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ecrabb Forum Moderator
Joined: 13 Mar 2006 Posts: 15909 Location: Utah
TV/Projector: JVC RS40, Epson 5010
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| Posted: Thu Feb 20, 2014 6:19 am Post subject: |
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| jbmeyer13 wrote: | | I understood it to be a chemical reaction between the glycol and the aluminum LC chamber. To my knowledge mold doesn't cause pitting in aluminum. |
Totally agree.
Ethylene glycol for automotive liquid cooling applications contains corrosion inhibitors. I always assumed it was because the cooling system contained dissimilar metals (steel block, aluminum radiator, brass fittings, etc.) But, I did a little googling and now I'm not so sure... Found this post right a the top:
http://www.chemicalprocessing.com/experts/corrosion/show/373/
| Quote: | Topic: What causes corrosion from ethylene glycol?
If a mixture of 50% warm ethylene glycol C2H6O2 and 50% water comes in contact with 6xxx series aluminum, it pits the bare machined surface. What is the reaction product? Will any product of oxidation/reduction get deposited? What is the reaction chain?
| Quote: | | I have limited experience with aluminum alloys so I am not sure of the reaction products or the exact corrosion mechanism in this case. However, most corrosion caused by ethylene glycol is related to its decomposition to organic acids (such as glycolic acid) especially under elevated temperatures. The corrosion of aluminum alloy in the presence of ethylene glycol is most likely a result of acidic attack by these acids. It is known that impurities often found in ethylene glycol/water mixtures, such as ferric, copper, and chloride ions, can accelerate this corrosion. Corrosion problems with ethylene glycol/water mixtures can be minimized or eliminated by using ethylene glycol that contains inhibitors. Most commercial ethylene glycols sold contain these corrosion inhibitors. It is not generally recommended to use uninhibited ethylene glycols for heat transfer applications. If uninhibited ethylene glycol is used, it must be used with caution and carefully monitored. |
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And this…
http://jes.ecsdl.org/content/126/1/11
| Quote: | The corrosion characteristics of some selected types of aluminum in uninhibited ethylene glycol/water solutions have been studied under conditions relevant to the operation of aluminum solar heat collector systems. Measurements of linear polarization resistance and maximum pit depth were used to assess the extent of corrosion activity. Pure aluminum (99.9%) as well as 1100 (commercially pure aluminum) and 3000 (∼1% Mn) series alloys were studied in aqueous solutions of 35 v/o (volume percent) reagent grade ethylene glycol. This investigation covered the temperature range from ∼25° to 100°C. The corrosion behavior of these aluminum compositions were determined under various hydrodynamic conditions and in the presence of dissolved oxygen, common water contaminants, and ethylene glycol thermal decomposition products.
It was found that the corrosion resistance of all four types of aluminum compositions in pure uninhibited ethylene glycol solutions is marginally acceptable. The maximum corrosion current density measured was 0.5 μA/cm2at 100°C. Localized pitting attack occurred even in the pure ethylene glycol/water system, however, the probable pitting penetration depth in 20 years was estimated at under 10 mils which would be too shallow to cause perforation failure. The corrosion rate was slightly temperature dependent; activation energies were found to be less than 5 kcal/mole.
The corrosion process was not significantly affected by the hydrodynamic conditions, the presence of dissolved oxygen, or by ethylene glycol decomposition products.
In the presence of common water contaminants, however, such as Cl−, Cu+2, and Fe+3, the corrosion resistance of aluminum and aluminum alloys decreased significantly. Severe pitting corrosion was observed in the presence of chloride and/or copper ions. Ferric ions produced significant acceleration of the uniform corrosion rate to up to several tens of mils per year, but pitting was less severe. These baseline corrosion data suggest that light gauge aluminum solar panels would not survive for a reasonable service period in uninhibited ethylene glycol‐water systems without some method of corrosion control. |
http://www.lytron.com/Tools-and-Technical-Reference/Application-Notes/Preventing-Corrosion-in-Cooling-Systems
| Quote: | Corrosion caused by uninhibited ethylene glycol
Studies show that uninhibited ethylene glycol will degrade into five organic acids - glycolic, glyoxylic, formic, carbonic, and oxalic - in the presence of heat, oxygen, and common cooling system metals such as copper and aluminum. Copper and aluminum act as a catalyst in the presence of uninhibited ethylene glycol. These organic acids will then chemically attack copper and aluminum in as little as three weeks under extreme conditions (212°F and oxygen bubbling into the uninhibited ethylene glycol solution) to form metal organic compounds in the fluid, which can lead to clogging of pipes, pumps, valves, etc.
