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This was in today's NASA Aviation Safety Reporting System Issue of the “Callback” Newsletter.  Was surprising to me. Never knew it was an issue.  Or is this an anomoly?

 

This FBO repair facility Aviation Maintenance Technician reported a serious safety issue. The investigation and level of concern clearly indicate superior professional dedication to the safety of flight and aviation itself.

■ Increased frequency of maintenance [is] required on carburetors and fuel injector systems due to suspected cadmium particulate matter being found in float bowls, fuel injector nozzles, fuel screens, and fuel jets. This impacts fuel flow and metering, impacting engine performance due to restriction of fuel flow. This phenomenon was observed on aircraft during unscheduled maintenance due to complaints of loss of power and also during routine scheduled maintenance. Particulate accumulation [was] also found in check valves, auxiliary fuel pumps and mechanical engine pumps. Clumps and screen obstruction [were] observed. This has been observed over the past four months, since aircraft started using Unleaded 94 Octane (UL94). The exact source of the cadmium is not definitively determined at this time. We suspect the cadmium is held in suspension in the fuel, and in addition to accumulating and clogging the fuel system, some particles are entering the combustion chamber with unknown impacts on cylinders, valves, and exhaust systems. A simple experiment was conducted. Aviation cadmium bolts were placed in [100 Octane Low Lead] 100LL and UL94 for a few hours. The bolts in 100LL remained intact with no change. The bolts in UL94 showed flaking with particles suspended in the fuel, sparkling. Cleaning of all fuel parts in the fuel systems clears the problem, but it reappears. We are concerned since we have limited experience with UL94 and have not seen anything like this in our careers, which total over 50 years together as A&P and IA [Inspection Authority Mechanics].


Gene

Gene Cartier
Montaer MC-01 (Bluey)
N834BR
Based at KHEF (Fayetteville, NC)

  • Re: UL94 Issues

    by » 16 hours ago


    Gene

    Given there is only one supplier of UL94 aviation fuel then why not say it is Swift Fuel UL94?  My only suggestion is to report this to Swift and supply fuel samples.  In my experience they are very willing to look at any such issue.  UL94 has been used extensively for many years by a large number of Rotax owners without complaint.  

    Such findings need to be looked at by chemists and Swift themselves so they can assist.  It is my understanding that UL94 is the same formula with the exception of lead.  if this is the case it makes no sense given auto fuels without lead have been used for literally decades without this ever reported. In the FAA unleaded fuel trials this was not ever seen in any of the fuels when I was party to those studies.  Materials compatibility is always one of the main things evaluated in fuels testing.   

    As a note I am unable to open the "Callback" issue you have noted, perhaps you can post here?

     

    Cheers


  • Re: UL94 Issues

    by » 16 hours ago


    Great post Gene, but I'm suspicious. This fuel has been under testing and development for almost 20 years so you would think that this would have shown up by now. There was a study done regarding a similar problem in jet fuel systems and it turned out to be that the cadmium used did not have a chromate conversion coating. Cadmium used in fuel tanks and fuel system components typically does have a Chromate conversion finish, so testing by placing aircraft bolts in UL94 may not be a valid test.  

    Failure of Jet Engine Fuel Control Unit Originated by Corrosion of Cadmium Coating | Journal of Failure Analysis and Prevention


  • Re: UL94 Issues

    by » 16 hours ago


    I'm also suspicious.  UL 94 has been around for a while and I have never heard of this issue.  Wonder if this part of the "Keep 100LL" disinformation campaign.

    Here is a link to the article.

    https://myemail.constantcontact.com/CALLBACK-539--December-2024--Everyday-Heroes.html?soid=1101073741327&aid=Ovp7nxlcQJE

     

     


    Gene

    Gene Cartier
    Montaer MC-01 (Bluey)
    N834BR
    Based at KHEF (Fayetteville, NC)


  • Re: UL94 Issues

    by » 13 hours ago


    I agree, it is rather suspicious...I am no closer to the link, apparently my system is not liked by them.  

    https://imgssl.constantcontact.com/ui/images1/icon_error_page.gif") no-repeat; width: 668.5px; padding: 0px 3px 15px 25px; font-family: arial, sans-serif; font-style: normal; font-variant-ligatures: normal; font-variant-caps: normal; letter-spacing: normal; orphans: 2; text-align: left; text-indent: 0px; text-transform: none; widows: 2; word-spacing: 0px; -webkit-text-stroke-width: 0px; white-space: normal; text-decoration-thickness: initial; text-decoration-style: initial; text-decoration-color: initial;">We're Sorry.
    The requested file was not found on our server.
    This could be for a variety of reasons, including:
    • You followed a broken or out-of-date link
    • You entered an incorrect URL
    • A file no longer exists

    If you followed a broken or out-of-date link, please inform the owner of the referring document. Email webmaster@constantcontact.com to report this error or continue on the Constant Contact home page.


    [ File Not Found : 404 ]


  • Re: UL94 Issues

    by » 13 hours ago


    https://asrs.arc.nasa.gov/publications/callback.html 

    seems the DEC 2024 issue hasnt been publicly posted yet??

     


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