Mercedes Mullins
Fuel tanks are essential components of automotive vehicles, storing and propelling fuel to the engine. Traditionally, steel was the material of choice for automotive fuel tanks, but in recent years, plastic has emerged as a popular alternative. This shift towards plastic fuel tanks is driven by the material's lightweight nature and flexibility in molding, enabling manufacturers to create odd saddle-shaped tanks. Additionally, plastic fuel tanks, such as those made from high-density polyethylene (HDPE), offer increased volume capacity compared to their steel counterparts. However, the recyclability of plastic fuel tanks remains a concern, with steel tanks being more easily recycled. To address this issue, automotive designers are exploring prototypes that can be easily disassembled into various material groups for recycling. Meanwhile, innovations in stainless steel fuel tanks offer a fully recyclable, lightweight, and durable alternative to both plastic and traditional steel tanks.
| Characteristics | Values |
|---|---|
| Materials | Steel, zinc-nickel coated steel, stainless steel, plastic (high-density polyethylene (HDPE), polypropylene (PP), regrind plastic (recycled polyethylene), plastic adhesive, ethyl vinyl alcohol (EVOH)) |
| Shape | Rectangular, cone bottoms, horizontal, cylindrical, vertical, saddle-shaped |
| Use | Safe storage and transportation of flammable substances such as gasoline, butane, motor oil, transformer oil, gas oil, natural gas |
| Pros | Steel tanks are recyclable, stainless steel tanks are lightweight, pressure-resistant, and have excellent crash properties, plastic tanks are flexible and lightweight |
| Cons | Steel tanks are heavy, stainless steel tanks are expensive, plastic tanks are difficult to recycle |
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What You'll Learn
Plastic fuel tanks
The molding process for plastic fuel tanks is important to consider. Rotationally molded plastic fuel tanks tend to be stronger, while blow-molded plastic fuel tanks may be more susceptible to weakness in their walls. Additionally, the recycling of plastic fuel tanks is a challenge due to the absence of a dedicated infrastructure for plastics and the sorting required for different plastic types.
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Steel fuel tanks
Steel is a preferred material for automotive fuel tanks due to its strength and formability, which make it suitable for all fuel tank applications. Steel is dimensionally stable in automotive fuels and will not swell, grow, or sag when exposed to fuel and elevated temperatures for extended periods. This stability allows for reduced clearances between the tank shell and the vehicle underbody, increasing the available volume within the vehicle architecture.
The heat resistance of steel is another important factor in its selection for fuel tanks. Steel is unaffected by extreme underbody temperatures, eliminating the need for additional heat shielding. Steel fuel tanks also offer improved durability compared to plastic tanks, and their thin walls provide a greater usable volume within a given packaging space. For example, a 21-gallon single-chamber SUV steel tank has 8% greater usable volume than an equivalent plastic tank.
While stainless steel tanks have been tested, they are more susceptible to breakage during stamping and are significantly more expensive than terne steel. Overall, steel fuel tanks offer a combination of strength, durability, heat resistance, and recyclability, making them a popular choice for automotive fuel tank applications.
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Stainless steel fuel tanks
Automotive fuel tanks are made from a variety of materials, including steel, stainless steel, carbon steel, alloy-coated steel, plastic, and polyethylene. Stainless steel fuel tanks offer several advantages over other types of tanks.
Firstly, stainless steel tanks are highly durable and resistant to corrosion. Stainless steel is a steel alloy with chromium added, which helps to prevent rust. This makes stainless steel tanks ideal for use in harsh, corrosive environments, ensuring a longer lifespan compared to other materials.
Secondly, stainless steel fuel tanks are lightweight, with walls as thin as 0.6 mm. This reduced weight contributes to lower vehicle weights, which can help reduce emissions. The lightweight property of stainless steel tanks also does not compromise safety. Due to deformation hardening, these tanks exhibit excellent crash properties and are pressure-resistant, making them a safe choice for fuel storage.