Literature references often state that copper and aluminum are compatible with uninhibited ethylene glycol, but usually those recommendations are based on a two-week chemical compatibility study of various metals at different temperatures. The study above indicates that uninhibited ethylene glycol typically does not begin to degrade until after three weeks under those extreme conditions. In conclusion, the reported data is based on ethylene glycol's ability to dissolve the metal and ignores the concern of degraded, acidic uninhibited ethylene glycol and its effects on metals. The latter is much more corrosive towards metals. |
So, then I thought I'd look at some actual tube coolant data sheets to see if there were inhibitors… The Techspray TV Coolant product data sheet lists 1,2-Ethanediol (ethylene glycol) and 1,2,3-Propanetriol (methylamino, glycerol, glycerin).
Now I have no idea what's what.
SC
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jbmeyer13
Joined: 03 Dec 2010 Posts: 1135
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| Posted: Thu Feb 20, 2014 5:50 pm Post subject: |
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Hey Steve- I saw those same links prior to my last response as well. I'm not even sure what series aluminum is used for the LC chambers so perhaps someone can chime in on that. I don't remember hearing about Sony G70 or G90 chassis having issue with glycol. Did you ever have any issues with your G70?
_________________ Projector: Modded 9501LC ULtra- MP VIM, Vold VNB, ETECH LVPS, Silver VIM Cables, HD10F's & a V1 case!
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ecrabb Forum Moderator
Joined: 13 Mar 2006 Posts: 15909 Location: Utah
TV/Projector: JVC RS40, Epson 5010
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| Posted: Thu Feb 20, 2014 6:06 pm Post subject: |
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| jbmeyer13 wrote: | | Hey Steve- I saw those same links prior to my last response as well. I'm not even sure what series aluminum is used for the LC chambers so perhaps someone can chime in on that. I don't remember hearing about Sony G70 or G90 chassis having issue with glycol. Did you ever have any issues with your G70? |
Nope, nor have I heard of people having issues with theirs. In fact, I'm not sure if I've ever seen "fungus" comments from any Sony or Barco owners. It seems to be primarily a Marquee issue. I'm assuming the Sony and Barco machines have a different LC chamber design that includes lined, painted, anodized, or otherwise protected LC chambers? Maybe Curt or somebody that has taken them apart can comment.
Based on your comments about pitting, the articles on ethylene glycol, and all the comments I've read over the years, it seems clear that the "fungus" issue is suspended particles composed of oxidized aluminum and/or whatever compounds the coolant converts to.
I've been fascinated by this issue for years. I'm frankly really amazed that the Marqee community hasn't been more proactive in finding a long-term cure. I realize it takes a long time for the problem to show up, but given the motivation (having to take your working machine down and tear it apart would seem to suffice) it seems like it shouldn't be hard for somebody to get to the bottom of the issue and find a cause.
SC
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jbmeyer13
Joined: 03 Dec 2010 Posts: 1135
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| Posted: Thu Feb 20, 2014 7:12 pm Post subject: |
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I wish it takes a long time to develop- I think Nash had some in a 2011 or 2012 model year tube IIRC.
The solution would be to anodize the LC chambers but that would require either:
1) Destroying the existing bellows and pulling everything apart
or
2) Finding a used LC housing with bellows needing to be replaced and also bare tubes
In both cases (assuming you can find some place that can anodize the housings for a reasonable price) you would need a competent tech to pot/reinstall the tubes. By the time you add up the cost of anodizing and labor for tube installation it's likely more than the tube itself is worth in this market.
This is the type of project Dragan should do as I'm pretty sure he has coated chambers with epoxy. Perhaps he's looked into it but concluded that the cost was not worth it.
_________________ Projector: Modded 9501LC ULtra- MP VIM, Vold VNB, ETECH LVPS, Silver VIM Cables, HD10F's & a V1 case!
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digitalayon
Joined: 02 Mar 2009 Posts: 921
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| Posted: Fri Feb 21, 2014 3:55 pm Post subject: |
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See....I would rather just change the fluid and call it a day. Especially when you are talking cost of epoxy and anodizing. Prolonging with a different solution makes more sense to me. I think I am going to try Galden this year on my projector.
