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This project aimed to find better solutions to substitute PbSn �terne� coated steel sheets for metallic fuel tanks, in the light of forthcoming alcohol containing fuels. We studied the properties, and carried out feasibility investigations, of different types of coated steel sheets:
- Existing materials that are not conventionally utilised for fuel tanks but that need to be tested with alcohol containing fuels and/or optimised with respect to the transformation properties;
- New coatings.

The results of these studies consist in the assessment for several types of coated steel sheets of the following properties:
- Stamping (by friction, powdering, hydroforming tests);
- Assembling (weldability and solderability with various techniques);
- Fuel resistance, to different fuel blend compositions with tests recommended by carmakers� specifications and on laboratory prototype (stamped and welded) tanks.

Based on these results, the transformation properties of different coatings, mainly hot dip aluminised and galvannealed steel sheets, were better defined. Two kinds of organic coated steel were selected for manufacturing fuel tank prototypes:
- Hot dip aluminised steel sheet with a new organic coating (film thickness 8 µm) consisting of an epoxy resin containing aluminium powder;
- Galvannealed steel sheets with a thin (1 µm) organic coating.

Both materials were successfully evaluated when full-scale fuel tanks were stamped and welded under industrial conditions. Finally, an updated survey of patents related to coatings for fuel tanks was conducted.

Additional information

Authors: SERRA M G, CSM, Rome (IT);CRAHAY J, CRM, Liège (BE);WARNECKE W, TKS, Duisburg (DE);RUTHENBERG M, TKS, Duisburg (DE)
Bibliographic Reference: EUR 20631 EN (2003), 173 pp. Euro: 25.00
Availability: EUR-OP reference: KI-NA-20631-EN-S Available from EUR-OP sales agents URL:
ISBN: ISBN: 92-894-5221-8
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