Durability Enhancement of De Aeration Tank

In this investigation, a vehicle was reported for a coolant leakage issue from the deaeration tank. The coolant leakage leading to engine overheating, air entrapment in the coolant, corrosion of the radiator, water pump, and other metallic parts, coolant contamination, reduced engine efficiency, environmental hazards, maintenance, and increased downtime. In this study, a failed sample was received for failure analysis. Failed, passed, and fresh samples were taken for analysis. In this study, mechanical properties, physical properties, and material characterization were done for all 3 samples. From the analysis, there is no significant difference observed between the failed, good, and fresh samples with respect to material properties, and there are no molding defects observed on the failed sample. Due to improper cooling of the blow molding process, internal stresses were created within the material, which caused microcracks within the material. Over the period of time, the microcracks propagated and caused coolant leakage from the DAT.