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The Effect of Hard Particle Wear on Diesel Injectors

Donaldson Filtration Solutions | 2015

Summary of Industry Cooperative Diesel Injector Hard Particle Wear Testing Conducted at Southwest Research Institute (SwRI)

2000 and 2011

Comparing 2 studies on filtration requirements – one for traditional unit injectors (done in 2000) and the other for high pressure common rail engines (done in 2011)

  • 2000 Injector Wear Study
    • Low sulfur diesel with narrow particles of dust at concentration of 203 mg/l were run through injection systems; degradation of performance was measured and injectors were inspected for damage; purpose was to identify type of filters capable of preventing damage to fuel injectors
    • Outcome: particulate 6-7 μm and larger likely to cause significant “push tube load loss” due to abrasive wear; aged or thermally stressed fuel produced soft sticky solid breakdown products that form in the liquid and can be captured by filters – loading of this material in filter media tended to improve other hard particle retention to some degree
  • 2011 HPCR Injector Wear Study
    • Low sulfur diesel with range of narrow cuts of dust were run through injection systems; damage and in-system component behavior as well as fuel cleanliness before and after filtration were measured
    • Outcome – particulate between 2-3 μm produced mechanical damage in a 24, 650 psi HPCR system; a different type of damage and wear occurred in HPCR systems compared to lower pressure systems (abrasive wear) – initial impact wear/indentation occurred on seal face and as it accumulated, severe erosive wear occurred due to high pressure leakage of fuel containing particulate passing across the sealing face when closed; filter integrity and consistent, high-efficiency performance is essential to protect modern HPCR injection systems

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