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Who is Intertek? Design Process

ASTM D1384-05 Engine Coolant Corrosion Test

Apparatus Optimization

Madeleine Jennings, Matt Bordman, Igor Shabatura

• Intertek is an industry-leading automotive

and petrochemical research and testing

company. Their San Antonio facility can

accommodate testing needs ranging from oil

and lubrication to powertrain testing.

Results

Problem Statement & Customer Requirements

Background Information

• ASTM D1384-05 Engine Coolant

Corrosivity testing measures the corrosivity

to metallic specimens of engine coolant

samples in 1000 mL tall-form beakers.

• Test requires metal coupons to be subjected

to 88 1℃ engine coolant samples, aerated

at 100 mL/min for 336 hours, or two weeks.

• Each engine coolant sample must be run in

triplicate.

• At the end of 336 hours, the coupons are

weighed to determine corrosivity levels of

the coolant being tested.

• The current apparatus can accommodate six

individual samples, or two engine coolant

tests, resulting in long lead times.

• Intertek asked the Team to double the

amount of tests from two to four.

• Homogeneous heat distribution is vital to

ensure tests remain within temperature

tolerance.

• Intertek prefers visual indication of air flow

to each sample

• Intertek requests ease of mobility for

storage purposes.

• The apparatus must be insulated to prevent

wasted thermal energy and accidental burn

injuries to passers-by.

• The Team utilized 6-3-5 Concept Generation to brainstorm ideas for their design. Due to customer

requirements, the team was restricted to two main designs, “Cart as Jig”, and “Tank as Jig”, seen in

the figures below, respectively.

• Ultimately, the Team chose the

“Tank as Jig” design, which

houses the various equipment

required for the test. This was

chosen due to Intertek’s desire

to move the test to a

permanent location.

• A concept selection matrix was used to select a

heater for the apparatus. Simulations indicated

that a heater with a lower watt density and longer

length would ensure the best heat distribution.

• The final design was drawn to ensure ease of

manufacture by standardizing bolt holes,

including bend radii in drawings, and designing

the tank structure using the sheet metal function

in Inventor, making the drawings easy to read

for the welder at Intertek. Components such as

the heater & controller were chosen specifically

for compatibility and ease of assembly.

• Intertek has agreed to manufacture the tank structure of the assembly, and

all sheet metal components of the project. The Team travelled to Intertek’s

facility to finish the assembly. Intertek’s CNC plasma cutter pictured to the

right was used to cut the sheet metal.

• Thermal simulations indicated that

selecting a heater with a lower wattage

density produces the most effective heat

distribution.

• Flow simulations indicate that placing the

mixer impeller 8-10 in. from the near wall

produces the best forced convection

currents in the tank, shown below.

• The flow meters and air manifold are

mounted to the tank itself, keeping the tank

modular and mobile.

• Due to simulation results, a small

modification to the lid was made to

accommodate change in impeller position.

• Failure Mode and Effects Analysis (FMEA) was

conducted on the design that the Team selected,

and the results are shown in the figure to the left.

Acknowledgements

The Team would like to thank Intertek for providing their

support and guidance, Texas State University for their

support, and Dr. Austin Talley for his mentorship

throughout the duration of this project. Without their

assistance, this project could not have been a success.