Additionally, stainless steel fuel tanks are fully recyclable, addressing the environmental concerns associated with fuel tank disposal. The ability to recycle stainless steel tanks can help reduce the amount of waste sent to landfills and promote sustainable practices in the automotive industry.
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Recyclability
Automotive fuel tanks are made from a variety of materials, including steel, zinc-nickel, terne, and plastic. Plastic fuel tanks are typically made from high-density polyethylene (HDPE), polypropylene (PP), regrind plastic (recycled polyethylene), plastic adhesives, or ethyl vinyl alcohol (EVOH).
The recyclability of automotive fuel tanks depends on the material they are made of and the recycling infrastructure available. Steel fuel tanks, for example, can be easily drained and recycled by melting them down. The infrastructure for recovering and recycling the ferrous content of cars is well-established, with 70-80% of a typical passenger car being made from recoverable steel and iron.
On the other hand, plastic fuel tanks present more challenges when it comes to recycling. While plastic tanks can be repaired, the process of molding plastic fuel tanks results in approximately 30% of the plastic material becoming industrial waste. Additionally, the various types of plastics used in fuel tanks must be sorted and separated, as mixing different types can ruin a batch of recycled material. Despite these challenges, some automotive manufacturers, such as General Motors and Tier 1 automotive supplier Delphi Automotive Systems, are addressing the recycling of plastic fuel tanks in their designs.
Stainless steel fuel tanks have also been proposed as a fully recyclable alternative to plastic tanks. Stainless steel tanks offer reduced weight, enhanced safety, and impressive durability. They are pressure-resistant and have excellent crash properties due to their deformation hardening.
In summary, the recyclability of automotive fuel tanks varies depending on the materials used and the recycling infrastructure in place. While steel tanks are relatively easy to recycle, plastic tanks present more challenges due to the need to separate different types of plastics and the high percentage of industrial waste generated during the molding process. Nevertheless, some manufacturers are addressing the recyclability of plastic tanks in their designs, and innovative materials like stainless steel offer fully recyclable alternatives.
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Multi-layered fuel tanks
Ford, for example, uses six-layer fuel tanks made of HDPE. These tanks consist of an inner layer of HDPE, followed by an adhesive layer, a barrier layer of polyamide or ethylene-vinyl alcohol copolymer, another adhesive layer, a layer of "regrind", and finally an outer layer of HDPE. This multi-layered design ensures that the fuel tank is durable and can withstand the demands of vehicle operation.
The use of HDPE in fuel tanks offers several advantages. Firstly, HDPE is a strong and durable material that can withstand the wear and tear of everyday use. Secondly, it is lightweight, which helps reduce the overall weight of the vehicle, leading to improved fuel efficiency. Additionally, HDPE is a cost-effective material that can be easily moulded into various shapes, making it ideal for mass production.
Other materials used in multi-layered fuel tanks include olefin compounds of polymers and antidiffusion-barrier additives, as well as steel substrates coated with terne or zinc-nickel. Stainless steel tanks have also been tested, but they are prone to breakage during stamping and are more expensive than other options.
The design and material choices for multi-layered fuel tanks aim to balance factors such as cost, weight, safety, and environmental considerations. These tanks are designed to safely store and transport flammable substances, prevent leaks, and meet stringent fuel emission standards.
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Frequently asked questions
Automotive fuel tanks are made of either steel or plastic. Before 1990, most car gas tanks were made of steel, but automakers have been moving toward plastic fuel tanks because the material is lighter in weight and more flexible to mould. Plastic fuel tanks are typically made from high-density polyethylene (HDPE), polypropylene (PP), regrind plastic (recycled polyethylene), a plastic adhesive, or ethyl vinyl alcohol (EVOH).
Plastic fuel tanks are lighter in weight and more flexible to mould into the odd saddle-shaped tanks used in some vehicles. They are also recyclable and provide safe storage and transportation of flammable substances.
Steel fuel tanks are easier to drain and recycle than plastic tanks. They are also considered safer than plastic tanks as steel is pressure-resistant and has excellent crash properties.
