Mercedes Mullins
The fuel tank has evolved over the years, with advancements in technology and safety standards. Fuel tanks are now constructed from a variety of materials, including metal and plastic, with each type of tank having its own advantages and disadvantages. The history of the fuel tank can be traced back to the early 20th century, with the development of self-sealing fuel tanks during World War II being a significant milestone. The fuel tank continues to be an essential component in various vehicles, including cars, aircraft, motorcycles, boats, and tractors, with craftsmen and manufacturers constantly refining their designs to meet the specific needs of each application.
| Characteristics | Values |
|---|---|
| Average fuel tank capacity for cars | 50–60 L (12–16 US gal) |
| Common materials for fuel tanks | Metal or plastic |
| Metal fuel tank construction | Welding stamped sheet metal parts together |
| Plastic fuel tank construction | Blow molding |
| Fuel tank sealant used in | Aerospace industry |
| Fuel tank sealant resistance | Water, alcohols, synthetic oils, and petroleum-based hydraulic fluids |
| Self-sealing fuel tank inventor | George J. Murdock |
| Self-sealing fuel tank patent | "Self-Puncture Sealing Covering for Fuel-Containers" |
| Self-sealing fuel tank patent number | U.S. patent 1,386,791 |
| Self-sealing fuel tank patent date | August 9, 1921 |
| Self-sealing fuel tank usage | Military aircraft built by the Glenn L. Martin Company |
| Self-sealing fuel tank advantage | Minimise damage from leaking or burning fuel |
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What You'll Learn
Self-sealing fuel tanks
A self-sealing fuel tank (SSFT) is a type of fuel tank that prevents fuel leaks and ignition after the tank has been damaged. It is typically used in aircraft fuel tanks or fuel bladders.
During World War II, self-sealing fuel tanks were used in German Do17s during the Battle of Britain. The fuel tanks were surrounded by a 1cm liner of alternating layers of vulcanized and non-vulcanized rubber. The final outer layer was made of leather. When a rifle round penetrated the outer liner, the fuel leak would set off a chemical reaction that would cause the rubber to melt back together and seal the puncture.
In the United States, several companies were involved in developing self-sealing fuel tank technology during the war. These included Ernst Eger of the United States Rubber Company (later Uniroyal), who patented a self-sealing fuel tank design in 1941, and Elmo E. Hanson, lead chemist for Firestone Tire and Rubber Company, who filed a patent for self-sealing tanks on January 21, 1941 (U.S. patent 2,404,766). Goodyear chemist James Merrill also filed a patent in 1941 (published in 1947) for a two-layer system of rubber compounds encased in a metal outer shell or the wing lining of an aircraft.
The use of self-sealing fuel tanks provided significant advantages in combat. Aircraft equipped with these tanks were able to withstand much more damage than those with conventional fuel tanks. For example, during the Pacific War, American aircraft with self-sealing fuel tanks had better chances of surviving damage compared to Japanese aircraft without this technology, such as the Mitsubishi A6M Zero.
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Metal vs plastic tanks
Fuel tanks are commonly made of metal or plastic. Metal tanks are typically made of steel or aluminium, while plastic tanks are made of high-density polyethylene (HDPE).
Metal fuel tanks are generally more durable and reliable than plastic tanks. Steel tanks, in particular, are incredibly strong and can withstand harsh weather conditions, external damage, fire, and explosions, making them ideal for industrial settings. They are also more resistant to corrosion and leaks, which can reduce the risk of contamination. Metal tanks are also more suitable for storing certain types of fuel, such as diesel, as they meet permeability requirements. Additionally, metal tanks are more easily recyclable and have a lower carbon footprint than plastic tanks. However, metal tanks are typically more expensive and heavier than plastic tanks, which can affect fuel economy. Metal tanks also require more maintenance, including regular cleaning and painting to prevent corrosion and rust.
Plastic fuel tanks offer greater flexibility in terms of shape and size, and can be completely customized to fit into specific spots, which is advantageous given the complex undercarriage of vehicles. Plastic tanks are also more lightweight, making them easier to transport and install. They are generally more affordable than metal tanks, as plastic is a less expensive material and is easier and less costly to produce. Plastic tanks also require less maintenance, as they are not susceptible to corrosion and only need to be cleaned to remove debris and sediment.
Despite these advantages, plastic tanks are more prone to damage from external factors such as UV exposure, extreme temperatures, and harsh weather conditions. They are also more likely to melt when exposed to fire, which can cause fuel to leak out and add to the flames. Plastic tanks are also more susceptible to stress cracking, which can be a potential cause of catastrophic failure, especially when used to store flammable fuels.
Overall, both metal and plastic fuel tanks have their own advantages and disadvantages, and the choice between the two depends on specific needs, budgets, and applicable regulations.
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Fuel tank construction
Fuel tanks are commonly made of metal or plastic. Metal fuel tanks are usually built by welding stamped sheet metal parts together, while plastic fuel tanks are often constructed using blow moulding, allowing for more complex shapes.
