Katerina Swanson
The materials used to make aircraft fuel tanks vary depending on the type of tank and the aircraft model. There are three main types of aircraft fuel tanks: integral, rigid, and bladder. Integral fuel tanks are constructed within the aircraft's wings or fuselage, while rigid fuel tanks are built separately and installed in the wings or fuselage. Bladder fuel tanks, on the other hand, are made of reinforced flexible materials such as synthetic rubber and are installed in a rolled-up form through a small opening in the aircraft. These tanks are used in various aircraft sizes and offer a long service life. In addition to these types, auxiliary externally mounted fuel tanks, known as drop tanks or external tanks, are commonly used on military aircraft and occasionally on civilian aircraft in emergencies. The placement of fuel tanks in the wings improves stability, reduces weight, and enhances safety by keeping fuel away from passengers and crew in the event of a leak or explosion.
| Characteristics | Values |
|---|---|
| Types | Integral, rigid, and bladder |
| Integral fuel tank material | Fuel-resistant sealant, non-corrosive aluminum frames |
| Rigid fuel tank material | Aluminum alloy, stainless steel, isophthalic polyester resin composite |
| Bladder fuel tank material | Reinforced flexible materials, synthetic rubber |
| Fuel capacity | Varies based on aircraft type and planned flight route; Airbus A380 can carry up to 254,760 kg of kerosene |
| Fuel transfer rate | Up to 800 kg of kerosene (almost 1000 liters) per minute during refueling |
| Fuel delivery | Gravity feed system, pumps, fuel injection, siphon feed fuel system |
| Fuel storage location | Wings, fuselage, empennage, belly, drop tanks |
| Safety features | Self-sealing fuel tanks, fuel pumps shut off when fuel output pressure is low, nitrogen enrichment in the fuel tank, fuel filters |
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What You'll Learn
Integral fuel tanks
Integral wing tanks require baffling to prevent fuel from sloshing or splashing into the wings when the aircraft manoeuvres. Baffle check valves are used to allow fuel to flow to the low, inboard sections but prevent it from flowing outboard. These valves ensure that the fuel boost pumps at the bottom of the tanks always have fuel to pump.
When performing maintenance on an integral fuel tank, all fuel must be emptied, and strict safety procedures must be followed. Fuel vapours must be purged from the tank, and respiratory equipment must be used by the technician. A full-time spotter must be positioned outside the tank to assist if needed. Aircraft with integral fuel tanks typically have sophisticated fuel systems with in-tank boost pumps.
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Rigid fuel tanks
Rigid tanks undergo pressure testing to ensure they won't leak or collapse during flight. The removable design of rigid tanks allows for easy repairs or replacements when necessary. Repairs to fuel tanks must be done in accordance with the manufacturer's specifications, and it is critical to follow safety procedures when welding repairs are performed. Fuel vapors must be removed from the tank to prevent explosions.
Rigid tanks are built separately from the aircraft and installed in the wings or fuselage. They are often used in older aircraft models. Newer tanks are experimenting with materials beyond aluminum and stainless steel, such as isophthalic polyester resin composite, offering seamless and lightweight constructions.
An example of a rigid tank is the Auxiliary Fuel Tank, which provides additional fuel capacity that can be transferred to the main fuel tank to extend the aircraft's range. Another example is the ATL Drop Drum, a transport container that can be pressure-filled with gasoline, jet fuel, or diesel and transported by helicopter, truck, rail, or vessel.
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Bladder fuel tanks
Bladder tanks are installed through a small opening, such as an inspection opening, into a specially prepared structural bay or cavity. They must be attached to the structure with clips or other fastening devices and should lie smooth and unwrinkled in the bay. This is particularly important on the bottom surface, so that fuel contaminants are not blocked from settling into the tank sump. Bladder tanks are also known as flexible tanks and can be bent and kinked, making them suitable for use in camouflage positions by the military.
Bladder tanks are often used in transport category and high-performance aircraft, where part of the structure of the wings or fuselage is sealed with a fuel-resistant sealant to form an integral fuel tank. Integral tanks are the lightest and offer the most space per unit of weight. They are typically positioned in the unused area inside the wings, which are then referred to as 'wet wings'. Baffles are needed to keep the fuel from sloshing or splashing into the wings when the aircraft manoeuvres.
