Sylvie Willis
Aluminium is a popular choice for fuel tanks, especially in boats, due to its low cost. However, it is essential to select the right grade of aluminium to ensure the tank's durability and safety. Various factors, such as weldability, bendability, corrosion resistance, and thickness, come into play when choosing the appropriate grade. Common grades used for fuel tanks include the 3000 series, 5000 series, and 6061, each with its own advantages and limitations. For instance, the 3000 series is known for its good corrosion resistance and bendability, while the 5000 series offers more structural support. Ultimately, the choice of aluminium grade depends on the specific requirements and constraints of the fuel tank application.
| Characteristics | Values |
|---|---|
| Aluminium grade for fuel tanks | 3003, 5052, 6061 |
| Welding | Easier to weld with softer aluminium |
| Bending | 3000 series and 5000 series are better for bending without cracking |
| Corrosion | Aluminium corrodes quickly in saltwater |
| Thickness | 1/8" thickness is good for welding and resistance to warpage |
| Baffles | Used to reduce sloshing and provide structural strength |
| Seams | Welded, brazed, or soldered seams are common |
| Inspection | Tanks should be inspected for leaks and pinholes |
| Cost | Aluminium tanks are cheaper than polyethylene tanks |
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What You'll Learn
Aluminium tanks are cheap, but polyethylene tanks are better
Aluminium tanks are generally cheaper and more readily available than polyethylene tanks. However, polyethylene tanks offer several advantages that make them a better choice in certain situations.
One of the primary benefits of polyethylene tanks is their resistance to corrosion. Unlike aluminium, polyethylene does not corrode when used for waste, and it is not linked to health concerns such as Alzheimer's disease when used for drinking water tanks. Polyethylene tanks also eliminate almost all condensation within the tank, reducing the risk of engine problems caused by water in the fuel.
Polyethylene tanks are also known for their longevity and low maintenance. They are built to last longer and require minimal upkeep, making them a cost-effective solution over time. Additionally, polyethylene tanks are seamless, while aluminium tanks have welded seams that can be prone to cracking, especially in high-performance applications.
Polyethylene tanks offer design flexibility and faster delivery times. They can be manufactured in various sizes to meet specific requirements and can be ordered and delivered within a shorter timeframe compared to aluminium tanks. This makes them a favourable choice for businesses looking to scale their operations quickly.
While polyethylene tanks have advantages, there are certain considerations to keep in mind. One drawback is that polyethylene tanks can allow fuel vapours to permeate through the plastic over time, which can be a problem in enclosed spaces like boat cabins during the summer. Additionally, polyethylene tanks may need to be grounded during fuelling to dissipate static electricity charges.
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Aluminium corrodes quickly when in contact with saltwater
Aluminium is known for its ability to resist corrosion. However, it can corrode under certain circumstances. Salt water is one of the factors that can lead to corrosion in aluminium. While aluminium does not contain any iron or steel and therefore does not rust, salt water can cause a chalky, white coating of aluminium oxide and unpleasant pitting.
Aluminium's natural resistance to corrosion can be combined with a protective coating to keep it in great shape. This protective coating prevents salt water from reaching the metal and causing corrosion. Marine-grade aluminium is highly resistant to destructive oxidation in water, including seawater, due to the toughness and adhesion of its natural oxide layer. However, when aluminium is placed in direct contact with a dissimilar metal like stainless steel in an electrolyte solution, galvanic corrosion can occur.
Galvanic corrosion is an electrochemical process in which one metal type corrodes preferentially to another when both metals are placed in contact with an electrolyte. This can happen surprisingly quickly and is something owners of aluminium boats should pay attention to. Chlorides exist in salt water and can eat through the oxide layer on the surface of aluminium, resulting in pitting.
To prevent corrosion in aluminium when in contact with saltwater, a powder coating can be applied. This coating acts as a barrier, preventing the salt water from reaching the metal and causing corrosion. Additionally, products like Ultra Safety Systems Tef-Gel can be used to prevent galvanic corrosion by blocking the electrolyte interface between metallic surfaces of dissimilar metals.
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$109.58
3000 and 5000 series aluminium are good for welding
Aluminium and its alloys are popular metals for fuel tanks due to their low weight, good corrosion resistance, and weldability. While there are various alloys, the 3000 and 5000 series are considered good choices for welding.
