Regan Brown
Fuel tanks are typically made of plastic polypropylene, regrind plastic, high-density polyethylene, ethyl vinyl alcohol, or a plastic adhesive. Metal fuel tanks, on the other hand, are usually made of steel or aluminium, and are built by welding stamped sheet metal parts together. The size, structure, and material of a fuel tank are determined by its application, and the type of fuel it will store. Fuel tank construction follows a series of specific steps, including creating a mockup to determine the size and shape of the tank, addressing design issues, and determining the thickness and alloy of the sheet to be used.
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What You'll Learn
Common materials used for auto fuel tanks
The most common materials used for automotive fuel tanks are metal or plastic. Metal fuel tanks are usually made of steel or aluminium, while plastic tanks are typically made from polypropylene, regrind plastic, high-density polyethylene, ethyl vinyl alcohol, or a plastic adhesive.
Metal fuel tanks are generally constructed by welding stamped sheet metal parts together. Steel and aluminium are used due to their durability, heat resistance, and resistance to corrosion and rusting. Steel tanks are commonly found in diesel vehicles, while aluminium tanks are used in gasoline-driven vehicles. Metal tanks may also be made of carbon steel, especially for the outer layer of the tank.
Plastic fuel tanks, on the other hand, offer advantages such as resistance to stress and cracking, flexibility, and durability. Plastic tanks are often constructed using blow moulding, which allows for more complex shapes. Plastic polypropylene, the most common material for fuel tanks, is valued for its flexibility and durability, ensuring safe containment of liquids even on rough terrain. Regrind plastic is another important component in plastic fuel tanks, and the use of plastic allows for lightweight construction, which is advantageous for increasing the range of a vehicle.
Other materials used in fuel tanks include fluoroelastomer, which is used for components such as o-rings, seals, diaphragms, and hose. The major requirement for in-tank elastomers is resistance to swell and chemical attack by the fuel, ensuring functionality throughout the life of the vehicle.
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Advantages of plastic fuel tanks
The most common materials for fuel tanks are metal or plastic. While metal tanks have their advantages, plastic tanks are also a popular choice due to several benefits they offer.
Plastic fuel tanks are usually made of plastic polypropylene, regrind plastic, high-density polyethylene, ethyl vinyl alcohol, or a plastic adhesive. The most common material for fuel tanks is plastic polypropylene due to its flexibility and durability, allowing the tank to safely contain liquids while also withstanding movement on rough terrain.
One of the main advantages of plastic fuel tanks is their lightweight nature, making them easier to transport and install. This is especially beneficial for smaller cars, where weight and space are crucial considerations. Plastic tanks are also generally more affordable than steel tanks due to the lower cost of the material and the ease of production through blow molding, which allows for more complex shapes.
Additionally, plastic tanks require less maintenance than steel tanks. While steel tanks need regular cleaning, painting, and protection from corrosion and rust, plastic tanks only require cleaning to remove debris and sediment. Plastic tanks are also less likely to develop leaks, reducing the risk of fuel contamination.
However, it is important to note that plastic tanks are more susceptible to damage from external factors such as UV exposure, extreme temperatures, and harsh weather conditions. The durability of steel tanks makes them ideal for industrial settings and vehicles that require higher temperatures, such as diesel engines. Nonetheless, with the right material selection and design considerations, plastic fuel tanks can be a reliable and cost-effective choice for many applications.
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The process of welding stamped sheet metal parts
Metal fuel tanks are usually built by welding stamped sheet metal parts together. The process of welding stamped sheet metal parts involves various steps and techniques. Firstly, the sheet metal stamping process involves forming and shaping straight metal sheets into the desired shape. This is achieved by bending the sheets on specialized equipment with specific dies and punches. Metal stamping is a cost-effective and efficient process that can produce complex shapes without adding or subtracting material. It is widely used in various industries, including automobiles and aerospace.
After the necessary sheet metal parts are fabricated, they can be assembled using techniques like riveting or welding. Riveting involves drilling holes and securing the pieces with rivets, while welding involves using heat, pressure, or both to fuse the parts together. Arc welding is a common welding procedure that creates watertight joints, making it suitable for fuel tank construction.
Additionally, different types of welding techniques, such as MIG, TIG, and laser welding, are employed based on the specific requirements and materials used. For instance, MIG welding is commonly used for heavy-duty fabrication, while laser welding is faster and more accurate, making it suitable for mass production.
The choice of welding technique depends on factors such as the thickness of the material, the speed and accuracy required, and the visual appearance of the weld. Furthermore, the welding process requires careful planning and skill to ensure successful outcomes, especially when working with thin metal sheets.
Overall, the process of welding stamped sheet metal parts involves a combination of stamping, fabrication, and welding techniques to create durable and leak-proof fuel tanks for automobiles.
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How to address design issues
Once the craftsman has created a mockup to determine the size and shape of the tank, the next step is to address the design issues that affect the structure of the tank. This includes deciding on the placement of the outlet, drain, fluid level indicator, seams, and baffles. The thickness, temper, and alloy of the sheet metal will also need to be determined at this stage.
