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THE NEW STEEL TANK— INNOVATIVE AND FUNCTIONAL
Peter R. MouldProgram Manager
Strategic Alliance for Steel Fuel Tanks (SASFT)
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OUTLINE
Yesterday’s steel fuel tank
Drivers for change
Today’s steel fuel tank― Innovative
Complex shape / design flexibilityDurable steel systemsOptimum fuel capacity
― Economically viableCost competitive and availableEnvironmentally friendly
Summary – The “footprint” of today’s steel tank
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YESTERDAY’S STEEL FUELTANKCharacteristics:
Simple shapes
Large flange― 2D weld seam― Large radii
Steel:― Terne coated― Low carbon― Wall thickness:
> 1 mm
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DRIVERS FOR CHANGE
Design flexibility – more complex shapes― Packaging restrictions― Driveshaft on AWD and RWD vehicles demands “saddle”
shape tanksIncreased durability
― 15 years or 150,000 miles― External corrosion resistance― Internal resistance to various fuels
Increased range/tank of gasoline― Volume/capacity
Commercial issues:― Cost competitiveness― Availability/supply infrastructure
AUTOMOTIVE REQUIREMENTS
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TODAY’S STEEL TANK
Complex shape― Facilitates packaging― Optimizes fuel capacity
Regulatory requirements― Durability > 15 years
Multiple steel systems available― Low evaporative emissions
Inherent impermeability of steel
Customer/market requirements― Lighter weight – wall thicknesses < 1.0 mm― High rigidity for shape stability― Resistance to broad range of fuels
Gasoline, flex fuels, diesel blends― Environmentally friendly
Material of choice for PZEVFully recyclable
CHARACTERISTICS THAT NOW MEET TODAY’S REQUIREMENTS
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TODAY’S STEEL FUEL TANK COMPLEX SHAPE
Ford Mustang
Mercedes Benz
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ENABLERS FOR COMPLEX SHAPEImproved formability
OLD STEELSDQ/DQSK
(0.03 to 0.06 C)
NEW STEELSIF
(< 0.005 C)
AUSTENITIC ANDFERRITIC STEELS
EXCELLENT DEEP DRAWING
STRETCHING& FLANGING
TODAY’S STEEL FUEL TANK COMPLEX SHAPE
COMPLEX SHAPED TANKS
FORMING SIMULATION
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Improved seam welding techniques
COPPER WIRECONTACT SURFACES
IMPROVEDWELDING OF
COATED STEEL
2D
3D MULTI AXIS
WELDING
Increased versatility
ENABLERS FOR COMPLEX SHAPE (continued)
EFFICIENT SEAM WELDING
OF COMPLEX TANKS
TODAY’S STEEL FUEL TANK COMPLEX SHAPE
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WIDE CHOICE OF STEEL ‘SYSTEMS’Pre-painted steels (10μ epoxy films) over:― Low carbon steels with various metallic coatings
(and limited post painting)EG Zinc – NickelHD GalvannealedHD Aluminized
Post-painted steels (up to 300μ PVC-type coatings) over:― Low carbon steels with various metallic coatings
HD AluminizedHD Tin – Zinc
― Stainless steels
Uncoated steels stainless steels……
TODAY’S STEEL FUEL TANK DURABLE STEELS
ALL DURABLEFOR BEYOND
15 YEARS
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ALL STEEL SYSTEMS – COMPATIBLE WITH DIFFERENT FUELS
Gasoline
Flexible fuels― Ethanol contents up to 85% (E85)
Diesel fuels― High temperatures
durability is maintainedno sag or distortion
― Cooling of fuel aided by the high conductivity of steel― Aggressive diesel fuels in North America
posing problems for a wide range of fuel system materialsnew steel approaches being addressed
TODAY’S STEEL FUEL TANK DURABLE STEELS
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TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
THREE CONTRIBUTING FACTORSVolume Effects of Steel versus Plastic Shells
Courtesy: Dr. G. Pozgainer
(Magna Steyr)
Example:• Wall thickness of 0.8 to 1.0 mm compared to a
thickness of 5 to 7 mm for a plastic tank
Average Tank Surface 1.5 m²: + 7.5 liters
• Reduced clearance with surrounding parts dueto the absence of swelling
Calculated Seam length 4m: + 2.4 liters
• Optimized volume due to internal packaging ofcomponents, fuel and vapour lines
Estimate: + 1.5 liters
• Volume loss due to packaging constraints
Estimate: - 4.0 liters
Net Volume Advantage: 7.4 liters
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TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
THREE CONTRIBUTING FACTORSVolume effects related to rigidity
Plastic tanks ― “stand-offs”―detract from fuel capacity
“Stand-offs”
NO “STAND-OFFS” INRIGID STEEL TANKS― VALUABLE SPACE
SAVED FOR FUEL
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THREE CONTRIBUTING FACTORSNew welding technologies/joint designs
enable smaller flanges and better use of engineering space……Conventional
seam weldflange
Plasma or MIG weld-reduced flange
Engineering space limit
10 mm
17 mm
3-4 mm
Shift tank walloutward
INCREASED FUEL
CAPACITY: ~ 5-15%
INCREASED FUEL
CAPACITY: ~ 5-15%
INCREASED FUEL
CAPACITY: ~ 5-15%
INCREASED FUEL
CAPACITY: ~ 5-15%
TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
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…… USED ON AUDI A8
PZEV TANK
USED ON AUDI A8
PZEV TANK
Courtesy: Dr. G. Pozgainer
(Magna Steyr)
TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
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REDUCED FLANGES — OPTIMIZE FUEL CAPACITY
Small flanges produced by plasma & MIG welding
● ● ●
Audi A8 BMW 3 series
TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
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REDUCED FLANGES — OPTIMIZE FUEL CAPACITYSASFT Developmental fuel tank
Overlap joint design
TODAY’S STEEL FUEL TANK MAXIMUM FUEL CAPACITY
JOINT DESIGN/WELD PROCESS OPTIMIZATION
CONTINUING
JOINT DESIGN/WELD PROCESS OPTIMIZATION
CONTINUING
● ● ●
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COST COMPETITIVEIncreased technical/performance requirements of fuel tanks
are increasing the cost competitiveness of steel tanks.
