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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