve Deposits

• Seeping valve seals
• Oil reaches valve head, forms deposits
• Small deposits upset calibration
• Rough idling, misfire, emissions, power
  loss,driveability problems
• Heavy IVD prevent closing
• Burn valve

• Destroy engine

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Combustion Chamber Deposits

• CCDs in all spark ignition engines
• Unavoidable product engine combustion
• Observed early as 1882
• Large amounts form in short trips
• With low coolant temperature,
• engine speed, load

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Combustion Chamber Deposits

• Hot carbon deposits cause knock/ping
• Reduced fuel efficiency
• Power loss
• Increased emissions
• Runaway surface ignition ... hole burned ...
  short time
• Serious engine damage
• Destroy engines

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Carbon Deposit Knock/Ping

• 1. Hot carbon deposit pre-ignition

2. Spark plug ignition
3. Flame fronts rush together
4. Pressure spike,ping waves
Piston damage from long-term pinging
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Knock/Ping Damage

• Combustion pressure reaches 1,200 PSI
• Few hundred explosions Shiny surfaces appear
  matted
• 10,000 shots surfaces exhibitssandblasted
  structure
• 200,000 shots cavitation-like roughness
  0.25mm in depth
• Back wall severely damaged

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CCD Flaking

• New field problem reported 2002 Papers
• CCD trapped in exhaust valve seat
• 5,000 - 10,000 miles ofmild, usually urban,
  driving cycles
• Standing engine cools
• Water condenses on combustion chamber deposit
• Triggers deposit flaking
• Trapped in exhaust valve, loss of compression
• Hard/no start, increased emissions, rough running

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Valve Seal and Stem Deposits

• To improve fuel economy emissions
• Reduced spring tension
• Tighter stem-to-guide clearance
• Causes prevalent valve sticking
• Poor starting, compression loss
• Sticky valve stem deposits cause valve stick
  open
• Cold start driveability problems
• Engine damage

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Crankcase Deposits

• Cold start water condensation
• Combustion by-products and contaminants
• Unburned fuel, acids, soot and residues
• Crankcase becomes sewer
• Causes piston ring sticking, plugging, breakage
• Restricts oil flow
• Carbon reduces heat transfer, traps heat in engine

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Direct Injection Engines

• Direct injection advantages
• 15 - 30 improved fuel economy
• 10 - 15 improved power
• 6 number lower octane requirement
• Improved volumetric efficiency
• Air/fuel ratio 601
• Reduced emissions

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Direct Injection Engine Deposits

• Why not?
• Texaco 1951, Ford 1968
• severe deposit problems, could not be overcome
• Deposit problem continues
• PCV oil intake valve deposits
• No fuel washing to remove
• Injector nozzles exposed hot combustion

• Deposits one major obstacleto direct injection
  engine becoming reality

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Deposit Problems - SAE Conclusion

• SAE Paper documentation
• Numerous SAE Papers

• Extensive testing
• Demonstrates need forregular FSC maintenance
• Deposit problemsrequire solution
• Safe
• Effective

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Presenting the solution Safe

• Vehicle

• Technician

• Environment

• No Alcohol, Methanol
• No Aldehydes, noxious odors to endanger
  technicians health

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Other Products MSDS
Hazardous Ingredients Acetone, Amine, Ammonia,
Ammonium Hydroxide, Amyl Acetate, Butyl Acetate,
Butyl Oxital, Cumene, Diacetone Alcohol,
Ethylbenzene, Heptane, Hexanol, Isopropanol,
Isopropyl Alcohol, Ketone, Methanol, Methyl
Acetone, Methyl Alcohol, Methyl Amyl Alcohol,
Methyl Ethyl Ketone, Methyl Pyrrolidone, Oxital,
Pentanol, Phenolic, Polyol, Polyolefin, Propanol,
Propyl Acetate, Stoddard Solvent,
Trimethylbenzene, Xylene.
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Other Products MSDS
Health Hazards Central nervous system effects
headaches, dizziness and loss of coordination
reproductive effects ... serious nervous system
depression ... damage to kidneys, blood, nerves,
liver and lungs dermatitis eye burns ...
dizziness, fatigue, drowsiness, nausea,
headaches, unconsciousness ... cancer and birth
defects or other reproductive harm ...
asphyxiation and even death
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Your Right to Know

• Hazard Communication Act of 1983
• Right to know hazards exposure on the job
• Including hazardous materials
• Request your MSDS sheets

• You cannot be fired or discriminated against
• You have the right for your doctor to read
• Protect your health
• An educated buyer is our best customer

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Presenting the solution Effective

• Tested and proven in demanding industrial
  applications worldwide

• The perfect combination
• Safe
• Effective
• Presenting products that produce happy
  technicians and customers!