Mercedes Mullins
Aluminum is a popular choice for marine fuel tanks due to its lightweight, strong, and anti-corrosive properties. It is also a soft metal that can be easily fabricated and shaped to fit the unique space in a vessel. However, aluminum is susceptible to corrosion from saltwater and can fail in less than five years. To extend the life of aluminum fuel tanks, good airflow around the tank is necessary to allow any stray seawater to drain off and dry. Additionally, aluminum should be protected from contact with copper, as the two metals are far apart on the galvanic scale and copper will damage the aluminum.
| Characteristics | Values |
|---|---|
| Material | Aluminum |
| Properties | Lightweight, strong, anti-corrosive, malleable, soft |
| Fabrication | Easy to fabricate and shape, can be treated with a protective polymer coating |
| Performance | Resists water damage, can withstand intense forces at sea, does not leak |
| Grades | 5052, 5086, 6061 |
| Thickness | 1/8", 3/16", 1/4" |
| Concerns | May corrode due to exposure to saltwater, can deteriorate rapidly when in contact with most other metals, may fail in less than five years |
| Cost | Replacing a failed tank can cost $30,000 to $60,000 |
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What You'll Learn
Aluminium is strong, lightweight, and anti-corrosive
Aluminium is the preferred material for marine fuel tanks because it is lightweight, strong, and anti-corrosive. Aluminium's strength comes from its high-density properties, which, when coupled with its low melting point, makes it ideal for fabrication into marine fuel tanks. Its high-density makeup also allows it to endure the intense forces that a ship experiences at sea without leaking.
Aluminium is also naturally malleable, making it easy to fabricate and shape into the exact size and form required for a given vessel. This malleability is especially useful given that each vessel is different and requires a unique tank shape and size.
Aluminium is strong enough to resist corrosion from saltwater. However, it is a highly anodic material that can deteriorate rapidly when in contact with most other metals, especially copper. Copper fittings in contact with aluminium can cause the tank to become sacrificial, so bronze or brass fittings should be used instead. To prevent corrosion, aluminium can be treated with a protective polymer coating that inhibits oxidation, tarnishing, and staining.
Aluminium marine fuel tanks are also popular because they are cheap. However, they may not always be the best option, as they can fail (start to leak) in less than five years. Aluminium tanks can also be susceptible to corrosion from the inside out due to microbial growth in the tank.
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It can be fabricated into nearly any shape
Aluminium is a popular material for marine fuel tanks because it is lightweight, strong, and anti-corrosive. It is also relatively cheap and soft, which makes it easy to work with and fabricate into nearly any shape. This is ideal for marine fuel tanks, as each vessel is different and requires a tank that fits precisely into a unique space.
Aluminium's natural malleability makes it easier for professional fabricators to craft fuel tanks in the exact shape and size required. Fabrication methods include CNC plasma or waterjet cutting, and welding. When fabricating aluminium for marine fuel tanks, it is important to ensure that the sheet meets the recommendations from the American Boat and Yacht Council (ABYC). This includes following blueprints closely to ensure the correct shape and size, as well as proper coating with anti-corrosive protection.
While aluminium is a popular choice for marine fuel tanks due to its strength and anti-corrosive properties, it is important to note that it is not completely impervious to corrosion. Aluminium can corrode when in contact with saltwater, and it is subject to fatigue when it endures continual flexing, such as when the fuel surges. To enhance the performance and longevity of aluminium marine fuel tanks, they can be treated with a protective polymer coating that will further inhibit oxidation, tarnishing, and staining.
The preferred type of aluminium for marine fuel tanks is 5052, which is often used without an epoxy paint sealer. However, some boat builders prefer 6061 aluminium because it is oxidizing aluminium, while 5052 is not. The thickness of the aluminium plate can vary, typically ranging from 1/8" to 1/4".
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It's a cheap option for boat manufacturers
Aluminum is a cheap option for boat manufacturers. It is a reasonably “soft" metal that can be worked into almost any shape. This malleability makes it easier for fabricators to craft fuel tanks to the exact shape and size required. Aluminum is also strong and anti-corrosive, and it can resist corrosion from saltwater.
Aluminum's strength comes from its high-density properties. Its high-density makeup, coupled with its low melting point, makes it ideal for marine fuel tanks. This is because it can endure the fabrication process without losing its ability to resist water damage. Aluminum fuel tanks can withstand the intense forces that a ship experiences at sea without leaking.
Aluminum is also a lightweight material, which is beneficial for boat manufacturers. Its lightweight nature, coupled with its strength, makes it ideal for marine applications. Aluminum's anti-corrosive properties also make it a good choice for marine fuel tanks, as it can resist saltwater corrosion.
