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A cooperative research and development program was organized to determine the critical particle size of abrasive debris that will cause significant wear in rotary injection fuel pumps. Various double-cut test dusts ranging from 0-5 to 10-20 μm were evaluated to determine which caused the pumps to fail. With the exception of the 0-5-μm test dust, all other test dust ranges evaluated caused failure in the rotary injection pumps. After preliminary testing, it was agreed that the 4-8-μm test dust would be used for further testing. Analysis revealed that the critical particle size causing significant wear is 6-7 μm. This is a smaller abrasive particle size than reported in previously published literature. A rotary injection pump evaluation methodology was developed. During actual operation, the fuel injection process creates a shock wave that propagates back up the fuel line to the fuel filter.

Extensive research has been carried out worldwide to find better plastic fuel barrier materials to meet increasingly stringent requirements due both to more restrictive emissions legislation and to the fact that widely different gasoline compositions are being used. This review accounts for the most recent progress in the field. Starting from a discussion of the fundamental aspects on permeation through polymer media, it also highlights current advancement in the areas of chemical surface treatment, multi-layered assembling and blending.