Ameer Randolph
Car fuel tanks are typically made from either steel or plastic. Before 1990, most car gas tanks were made of steel. However, automakers have increasingly shifted towards plastic fuel tanks due to their lighter weight, flexibility in molding, and toughness. Plastic fuel tanks can be up to 20% lighter than steel tanks and are less likely to rupture during a collision. On the other hand, steel tanks offer enhanced safety in certain situations, such as fires, due to their pressure resistance and deformation hardening. The choice between steel and plastic fuel tanks involves trade-offs in weight, safety, durability, and cost, with automakers striving to balance these factors to meet customer needs and regulatory requirements.
| Characteristics | Values |
|---|---|
| Material | Steel, Plastic, Polyethylene, Aluminium, Stainless Steel, Titanium |
| Weight | Steel is heavier than plastic |
| Durability | Steel is more durable than plastic |
| Safety | Plastic is safer than steel due to its ability to absorb impact without bursting |
| Recyclability | Steel is easier to recycle than plastic |
| Flexibility | Plastic is more flexible than steel |
| Cost | Plastic is cheaper than steel |
| Shape | Plastic can be moulded into various shapes to fit into specific spots |
| Maintenance | Plastic is lower maintenance than steel, especially for off-road driving |
| Environmental Impact | Plastic and steel have a similar environmental impact over their life cycle |
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What You'll Learn
Steel vs. plastic fuel tanks
Car fuel tanks have traditionally been made of steel, but since the 1990s, plastic has increasingly been used as an alternative. By 1996, plastic had replaced steel in one out of four fuel tanks manufactured in North America, and last year, plastic gas tanks had taken over an estimated 72% of the market in North America and almost 50% worldwide.
Steel Fuel Tanks
Steel fuel tanks are extremely reliable, having been used in cars for over 100 years. They are made to meet permeability requirements and can better prevent leakage. Steel can also withstand high temperatures and is less likely to catch fire than plastic tanks. They are also easier to recycle, as they can simply be drained and tossed into a pile of scrap for melting down. Steel tanks are also generally cheaper than plastic ones. However, steel tanks are heavier than plastic tanks, which can affect fuel economy. They are also less flexible, which can make them more difficult to mould into the odd saddle-shaped tanks used in some vehicles.
Plastic Fuel Tanks
Plastic fuel tanks are made from high-density polyethylene (HDPE). They are much lighter than steel tanks, weighing around 20% less, which can lead to better fuel economy. They are also flexible, allowing them to be customized to fit into specific spots in a vehicle's complex undercarriage. Plastic tanks also have better insulating properties, so you won't hear the gasoline moving around in the tank. They are also not affected by corrosion from salt, gravel, and other road debris, which can destroy metal tanks. Plastic tanks also have more design freedom, as they don't have seams, making them less likely to rupture in a crash.
Safety
The safety of plastic vs. steel fuel tanks is a highly debated topic. Some argue that plastic tanks are safer because they don't generate sparks and are more flexible, springing back into shape after impact. Steel tanks, on the other hand, can crumple and burst at the seams, causing fuel to be ejected under pressure. Plastic tanks are also less likely to become rapidly pressurized and vent flammable vapors in an under-car fire. However, others argue that steel tanks are safer because they can withstand higher temperatures and are less likely to melt and leak fuel in a fire. Plastic tanks, being made of a softer material, may melt and cause fuel to leak out, adding to the flames.
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The safety of plastic fuel tanks
Plastic fuel tanks have become increasingly common in automotive design since the 1990s. By 2016, 98% of vehicles in the US were fitted with plastic fuel tanks. Automakers have turned to plastic fuel tanks because the material is lightweight and flexible, allowing it to be moulded into odd saddle shapes. Plastic tanks are also non-corrosive and do not rust like metal tanks, which can be damaged by road salt, debris, mud, and water.
Plastic tanks are considered safer than steel tanks in crashes. Their seamless construction means they are not vulnerable to failure at weak points like seams. In a crash, plastic tanks can deform and rebound without failing, maintaining their original volume and safe tank pressure. Steel tanks, on the other hand, tend to crumple and burst at the seams, ejecting fuel under pressure. Plastic tanks are also not a source of sparks, which is important in a fire control situation.
However, plastic tanks are not without their drawbacks. In the event of a fire, a plastic tank will eventually melt, causing the fuel to become rapidly pressurised and vent flammable vapour. This is a serious concern, as cars are already highly flammable. The recyclability of plastic tanks is also questionable. Multi-layered tanks made of multiple plastics bonded together are difficult to separate for recycling, presenting a challenge for auto dismantlers.
While plastic tanks offer enhanced safety in crashes, they may contribute to fires, which are a significant challenge for engineers. The recyclability of plastic tanks is also a concern, especially as older vehicles with plastic tanks reach the end of their life. Overall, while plastic fuel tanks have some safety advantages over steel tanks, they also present new challenges that must be addressed.
