A Steel Solution for Plug-In Hybrid Electric Vehicles

FutureSteelVehicle Steel Fuel Tank

The WorldAutoSteel organization has developed optimum low mass designs for steel-intensive future vehicles. Several powertrains were used for the study, including a plug-in hybrid electric vehicle having an electric mode driving range of 40 miles (PHEV-40). The vehicle has an internal combustion engine to augment the driving range.

SASFT recently completed a computer generated low mass design for the gasoline fuel tank of the

PHEV-40. To provide the necessary rigidity to meet pressure-vacuum requirements of the sealed tank, a thickness of 1.8 mm low carbon (low strength) steel was required. However, by using high-strength steels, an innovative structural baffle system and advanced manufacturing, the study showed that thinner steels can be used for the tank shell and baffles resulting in a mass reduction of about 50 percent. Thus, new advanced high-strength steels offer a powerful means of reducing the mass of current sealed steel tanks of PHEVs.

About the Strategic Alliance for Steel Tanks (SASFT)

The Strategic Alliance for Fuel Tanks (SASFT) is an international alliance of companies specializing in the various areas of fuel tank production, possessing a common interest in the development, optimization and application of steel fuel tanks for automobiles. SASFT was organized by the American Iron and Steel Institute in 2000 to bring together the diverse business disciplines involved in designing, manufacturing and supplying steel fuel tanks in the automotive market. For more information on SASFT, please visit