To address these design issues effectively, craftsmen and engineers need to consider the specific requirements and constraints of the vehicle in which the fuel tank will be installed. For example, the size of the fuel tank will depend on the available space and weight constraints of the vehicle. A larger fuel tank will result in a greater range for the car, but it may also take up valuable space in the passenger compartment or trunk. The weight of the fuel tank is also a critical factor, especially for smaller cars, as a heavier tank can affect the vehicle's performance and handling.
Another important design consideration is the choice of materials for the fuel tank. The most common materials are metal or plastic. Metal fuel tanks are typically made of steel or aluminum, which offer durability and heat resistance. Plastic fuel tanks, on the other hand, are often made of high-density polyethylene, which provides resistance to stress and cracking. Plastic fuel tanks are also lighter and offer more design freedom. However, metal fuel tanks may be preferred in certain applications due to their ability to withstand high temperatures and provide better impact resistance.
To meet safety requirements, fuel tanks must also be designed to prevent leaks and minimize the risk of ignition. This can be achieved through various methods, such as using specific resins to dissipate electrostatic charges during fuel tank filling or incorporating a rigid outer shell and flexible inner lining to minimize the potential for punctures in the event of a collision. Additionally, openings for the filler neck, fuel pickup, drain, and fuel-level sending unit must be carefully placed and sealed to prevent leaks.
Finally, craftsmen and engineers should consider the manufacturing process and cost implications of their design choices. For example, plastic fuel tanks can be easily manufactured using blow molding, which allows for more complex shapes. The use of similar materials for the inner and outer layers of the tank can also help reduce manufacturing costs and ease the design process for handling thermal expansion and contraction.
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$119.8
The use of fluoroelastomer components
Fluoroelastomers are a class of high-performance elastomers that are integral to the design of automotive fuel systems. They are used in fuel injector O-rings, fuel hose linings, and seals within the fuel handling system. Their resistance to high temperatures and aggressive chemicals, such as fuel additives, ensures that these components offer long-lasting performance, reducing the need for frequent replacements and enhancing vehicle reliability.
Fluoroelastomers are composed primarily of fluorine, carbon, and hydrogen, with occasional additions of vinyl or peroxide. The high fluorine content gives them their exceptional resistance characteristics. The fluorine atoms create a protective barrier around the polymer chain, preventing the ingress of harmful substances and shielding against extreme temperatures. This unique property makes fluoroelastomers ideal for use in automotive fuel systems, where they provide a reliable barrier against fuel leaks and emissions.
One of the initial uses of fluoroelastomers in the automotive industry was in fuel injector O-rings. These O-rings are crucial for creating a tight seal and preventing fuel leaks. The bulk of these O-ring seals are made from bisphenol-cured VDF/HFP copolymers, which offer long-term resistance to compression set. However, in more demanding environments, O-ring seals made of high-fluorine terpolymers or thicker veneers are used to withstand aggressive fluids and severe conditions.
The use of fluoroelastomers in fuel hose linings is another important application. Initially, composite fuel-line hoses used a thin layer of extruded fluoroelastomer as an inner barrier. While this design effectively reduced emissions, lower emission standards have driven the use of thicker veneers or high-fluorine terpolymers, resulting in higher costs. Despite this, fluoroelastomers remain a critical component in fuel hose fabrication due to their ability to resist degradation and maintain their integrity under harsh conditions.
In addition to their heat and chemical resistance, fluoroelastomers exhibit excellent flexibility, making them ideal for use in automotive fuel systems. They can maintain their shape and seal even when exposed to high temperatures and external forces. This adaptability ensures that fluoroelastomer components can withstand the vibrations and movements associated with vehicle operation, further enhancing their reliability in the automotive sector.
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Frequently asked questions
Auto fuel tanks are typically made of plastic polypropylene, regrind plastic, high-density polyethylene, ethyl vinyl alcohol, or a plastic adhesive. They can also be made of steel, iron, or aluminum, which can withstand high temperatures.
Plastic fuel tanks provide resistance to stress and cracking. They are also lighter, not subject to corrosion, low cost, and offer better safety in terms of impact and fire resistance.
Aircraft typically use three types of fuel tanks: integral, rigid removable, and bladder. Integral tanks are areas inside the aircraft structure that have been sealed to allow fuel storage, such as the “wet wing” commonly used in larger aircraft. Rigid removable tanks are typically made of metal and can be removed for inspection, replacement, or repair. Bladder tanks, or fuel cells, are reinforced rubberized bags installed in a section of the aircraft designed to accommodate the weight of the fuel.
The average fuel tank capacity for cars is 50–60 L (12–16 US gal). However, the size of the fuel tank can vary depending on the vehicle type and minimum travel distance within a refueling cycle.
The construction of auto fuel tanks follows a series of specific steps. First, a mockup is created to determine the size and shape of the tank. Then, design issues affecting the structure of the tank are addressed, such as the placement of the outlet, drain, fluid level indicator, seams, and baffles. The craftsman then determines the thickness, temper, and alloy of the sheet metal that will be used to make the tank. The sheet is cut into the necessary shapes, and the pieces are bent to create the basic shell and/or ends of the tank. Finally, openings are added for the filler neck, fuel pickup, drain, and fuel-level sending unit, and the tank is leak-tested.