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The safety of steel fuel tanks
Car fuel tanks have traditionally been made of steel, but since 1990, plastic has increasingly replaced steel as the material of choice. By 1996, plastic had replaced steel in one out of four fuel tanks manufactured in North America, and by 2016, 98% of vehicles in the US were fitted with plastic fuel tanks. Automakers have been moving toward plastic for fuel tanks because the material is lighter in weight and more flexible to mould into the odd saddle-shaped tanks used in some vehicles today.
However, steel fuel tanks still have their advantages. Firstly, they are recyclable. While most of the cars with plastic fuel tanks are still on the road, in a few years, many of these vehicles will be retired, presenting auto dismantlers with the challenge of recycling complex multi-layered tanks composed of multiple plastics bonded together. In contrast, it is much easier to recycle steel tanks, which can simply be drained and tossed into a pile of scrap for melting down.
Secondly, steel tanks are pressure-resistant and have excellent crash properties due to appropriate deformation hardening. While steel tanks are more vulnerable to failure in a crash than plastic tanks, which can deform and rebound without failing, the difference in safety performance may be down to design detail rather than the inherent qualities of the materials.
Finally, steel is cheaper than plastic.
In conclusion, while plastic fuel tanks have become more common due to their lighter weight and greater flexibility, steel fuel tanks remain a competitive alternative due to their recyclability, safety performance, and lower cost.
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Recyclability of plastic fuel tanks
Plastic fuel tanks are typically made from five different materials: high-density polyethylene (HDPE), polypropylene (PP), regrind plastic (recycled polyethylene), a plastic adhesive, or ethyl vinyl alcohol (EVOH). These tanks are formed through a process called rotational molding or "rotomolding", which involves heating and rotating a mold to shape the plastic into a seamless one-piece construction.
The recyclability of plastic fuel tanks is a complex issue that involves several factors. Firstly, plastic fuel tanks are often composed of multiple layers of different plastics bonded together, which makes separating these plastics for recycling a challenging task. This is in contrast to steel tanks, which can be easily melted down for recycling without the need for separation. The lack of technology for quickly collecting and sorting various plastics poses a significant challenge for recyclers. Additionally, recycled plastics may not be as cost-competitive as virgin plastics, and the recycling process can result in industrial waste.
However, some types of plastic fuel tanks are easier to recycle than others. For example, HDPE gas tanks are simpler to dismantle and avoid type mixing. On the other hand, barrier-type and multilayer tanks that meet stricter emissions standards can be more challenging to recycle in a cost-effective manner.
The absence of a comprehensive plastics recycling infrastructure further complicates the recyclability of plastic fuel tanks. While steel has a well-established recovery and recycling process, with 70-80% of a typical passenger car being recoverable steel and iron, plastic fuel tanks often end up in landfills due to the difficulties in recycling them.
Despite these challenges, there are efforts within the automotive industry to address the recycling and disposal issues of plastic fuel tanks. For example, companies like General Motors and Delphi Automotive Systems are considering the whole life cycle of materials and their environmental performance. Additionally, the use of recycled plastics in fuel tanks, such as regrind plastic (recycled polyethylene), demonstrates a step towards more sustainable practices.
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Stainless steel fuel tanks
Most car fuel tanks were made of steel before 1990. However, automakers have increasingly turned to plastic fuel tanks as they are lighter in weight and more flexible to mould into the odd saddle-shaped tanks used in some vehicles.
Despite this shift, stainless steel fuel tanks remain a competitive alternative. They are marked by extremely thin walls and uniquely tailored strength, weighing almost half of their plastic alternatives. This reduction in weight can help reduce vehicle emissions. They also provide three extra litres of volume and have enhanced safety properties. Stainless steel tanks are pressure-resistant and have excellent crash properties due to their deformation hardening.
Stainless steel is a steel alloy with chromium added to help prevent rust. Therefore, a stainless steel fuel tank will last longer in harsh, corrosive environments.
Some manufacturers, such as Hot Rod Hardware, offer stainless steel fuel tanks for various vehicles, including custom builds and upgrades.
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Frequently asked questions
Car fuel tanks can be made of either plastic or steel. Plastic fuel tanks are more common, with an estimated 72% of the market in North America and 50% worldwide.
There are pros and cons to both plastic and steel car fuel tanks. Plastic fuel tanks are lighter, more flexible, and safer in a crash, but they are harder to recycle and may melt in a fire, causing fuel to leak out. Steel fuel tanks are more durable and recyclable, but they are heavier and may burst at the seams in a crash, causing fuel to be ejected under pressure.
Yes, in addition to plastic and steel, car fuel tanks can also be made from polyethylene, a type of plastic that is 20% lighter and just as reliable as steel. Other materials used for fuel tanks include aluminium, titanium, and carbon steel, which are typically used for the inner layer of tanks made from composite materials.