The 3000 series is a medium-strength alloy of aluminium mixed with manganese. It is very weldable, formable, and can take heat treatment well. This series is often used in applications such as air conditioners, cookware, and heat exchangers. When welding 3000 series alloys, it is recommended to use either 4043 or 5356 filler metal.
The 5000 series alloys, on the other hand, are high-strength alloys of aluminium mixed with magnesium. They exhibit a high degree of tensile strength and formability, making them widely used for heavy-duty fabrication in the transportation and infrastructure industries. The 5000 series alloys are readily welded using 5356 filler metal. However, for stronger alloys within this series, such as 5083, 5183, or 5556, it is advised to use filler metals.
Both the 3000 and 5000 series offer advantages for welding. The 3000 series is softer and more formable, making it suitable for applications that require bending. Meanwhile, the 5000 series provides more structural support due to its higher tensile strength.
When choosing between these series for welding, it is important to consider the specific requirements of your project. The 5000 series may be preferred for projects that demand higher strength and structural integrity. However, if formability and bending are more crucial factors, the 3000 series could be a better option. Additionally, it is worth noting that mixing and matching welding rods of different series is generally not recommended.
In summary, both the 3000 and 5000 series aluminium alloys offer good weldability and are suitable for different applications. By understanding the unique characteristics and considerations of each series, you can make an informed decision based on the specific needs of your project.
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5052-H32 aluminium is the suggested grade for diesel fuel tanks
Aluminium is a popular material for fuel tanks, especially in vehicles and aircraft. The 5052 grade of aluminium is widely regarded as the best option for diesel fuel tanks. Specifically, the 5052-H32 variety of aluminium is recommended for diesel fuel tanks.
The 5052-H32 aluminium sheet is commonly used for fabricating fuel tanks for vehicles and aircraft. It is a variety of the 5000 series of aluminium, which is known for its structural strength and formability. This makes it ideal for welding and bending into the desired shape without compromising its structural integrity.
The 5052-H32 aluminium sheet is available in various thicknesses, ranging from 0.025 inches to 0.050 inches, and can be cut to specified dimensions, making it a versatile option for fuel tank fabrication. It is also known for its top quality and has received positive reviews from customers who have used it for their projects.
Additionally, the 5052-H32 aluminium sheet is compatible with different welding processes and can be welded and bent without cracking or leaking, making it a safer option for fuel tanks. It is important to note that mixing and matching different series of aluminium and welding rods is generally not advised to avoid potential issues.
Overall, the 5052-H32 grade of aluminium is the suggested choice for diesel fuel tanks due to its formability, structural strength, and compatibility with welding processes. It is a safe and versatile option that has been proven effective for fabricating fuel tanks in various applications.
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6061 aluminium is crack-prone for tight radius bends
Aluminium is a versatile material used in the construction of fuel tanks, especially for boats and cars. The 3000 and 5000 series of aluminium alloys are good for welding, with the 5000 series being more structural. The 5052-H32 grade is the suggested grade of aluminium for diesel fuel tanks.
However, the 6061 grade of aluminium is known to be crack-prone when bending, especially at tight radius bends. This is because, as an aluminium alloy, it has been thermally treated, which increases its strength. The strengthening of the metal through this process of artificial aging makes it more difficult to bend without cracking. The bend radius required to avoid cracking increases as the thickness of the aluminium sheet increases. For example, a 0.25-inch-thick 6061-T6 aluminium sheet will crack if bent past an external angle of 86 degrees.
To avoid cracking, a large bend radius relative to the material thickness is required. This can be achieved by performing a three-step bend: a 2-degree bend in front of and behind the bend centreline, followed by an 86-degree bend in the centre. Another strategy is to air-bend with a relieved die, which provides the clearance needed for the punch to penetrate deeper into the die space. Heating the aluminium can also make it easier to bend, although aluminium does not behave like steel when heated.
It is important to note that bending aluminium can also affect the hardness and strength of the material. Working the metal can induce strain hardening, and bending it can make the aluminium harder and more brittle, increasing the likelihood of failure. Therefore, it is crucial to consider the design and function of the fuel tank when choosing the grade of aluminium to use.
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Frequently asked questions
Grades 3000 and 5000 are good for welding, with 3000 being softer and 5000 being more structural. Grades 3003, 5052 and 6061 are also used for fuel tanks.
5052-H32 grade aluminium is the suggested grade for diesel fuel tanks.
Aluminium tanks are cheap, but they are not the best option. Polyethylene tanks are better but more expensive.
3003 alloy is good for boat fuel tanks as it has good corrosion properties.
