Corus, the international metals company, has announced the launch of Neotec, a lead-free metallic-coated steel specifically designed to help vehicle manufacturers develop emission-free fuel tanks that meet not only future environmental legislation but also recycling targets for vehicles at the end of their life.
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Tough environmental legislation such as the Californian Partial Zero Emission Vehicle legislation (PZEV) requires vehicles to have zero fuel evaporative emissions. Corus anticipates that as other American states and automotive markets, including Europe, adopt similar legislation so vehicle manufactures will come under increasing pressure to develop an alternative to the plastic fuel tank.
Even adapted plastic fuel tanks designed to reduce permeation will struggle to meet PZEV legislation and moreover will significantly increase manufacturing costs, the company claims.
Another major driver behind the development of Neotec has been the European End-of-Life Vehicle (ELV) Directive, which from July 2003 will require vehicle manufactures to reduce hazardous substances such as lead, mercury and other heavy metals. Neotec is lead free and meets ELV legislation.
European ELV directives also dictate recovery or re-use rates of over 85% from 2006 and over 95% from 2015. With an average vehicle life of over 14 years, new car design needs to reflect this now, Corus claims.
The Neotec steel fuel tank is claimed to offer vehicle manufacturers a cost-effective alternative to plastic fuel tanks to help meet ELV targets and reduce end-of-life recycling costs. Corus claims that plastic is significantly more expensive to recycle than steel, but when impregnated with fuel it poses an additional recycling challenge and further recycling costs, whereas steel is readily recycled.
Corus Colors business manager Andrew Milner said: “We have received a very positive response from the industry and Neotec is now being used by MG Rover Group in its Rover 25 & 45 and MG ZR & ZS models and other OEMs are currently evaluating the product.”
Milner said steel is lead-free and impervious to evaporative fuel emissions while the coating also protects against internal fuel corrosion as well as external environmental corrosion. Neotec can be formed into complex shapes using conventional stamping and welding processes and, with the latest hydroforming techniques, significant design flexibility can be achieved.
