Fuel Cell Foam: When To Replace For Optimal Performance

Fuel cell foam is an important safety feature in vehicles that prevents fuel from sloshing around and reduces the risk of an explosion. While it is not necessary to replace the foam regularly, it is crucial to inspect and maintain it properly. Over time, the foam may start to deteriorate, especially if it comes into contact with certain fuel additives. Therefore, it is recommended to check the foam periodically and replace it if there are signs of disintegration or if it is no longer effective in reducing fuel slosh. Additionally, it is essential to use the appropriate type of foam for the specific fuel being used, as some foams are not compatible with certain fuel types, such as alcohol or methanol.

Fuel cell foam deterioration

Fuel cell foam is essential for safety. It prevents fuel from sloshing around during turns and also suppresses explosions. The foam sits inside the fuel cell, separate from the bladder, and is stacked in rectangular bricks.

While fuel cell foam is necessary, it does have a lifespan and requires regular attention and maintenance. It is recommended that the foam is inspected on a maintenance schedule and that the fuel cell is matched with the correct type of foam for the fuel being used.

Some racers have claimed that fuel cell foam breaks down and clogs fuel filters. However, fuel cell manufacturers have stated that this is not a common issue today. Paul Culp of Superior Fuel Cells commented that they have "had no experiences with foam deterioration clogging filters". Similarly, Dave Dack of Aero Tec Laboratories (ATL) stated that "years ago, foam would break down from fuel additives", but that today, they are "not seeing premature aging from foam, not even from gasoline fuels with an ethanol content".

Despite this, it is important to note that the fuel used can affect the performance of the fuel cell foam. For example, ethanol-style fuels are corrosive and can attack the fuel system, potentially leading to blockages at the fuel filter. Additionally, switching between different types of fuel with the same cell can cause a chemical reaction that accelerates the deterioration of the fuel system. Therefore, it is recommended to use a separate fuel cell for different types of fuels.

In summary, while fuel cell foam deterioration may not be a prevalent issue as claimed by some racers, it is still important to regularly inspect and maintain the foam, ensuring that it is matched with the correct fuel type and fuel cell.

Fuel sloshing

To prevent fuel sloshing, fuel tanks are typically designed with specialized baffles or subdivisions that restrict the movement of fuel within the tank. These baffles act as barriers, limiting the area available for the fuel to move and reducing the impact of sloshing on the overall dynamics of the vehicle or aircraft. Additionally, open-cell foam is commonly used in fuel tanks, including those in race cars, to effectively suppress sloshing and improve performance. The foam fills the tank, acting as a barrier and absorbing the impact of the fuel, reducing the chances of fuel tank rupture and explosion in a collision.

It is important to note that fuel sloshing can still occur even with baffles or foam in place, especially during extreme maneuvers or hard landings in aircraft. In such cases, additional measures such as mesh or plastic bladders within the fuel tanks may be necessary to prevent sloshing and maintain stability.

The type of foam used in fuel tanks is also crucial. Cheap foam may disintegrate over time, clogging fuel filters and compromising safety. It is recommended to use high-quality foam designed specifically for fuel cells, as this foam is made from materials that can withstand fuel additives and alcohol-based fuels like ethanol. Regular maintenance and inspection of the foam is also essential to ensure its effectiveness and integrity over time.

In summary, fuel sloshing is a common issue in vehicles and aircraft, and it can have significant impacts on performance and safety. By utilizing specialized baffles, foam, or other methods, fuel sloshing can be effectively managed, improving overall vehicle dynamics and safety.

Safety

Fuel cell foam is an important safety feature in vehicles. Its primary function is to prevent explosions by suppressing the ignition of fuel in the event of a breach in the fuel cell bladder. The foam ensures that there are no concentrated batches of vapours, thereby preventing a flame front from developing and reaching explosive velocity. This significantly reduces the probability of the fuel cell exploding in case of a fire.

Additionally, fuel cell foam also reduces fuel sloshing, which can cause weight shifts during turns, affecting the grip on tires. By minimising sloshing, the foam improves performance and safety, especially in racing.

To maintain safety, it is crucial to regularly inspect and maintain fuel cell foam. It should be carefully removed from the bladder and inspected for any signs of damage or deterioration. The fuel used can also impact the performance of the foam, so it is important to use the correct type of foam for the specific fuel. For example, foam specific to gasoline or alcohol-based fuels should be used, as universal HVAC-type air filter foam can turn into a goopy substance when exposed to race fuels.

Furthermore, switching between different types of fuel with the same cell is discouraged, as it can cause a chemical reaction that accelerates the deterioration of the fuel system. This includes the fuel cell foam, which may break down and clog fuel filters. Therefore, it is recommended to use a separate fuel cell for different types of fuels.

