New American Iron and Steel Institute Study
Shows Steel's Potential To Match Design Flexibility of
Plastic Auto Fuel Tanks
DETROIT, March 6 A new engineering feasibility study shows
that steel fuel tanks can meet design flexibility, volume capacity and weight
requirements for complex, saddle-shaped fuel tanks while providing the
inherent impermeability favored for meeting new, stringent evaporative
emissions standards. The study also highlighted the additional economic and
environmental incentives of low cost and convenient, profitable recyclability
of steel tanks.
The Strategic Alliance for Steel Fuel Tanks (SASFT) conducted the study to
explore the potential of fuel tanks made from new steels and using advanced
manufacturing processes to match or exceed the performance of current, blow-
molded, multi-layer plastic tanks that have been growing in popularity. The
study used a current-production plastic tank as a benchmark on which to base a
redesign in steel. SASFT revealed and exhibited the study results at the
Automotive Fuel Systems 2001 conference March 2 in Dearborn, Mich., organized
by the ITB Group, a Novi, Mich., automotive consulting company.
"What we found in the feasibility study is that not only are steel tanks
cost-competitive with current plastic tanks, but they also can meet
challenging design specifications for irregular shapes," said Peter Mould,
program manager, SASFT. "This will enable vehicle makers to take advantage of
steel's intrinsic impermeability to meet new regulations on evaporative
emissions, such as PZEV (partial zero emission vehicle)."
Automakers are re-evaluating plastic fuel tanks in favor of systems made
of stainless steels and coated low carbon steels because plastic tanks
currently are unable to meet the stricter requirements of the California Air
Resources Board (CARB) that take effect in 2003. Meeting stricter
requirements for permeability may require plastic fuel tanks to become heavier
and more costly, thereby mitigating the perceived weight and cost advantages
plastic fuel tanks have enjoyed.
Key to the successful redesign of the existing plastic tank in steel was
use of highly formable steels that allow for greater flexibility in the
forming of complex shapes, and innovative advancements in a seam welding
process that enables high-speed welding of complex shapes with tight radii.
Collaborating on the engineering feasibility study under the SASFT
umbrella were a number of companies including, in particular, Metalsa, Mexico,
who performed the CAD redesign, Soudronic Ltd., who developed a new 6-axis
welding approach, and Bethlehem Steel and Ispat Inland, who conducted forming
analyses.
SASFT also is targeting 15-years- and 20-years-in-service steel systems to
meet future regulations for corrosion resistance. The steel systems include
stainless steel, as well as pre-painted and post-painted low carbon steels.
Steel fuel tanks are fully recyclable, an advantage of particular
importance as governments continue to tighten requirements for end-of-life
vehicles. In contrast, plastic tanks currently are not suitable for recycling
and pose an increasing concern for disposal in landfills.
The American Iron and Steel Institute (AISI) organized the Strategic
Alliance for Steel Fuel Tanks (SASFT) as an international, multi-functional
group of fuel system manufacturers, users and material suppliers to encourage
further development of technologies and performance of steel fuel tanks. It
is the only forum dedicated exclusively to the development and sharing of
technology in steel fuel tank systems, and demonstrates the power of a global
and diverse group to innovate, develop and design new approaches.
SASFT has received interest and participation from fuel system
manufacturers (such as Visteon Automotive Systems, Tesma/Magna, Canada, Tower
Automotive/Metalsa, Mex., Narmco Group, Canada, and Pilot Industries, Inc.),
OEMs (such as General Motors, Ford and Nissan) and a sealing supplier (Parker-
Seal). Additionally, European and Asian steel manufacturers (such as Corus
Group, ThyssenKrupp Stahl, Usinor Group, Nippon Steel and Kobe Steel) are
bringing a global view of fuel system materials to the SASFT group. The
Alliance's goals include working to develop next generation steel fuel tanks
and exploring strategies whereby steel could provide "one-stop-shop"
capabilities for fuel tank customers. Additionally, the Alliance will promote
steel as the safe, affordable, durable, and non-permeable choice for fuel
tanks.
The American Iron and Steel Institute (AISI) is a non-profit association
of North American companies engaged in the iron and steel industry. The
Institute comprises 42 member companies, including integrated and electric
furnace steelmakers, and 156 associate and affiliate members who are suppliers
to or customers of the steel industry. For more news about steel and its
applications, view American Iron and Steel Institute's website at
http://www.steel.org .
The Automotive Applications Committee (AAC) is a subcommittee of the
Market Development Committee of AISI and focuses on advancing the use of steel
in the highly competitive automotive market. With offices and staff located
in Detroit, cooperation between the automobile and steel industries has been
significant to its success. This industry cooperation resulted in the
formation of the Auto/Steel Partnership, a consortium of DaimlerChrysler, Ford
and General Motors and the member companies of the AAC.
This release and other steel-related information are available for viewing
and downloading at American Iron and Steel Institute/Automotive Applications
Committee's website at http://www.autosteel.org .
Automotive Applications Committee member companies:
Bethlehem Steel Corporation
Dofasco Inc.
Ispat Inland Inc.
LTV Steel Company
National Steel Corporation
Rouge Steel Company
Stelco Inc.
U. S. Steel Group, a unit of USX Corporation
WCI Steel, Inc.
Weirton Steel Corporation
