NEW AISI STUDY SHOWS STEEL’S POTENTIAL TO MATCH DESIGN FLEXIBILITY OF PLASTIC AUTO FUEL TANKSDETROIT, MI, March 6, 2001 – 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 reevaluating 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 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 key 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. For more news or information, view the American Iron and Steel Institute/Automotive Applications Committee's website at www.autosteel.org. American Iron and Steel Institute/ |
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