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jbmeyer13
Joined: 03 Dec 2010 Posts: 1135
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| Posted: Fri Feb 21, 2014 4:23 pm Post subject: |
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| digitalayon wrote: | | See....I would rather just change the fluid and call it a day. Especially when you are talking cost of epoxy and anodizing. Prolonging with a different solution makes more sense to me. I think I am going to try Galden this year on my projector. |
Give it a try. At $400/gallon you won't be saving anything in the near term but if it works you might be able to sell off what you don't need and recoup part of your investment.
As Tim stated, glycol was chosen specifically for it's optical properties. I'd suggest employing a test bed projector first with resolution patterns to compare sharpness, brightness, contrast, etc. If the visual results with the new solution are equal or hopefully even better you can then run the projector for a few hundred hours to see if there's any effect on the tubes.
It all really comes down to how much time you want to allocate towards this endeavor. Anodizing should guarantee that you won't have any issues down the road and would be the quickest method to achieving the desired result. Using a new solution really requires extensive testing as mentioned above to arrive at reliable conclusions.
_________________ Projector: Modded 9501LC ULtra- MP VIM, Vold VNB, ETECH LVPS, Silver VIM Cables, HD10F's & a V1 case!
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ecrabb Forum Moderator
Joined: 13 Mar 2006 Posts: 15909 Location: Utah
TV/Projector: JVC RS40, Epson 5010
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| Posted: Sat Feb 22, 2014 12:00 am Post subject: |
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| jbmeyer13 wrote: | The solution would be to anodize the LC chambers but that would require either:
1) Destroying the existing bellows and pulling everything apart
or
2) Finding a used LC housing with bellows needing to be replaced and also bare tubes |
Duh. I was thinking it could just be disassembled… Take some screws out, disassemble, clean, anodize/coat/epoxy, reassemble, and reinstall. I totally forgot that the LC chamber is literally glued to the tube. Yeah, OK… So, a few hours taking the tubes out to clean and refill isn't so bad in the grand scheme.
SC
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mc86
Joined: 20 Sep 2008 Posts: 767 Location: pittsburgh, pa
TV/Projector: ECP 4500 (Vidikron box), ECP4500+, wanting 07MS/07MTS, evaluating pc soft-blend
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| Posted: Sun Mar 02, 2014 1:09 am Post subject: |
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Regarding the use of something other than glycol regarding the optical properties: For a LC machine, I think the curvature of the c-element is probably a function of the distance in the bellows and the index of refraction of the fluid. Changing the index of refraction a lot could make a difference. I dunno. 1.42 or whatever down to 1.28 is a big difference, it seems to me. The sensitivity to the performance of the entire optic system to this, I couldn't venture a guess.
As per the heat transfer, I could do better than a guess. My lab also uses some fluorinated heat transfer fluid (3M brand) that is very similar. Mine is called Fluorinert 70. It was $100 for maybe 2L (1/2 gallon) 10 years ago.
Without evaluating the Raleigh # to determine if there is natural convection or not, I would imagine with fluorinert there is convection. With glycerol there may not be (or if there is, to a much smaller level). Here is why: the performance of a fluid when used as a cooling agent in natural convection cases is, amongst other things, dependent on the ratio of the buoyancy forces (think how much the density changes as temperature changes) to the viscous resistance to flow. This is a ratio called the Grashof number. Fluorinert will have a grashof number that is about 5000x that of glycerol (all other things being equal). This is b/c Fluorinert has a thermal expansion coefficient 3X that of glycercol and is 1/1600th the kinematic viscosity. Add to this the fact fluorinert is 1/5 as thermally conductive and an interesting relational understanding emerges. The heat from the tube face (a flat surface) would make a higher local temperature in fluorinert b/c it conducts less readily (I'll assume densities and heat capacities are similar, which is likely). Remember -- Fluorinert expands much more rapidly as it heats than glycerol would have AND is way less viscous than glycerol. The result is that convective currents are much more likely to form and are greater than those which might be formed by glycerol all other things being equal. Either way, the heat transfer is almost certainly going to be a lot faster with fluorinated heat transfer compounds. So...yes, fluorinated heat transfer fluids will remove heat away from the surface at a faster rate. Whether or not that matters or how much, depends on the phosphor and the glass at that point.
Also, regarding the cooling -- last May/June (2013) I prepared to do two phosphor browning experiments, but they didn't happen last summer. They may shed a little initial light on the topic of the role of temperature in phosphor browning. I'll post some updates to that in the days ahead.
PS - Today was 1st time since Jan 1 I've made time to read CRT forum -- I miss getting to tinker and think about this stuff. And to share and laugh with you all.
Matt
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