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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.