IncreasedIncreasedcompetitivenesscompetitiveness
of steel tanksof steel tanks
MonolayerMonolayerplastic tanksplastic tanks
MultilayerMultilayer(LEV II)(LEV II)
MultilayerMultilayerPZEVPZEV
PLASTIC TANKSPLASTIC TANKS
TODAY’S STEEL FUEL TANK COST COMPETITIVE
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TODAY’S STEEL FUEL TANK SUPPLY INFRASTRUCTURE
INDEPENDENT STEEL TANK MANUFACTURERS – SASFT MEMBERS
……
AsiaAmericas/Europe
GLOBAL SUPPLY INFRASTRUCTURE
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TODAY’S STEEL FUEL TANK LOW EVAPORATIAVE EMISSIONS
Steel Fuel Tanks — the choice for
PZEV
California Air Resources Board:
― Certified gasoline PZEV models
● 14 in 2003● 23 in 2004 ● 29 in 2005● 40 in 2006
Steel Fuel Tanks . . .the choice for PZEV vehicles
SteelSteel/plastic bladder
PZEVATPZEV
Camry LE, SE or XLEPrius – Hybrid
20042004
SteelSteel
PZEVPZEV
S60 2.4 SedanV70 2.4 Wagon
20042004
SteelSteelSteelSteel
PZEVPZEVPZEVPZEV
Legacy 2.5 GT SedanLegacy 2.5 GT WagonLegacy L Sedan/WagonOutback Ltd Sedan/Wagon
2004200420042004
SteelSteel
PZEVPZEV
Altima 2.5, 2.55, 2.55LSentra 1.8, 1.85
20042004
SteelPZEVGalant DE & ES2.4L2004
SteelSteel
ATPZEVPZEV
Mariner HEV 4WDMilan
20062006
SteelPZEVE350 – 3.5L 2005
SteelSteelSteel
PZEVPZEV
ATPZEV
Mazda 3 – 2.0L/2.3L Mazda 6 – 2.3L Tribute HEV 4WD
200420062006
SteelSteel
PZEVPZEV
Elantra – GLS & GTSpectra – 2.0L
20052005
Hyundai – Kia
SteelSteel
ATPZEVPZEV
Civic – Hybrid Accord – EX/LX Sedan
20042004
SteelSteelSteel
PZEVPZEVPZEV
325C1 – Coupe3251 – Sedan3251 – Wagon
200520052005
SteelSteel
PZEVPZEV
Sebring – Sedan Stratus – Sedan
20042004
Steel
Steel
Steel
ATPZEV
PZEV
PZEV
Escape – Hybrid- 2WD, 4WD
Focus – Wagon- 2X3/2X4/2X5
Fusion
2005
2005
2006
Tank MaterialEmission RatingModel Name/TypeModel YearCompany
CARB PZEV certified vehicles for 2006
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TODAY’S STEEL FUEL TANK SUSTAINABLE
COMPARISON OF EOL FOR PLASTIC & STEEL FUEL TANKS
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TODAY’S STEEL FUEL TANK SUSTAINABLE
FULLY RECYCLABLEAllows compliance to End Of Life (EOL) Regulations
Courtesy: Dr. G Pozgainer(Magna Steyr)
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TODAY’S STEEL FUEL TANK SUMMARY
THE ‘FOOTPRINT’ OF TODAY’S STEEL FUEL TANK
OPTIMUM FUEL
CAPACITY
DURABILITY
DESIGN FLEXIBILITY
ENVIRO-FRIENDLY
INNOVATIONCOST
COMPETITIVE
GLOBALAVAILABILITY
ECONOMIC ISSUES
THE ‘INNOVATIVE’CHOICE FOR AUTOMAKERS
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