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About 10 years ago in the US, an automotive OEM consortium formed the Oxygenated Fuels Task Force which in turn created the SAE Cooperative Research Project Group 2 to develop a simple rational method for qualifying materials. At that time the focus was Methanol/Gasoline blends. This work resulted in SAE J1681, Gasoline/Methanol Mixtures for Materials Testing. Recently this document was rewritten to make it the single, worldwide, generic source for fuel system test fluids. The paper will describe the rationale for selecting the fuel surrogate fluids and why this new SAE standard should replace all existing test fuel or test fluid standards for fuel system materials testing.

Coextruded plastic fuel tanks containing 27% post consumer recycled material were produced. The recycled material was high-density polyethylene recovered from end-of-life vehicle fuel tanks. Recovered fuel tanks contain residual fuel inside the tank and absorbed in the tank wall. The mechanical recycling process employed was effective at removing the residual fuel. Mechanical properties of the regenerated material are similar to mechanical properties of virgin High Density Polyethylene (HDPE). The regenerated material was successfully molded into plastic fuel tanks with minor adjustments to the process.