In summary, fuel cell foam plays a critical role in vehicle safety by preventing explosions and reducing fuel sloshing. Regular maintenance and the use of appropriate foam for specific fuels are essential to ensure the effectiveness of this safety feature.

Fuel type

Fuel cell foam is an important safety feature in vehicles, particularly in racing cars. The foam is placed inside the fuel cell to suppress the chance of an explosion in the event of a crash. It does this by preventing a large batch of fuel vapours from accumulating, which could otherwise lead to a rapid rate of combustion and an explosion.

The foam also offers other benefits, such as reducing fuel sloshing, which can improve performance, and giving shape to the flexible bladder of the fuel cell.

There are different types of foam available, depending on the type of fuel used in the vehicle. For example, fuel cell company Aero Tec Laboratories (ATL) offers yellow SF-103 foam for gasoline with up to 85% ethanol (such as E85) and charcoal grey SF-110 for 100% alcohol. It is important to use the correct type of foam for your application, as using the wrong type can lead to a gooey mess that clogs your fuel filters.

Additionally, it is important to note that switching between different types of fuel with the same fuel cell can cause problems in some cases. This is because the change in fuel can cause a chemical reaction that accelerates the deterioration of the fuel system, including the fuel cell foam. Therefore, it is recommended to use a separate fuel cell for each type of fuel you use.

Finally, fuel cell foam does have a lifespan and requires regular maintenance and inspection. Racers should carefully remove the foam from the bladder and inspect it for any signs of deterioration or damage. If the foam is damaged or falling apart, it is important to replace it with new foam from a reputable manufacturer to ensure the continued safety and performance of the vehicle.

Maintenance

Fuel cell foam requires regular attention and has a lifespan. Freddie Turza, of VP Racing Fuels, recommends that the foam needs to be inspected on a maintenance schedule. When inspecting the foam, carefully remove it from the bladder and place it on a clean surface. Avoid ripping the foam, as some manufacturers cut the foam in a way that cauterizes the foam’s edges to prevent it from falling apart.

Paul Culp, of Superior Fuel Cells, recommends checking the filter every three races and looking for particles that could simply come from dirt or fuel that was in a bad barrel or container. Culp also discourages the practice of poking a stick into a fuel cell to measure fuel levels, as this can introduce contaminants and damage the foam and bladder.

The fuel you use may affect the performance of your fuel cell’s foam. Dave Dack, of Aero Tec Laboratories (ATL), recommends conferring with manufacturers when making a fuel cell purchase, as the bladder and foam used is the most critical decision in safety and performance. For example, ATL offers foam specific to the fuel used. ATL recommends its yellow SF-103 for gasoline up to 85% ethanol (such as E85) and its charcoal gray SF-110 for 100% alcohol.

In addition, Dack warns against using HVAC-type, air-filter foam in fuel cells, as this type of foam can turn into a goopy substance after exposure to race fuels.

Turza discourages racers from switching types of fuel with the same cell, as the changing of fuel back and forth can cause a chemical reaction that accelerates deterioration of the fuel system. All ethanol-style fuels are corrosive and will attack the fuel system to some degree, so it is best to have a separate fuel cell for the different fuels you use.

While most foam withstands corrosive, alcohol-based fuels such as ethanol, other components of your fuel system may struggle. Deterioration of those items can lead to blockages at your fuel filter. Ethanol can also affect bladders, so it is important to ensure that your bladder is rated for the type of fuel you are using.

The average fuel cell has a life expectancy of between 7-15 years, depending on fuel used, storage conditions, ventilation, heat and UV exposure, and fitment inside the can and vehicle. For fuel cells in climates with high humidity, it is recommended to store them in a cool and dry environment if possible, with extra drain and vent holes in the can/bulkhead, and to drain the fuel before storage of the vehicle for more than 30 days. These steps can add years to the life of the fuel cell in highly humid environments.

All fuel cells from Harmon Racing Cells come with a 7-year warranty and free maintenance throughout the warranty period. Maintenance usually includes new gaskets, bolts, washers, cleaning and inspection, and any slight repairs or adjustments that may need to be made to the fuel cell. Harmon Racing Cells recommends that, for customers running in dirty or off-road environments, the fuel cell bladder should be removed from the can for periodic inspection and cleaning of the inside of the can. For track and road applications, they recommend inspection of the fuel cell compartment to check for proper ventilation and removal of any excess spillage or fluids that may have built up during normal use. These tasks should be done every 6-12 months depending on use. The foam, fuel lines, vents, pickups, anti-spills, and other hardware are expected to last the life of the cell, so replacement is not recommended unless there is a noticeable problem with leakage or performance. Gaskets can be replaced every 2 years if desired, but this is not necessary unless the gasket is damaged or the plate is being removed regularly for cleaning/inspection.

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