When constructing a metal fuel tank, the craftsman typically creates a mock-up to determine the size and shape of the tank, using foam board or cardboard. Once the design is finalised, the craftsman addresses structural design issues, such as the placement of the outlet, drain, fluid level indicator, seams, and baffles. The thickness, temper, and alloy of the sheet metal must also be determined before cutting and bending the pieces to form the tank's shell and ends. Baffles, which are used to reduce sloshing and improve structural integrity, may contain lightening holes to reduce weight and enhance strength.
After the basic structure is assembled, openings are added for the filler neck, fuel pickup, drain, and fuel level sending unit. The ends of the tank are then sealed using various methods, including soldering, brazing, welding, and epoxy-type sealants. Finally, the tank undergoes leak testing to ensure its integrity.
For plastic fuel tanks, high-density polyethylene (HDPE) is a viable short-term option, but it may become saturated over time as fuels like diesel and gasoline permeate the material. This saturation can lead to environmental stress cracking, which, combined with the flammability of fuels, poses a risk of catastrophic failure. Therefore, while HDPE plastic may be suitable for temporary diesel and gasoline storage, it may not be the best choice for long-term fuel tank construction.
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Fuel measurement
Another approach to fuel measurement is calculating the gallons per inch. This is done by filling the tank to a certain level, measuring the gallons of fuel added, and then dividing the gallons by the inches the fuel occupies in the tank. This method provides a gallons-per-inch ratio that can be used to estimate the remaining fuel. However, it is important to note that the shape of the tank can affect the accuracy of this measurement, especially in round tanks or those with built-in steps.
The choice between plastic and metal fuel tanks also influences fuel measurement considerations. Plastic fuel tanks, made from high-density polyethylene (HDPE), are functionally viable in the short term but may become saturated over time as fuels like diesel and gasoline permeate the material. Metal fuel tanks, on the other hand, are typically constructed by welding stamped sheet metal parts together. While metal tanks offer more long-term stability, both types require careful construction to prevent leaks, with techniques like soldering, brazing, welding, and the use of sealants employed to ensure fuel containment.
In certain cases, fuel measurement may involve considerations beyond the volume of fuel. For example, in aircraft and racing cars, fuel tanks often have baffles with lightening holes to reduce weight while adding strength. Additionally, some vehicles have a smaller reserve tank or a large secondary tank ("sub-tank") to extend their range. These design variations impact fuel capacity and measurement strategies, highlighting the interplay between fuel volume, vehicle performance, and overall range.
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Fuel tank safety
To ensure fuel tank safety, strict procedures are implemented. These include grounding procedures to prevent static electricity buildup, ensuring fuel and aircraft system compatibility, and avoiding overfilling. Additionally, inerting systems may be installed to reduce the risk of fire or explosion by replacing oxygen with inert gases like nitrogen, creating a non-flammable environment within the tank. Proper airflow management is vital to preventing vapour buildup and pressure spikes that could lead to explosions. Ventilation systems are meticulously engineered to maintain fresh air circulation and pressure relief. Sealing fuel tanks is also crucial to prevent leaks and spills.
Aviation authorities worldwide, such as the Civil Aviation Authority (CAA) in the UK, the European Union Aviation Safety Agency (EASA), and the Federal Aviation Administration (FAA) in the United States, set stringent rules and standards for fuel tank safety. Manufacturers, operators, engineers, and maintenance crews must adhere to these regulations. Rigorous training on fuelling procedures and emergency protocols is provided to all aviation personnel, from pilots to ground crews.
On-site fuel storage tanks are also crucial for many businesses, providing a convenient and reliable fuel source for various operations. However, safety must be a top priority when handling and using these tanks to protect employees, the business, and the surrounding environment. It is essential to install these tanks in suitable locations away from potential hazards, such as ignition sources, high-traffic areas, and buildings. Regular inspections and maintenance of the tanks and their components, including valves, pumps, and gauges, are necessary to identify and address any signs of damage or deterioration promptly.
Additionally, employee education on the risks associated with fuel storage tanks, such as fire hazards and fuel spillage, is vital. Implementing safety protocols, such as the proper use of personal protective equipment (PPE) and specialised fuel transfer equipment, helps minimise the risk of accidents and spills. Fire safety equipment, including extinguishers, alarms, and smoke detectors, should be installed near the fuel storage tank and regularly maintained. Developing and communicating an emergency response plan is also essential to outline procedures in case of a fuel-related incident.
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Frequently asked questions
Fuel tanks are constructed by metal craftsmen or handmade in the case of bladder-style tanks. The first safety standards for fuel tanks were developed in 1904 by the National Board of Fire Underwriters.
George J. Murdock applied for the patent "War Aeroplane Fuel Tanks" in 1917 and was eventually granted the patent in 1921.
Ernst Eger of United States Rubber Company (later Uniroyal), Elmo E. Hanson of Firestone Tire and Rubber Company, and Goodyear chemist James Merrill were all involved in developing self-sealing fuel tanks and received patents for their work in the early 1940s.
