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Getting the Lead Out

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Key Takeaways:

  • Aviation is the last sector still using leaded fuel (100LL avgas), facing inevitable environmental pressure to transition to unleaded alternatives.
  • Replacing 100LL is challenging as the new fuel must safely power the entire piston engine fleet, especially high-performance engines reliant on lead for detonation prevention, making automotive gasoline unsuitable due to varying specifications and ethanol.
  • Teledyne Continental has made significant progress with 94UL avgas (unleaded 100LL), successfully testing it in many popular and even some high-powered engines with minimal or no required modifications.
  • While some highly stressed engines may still require specific solutions, the author is optimistic that 94UL provides a viable and widely applicable replacement, facilitating the industry's shift away from leaded fuel.
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For many years airplanes have been the only transportation vehicles still allowed to use leaded fuel in the United States. Even NASCAR transitioned to unleaded gasoline for its stock car races a couple years ago in a symbolic move of going green. In aviation we have had a solid defense for leaded fuel because there has been no other option. Many high-powered piston engines can’t operate to their full power potential without the knock retarding presence of tetraethyl lead in the fuel. Aviation did its part in the three-decade-old effort to ban lead from motor fuels by creating 100 low lead octane avgas, which contains a fraction of the lead used in the original 100 octane formula. But there is still lead in 100LL and even the comparatively tiny amount of lead exhausted by all piston airplanes is too much for society to accept indefinitely.

There are several unleaded gasoline formulas that can power the majority of aircraft piston engines because the biggest number of engines are the low-powered naturally aspirated type that power the huge fleets of Skyhawks, Cherokees and other light singles. However, the actual use of avgas is stood on its head by the fact that the majority of the fuel is burned by a minority of high-powered airplanes that fly more and consume more fuel than the lighter airplanes. Since FBOs are realistically able to supply only one version of avgas, a 100LL replacement needs to serve the entire piston fleet, or at least come as close as possible to that goal.

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