Bladder tanks can be a convenient alternative to rigid tanks as they can be removed, repaired or replaced in the event of a leak or malfunction. Repairs to fuel tanks must be done in accordance with the manufacturer's specifications and all safety procedures must be followed. For example, fuel vapours must be removed from the tank to prevent explosion. This involves washing out the tank with water and detergent, and running steam or water through it for a specified period of time. Once repaired, fuel tanks need to be pressure-checked, usually while installed in the airframe, to prevent distortion while under pressure.
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External fuel tanks
The use of external fuel tanks dates back to the early 20th century, with the first recorded use in 1923. During World War II, the Luftwaffe employed external fuel tanks with a capacity of 300 litres, and the Mitsubishi A5M utilised an external underside drop tank to extend its range. External tanks are usually jettisoned when empty or in emergencies to reduce drag, weight, and increase manoeuvrability.
External tanks can range in capacity from 275 to 600 gallons, with some larger tanks available for specific aircraft, such as the 1360-gallon tank for the C-130 transport aircraft. The tanks are designed to be expendable and jettisoned, although modern tanks may be retained during combat and only dropped in emergencies.
One disadvantage of external fuel tanks is the drag penalty they impose on the aircraft, reducing roll rates for air manoeuvres. Additionally, they reduce the number of external hardpoints available for weapons and increase the aircraft's radar signature. Despite these drawbacks, external fuel tanks remain a valuable option for aircraft requiring extended range and endurance.
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Fuel tank safety
Safety procedures are crucial, especially during welding repairs, to prevent explosions. Fuel vapors must be removed before repairs by washing the tank with water and detergent, and then running steam or water through it for a specified time. Afterward, pressure checks are necessary to prevent distortion under pressure.
Integral fuel tanks, formed within the aircraft's structure, offer the most space and are usually located in the wings, requiring baffling to control fuel movement during maneuvers. These tanks are sealed with a fuel-resistant sealant to prevent leaks, and maintenance requires draining fuel and wearing respiratory protection to purify fuel vapors.
Rigid fuel tanks, constructed separately from the aircraft, are often removable for easy repairs. They are designed to prevent leaks through riveting and seam welding, and they undergo pressure testing to ensure integrity.
Bladder fuel tanks, made of reinforced flexible materials, offer the advantage of easy installation through small openings. They must be attached securely, ensuring a smooth surface to prevent fuel contaminants from settling.
Fuel system safety training is available to satisfy regulatory requirements, covering historical incidents, ignition prevention, and practical considerations. These measures are crucial to ensure the airworthiness of aircraft and safeguard against accidents related to fuel tank safety.
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Frequently asked questions
Aircraft fuel tanks are made of various materials, depending on the type of tank and the aircraft. The three main types of fuel tanks are integral, rigid, and bladder. Integral tanks are constructed within the aircraft's structure, often in the wings, and are made of a fuel-resistant sealant with an aluminium frame. Rigid tanks are typically made of aluminium alloy or stainless steel and are removable for easy repairs. Bladder tanks are made of reinforced flexible materials, such as synthetic rubber, and can be rolled up and inserted into a small space in the aircraft.
Each type of fuel tank has its benefits and is designed to meet the specific operational requirements and structural constraints of different aircraft models. For example, bladder tanks are used because they don't require large cuts into the aircraft structure for installation, while rigid tanks are preferred in some cases for their ease of removal and repair.
Aircraft fuel tanks are designed to store and deliver clean fuel to the engine at the correct pressure and flow rate. They are equipped with fuel pumps that create the necessary pressure to deliver fuel at the correct engine flow rate. Fuel lines, typically made of stainless steel or aluminium, carry fuel from the tanks to the engines and must withstand high pressures and temperatures.
Aircraft fuel tanks can be internal or external. Internal tanks are located within the aircraft's structure, often in the wings, to utilize the hollow structure and provide efficient use of space. External tanks are mounted outside the aircraft and are common on military aircraft. Fuel tanks in the wings help maintain structural integrity and reduce weight on the tailplane, while also keeping fuel away from passengers and crew in the event of a leak or explosion.
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