However, some people feel that aluminum tanks are unsafe for marine use due to their highly anodic nature. Aluminum can deteriorate rapidly when in contact with most other metals. It also quickly corrodes when exposed to water, particularly saltwater. Aluminum is also subject to fatigue when it endures continual flexing, such as when the fuel surges.
Despite these concerns, aluminum is a commonly used material for marine fuel tanks due to its low cost and ease of fabrication. Boat manufacturers can install aluminum fuel tanks in ways that almost ensure there will be problems. For example, they may seal the cockpit on top of the tank without leaving a way to inspect or replace it.
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Aluminium tanks can fail in less than five years
Aluminium is a popular material for marine fuel tanks because it is lightweight, strong, and anti-corrosive. It can withstand saltwater, which is an important factor as saltwater can quickly degrade other materials. However, despite its anti-corrosive properties, aluminium fuel tanks can still fail in less than five years.
There are several factors that contribute to the failure of aluminium tanks. One of the main issues is corrosion. While aluminium is resistant to saltwater corrosion, it can still be susceptible to corrosion from other sources. For example, if the tank is in contact with copper fittings, the aluminium can become sacrificial and corrode over time. This is because aluminium and copper are far apart on the galvanic scale, and copper will damage the aluminium.
Another factor that can lead to corrosion is the presence of water in the fuel. Water can enter the tank through various means, such as through vent lines or condensation. This water collects at the bottom of the tank and can cause corrosion, especially in combination with other ingredients. Additionally, if the tank is placed in the lowest part of the boat where water sits, the constant exposure to water can accelerate corrosion and failure.
Improper installation and construction can also contribute to the early failure of aluminium tanks. For example, if the tank is foamed in place and the foam gets soaked with saltwater, it can fail faster. In some cases, builders may install the tank without leaving a way to inspect or replace it, making it difficult to identify issues before they become bigger problems.
To extend the life of aluminium tanks, proper maintenance and inspections are crucial. It is recommended to inspect the inside of the tank every three years, depending on factors such as frequency of use, fuel polishing, and climate. By identifying and addressing issues early on, boat owners can help prevent tank failure and ensure the safe and reliable operation of their vessels.
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Copper fittings can cause the tank to become sacrificial (due to corrosion)
Aluminum is the preferred material for marine fuel tanks because it is lightweight, strong, and anti-corrosive. It can be easily fabricated and shaped, and its high-density makeup, coupled with a low melting point, makes it ideal for marine fuel tanks.
However, aluminum is susceptible to corrosion under certain conditions. Water, for instance, can cause corrosion in aluminum tanks. Virtually all diesel fuel contains some moisture, and in cases where the tank is not full, moisture condenses on the inside of metal tanks. These droplets sink and collect at the bottom, providing a breeding ground for microbes that feed off molecules in the fuel. As dead cells and waste form, they settle as sludge, and this buildup of organic acids attacks the protective oxide film on the surface of the aluminum, leading to corrosion.
Another factor contributing to corrosion in aluminum tanks is their exposure to saltwater. Aluminum corrodes quickly when in contact with saltwater, and this process is accelerated when the aluminum is in contact with other metals, especially copper. Copper fittings in an aluminum marine fuel tank can cause the tank to become sacrificial due to galvanic corrosion. This occurs because aluminum readily becomes sacrificial to protect other metals, such as bronze, which is commonly found in seacocks.
To mitigate this issue, bronze or brass fittings may be used but should not attach directly to the tank. Instead, a stainless fitting can be attached to the tank to receive the bronze fitting, reducing the risk of corrosion. Additionally, aluminum can be treated with a protective polymer coating to enhance its anti-corrosive properties and further inhibit oxidation.
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Frequently asked questions
Aluminum is the preferred material for marine applications because it is lightweight, strong, and anti-corrosive. It can also be easily fabricated and shaped.
5052 aluminum is the preferred grade for marine fuel tanks. Other grades can be used but typically require an epoxy paint sealer.
The thickness of an aluminum marine fuel tank can vary depending on the specific requirements and range from 1/8″ to 1/4″ plate thickness.
Aluminum is a soft metal that can be susceptible to corrosion and fatigue over time, especially when in constant contact with saltwater. It is also a highly anodic material and can deteriorate rapidly when in contact with certain other metals, such as copper.
To extend the life of an aluminum marine fuel tank, it is important to ensure good airflow around the tank to allow any stray seawater to drain and dry. Additionally, it is recommended to avoid contact with copper and repeated exposure to seawater, as these can contribute to corrosion and tank failure.
