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Steel CompaniesNorth AmericaAK Steel CorporationDofasco Inc.Mittal Steel USANorth American StainlessNucor CorporationSeverstal North America Inc.Stelco Inc.United States Steel Corporation

Steel CompaniesEuropeCorusThyssenKrupp StahlArcelor

Steel CompaniesAsiaJFE SteelNippon Steel CorporationNisshin SteelSumitomo Metal Industries, Ltd.Tata Steel

Fuel System ManufacturersAmericasAethra Componentes Automotivos LtdaFuel Systems LLCMartinrea InternationalMetalsaSpectra Premium Industries

...Participating SASFT Member Companies

w w w . s a s f t . o r g

Fuel System ManufacturersEuropeInergy Automotive SystemsUnipart Eberspacher

Fuel System ManufacturersAsiaDong Hee Industrial Co. Ltd.Horie Metal Co., Ltd.Unipres Corporation

Material/Equipment SuppliersNorth AmericaComau-PicoHarley Davidson EngineeringITT IndustriesMagni Group, Inc.

Material/Equipment SuppliersEuropeSoudronic Automotive NAFTA

Associate Members(Auto Manufacturers)DaimlerChrysler CorporationFord Motor CompanyGeneral Motors CorporationNissan Motor Co., Ltd.

Strategic Alliance for Steel Fuel Tanks2000 Town Center, Suite 320Southfield, Michigan 48075tel: 810.225.8250fax: 810.220.3065

STEEL FUEL TANK SYSTEM PROVIDERS . . .

...The Link to a Global Network of Steel Fuel Tank Manufacturers

w w w . s a s f t . o r g

Introductory Message 3

Benefits of Using Steel Fuel Tanks 4

Proven Corrosion Resistance 6

Steel Fuel Tank Manufacturers 10

Strategic Partners 20

- 1 -

For over a century, North American steel producers have left their day-to-day rivalries behind to work as partnersand members of the American Iron and Steel Institute (AISI) in furthering its mission to promote steel as thematerial of choice and to enhance the competitiveness of the North American steel industry and its membercompanies. AISI's overall mission centers around common goals and a clear vision for the future:

- To provide high-quality, value-added products to a wide array of customers;- To lead the world in innovation and technology in the production of steel;- To produce steel in a safe and environmentally responsible manner; and- To increase the market for North American steel in both traditional and innovative applications.

AISI is comprised of producer member companies, including integrated, electric furnace, and reconstituted mills;associate member companies, which are suppliers to, or customers of, the industry; and affiliate member organiza-tions, which are downstream steel producers of products such as cold rolled strip, pipe and tube, and coated sheet.

Traditionally, AISI members have addressed steel production and marketing issues through committee activities.Additionally, especially for market applications, AISI has coordinated broader participation of its steel industrymembers together with other companies having common interest in the development of specific markets. Thecombined resources of diverse participating companies have led to great accomplishments and exciting new productapplications.

One such AISI-organized group, the Strategic Alliance for Steel Fuel Tanks (SASFT) has been highly successful insteel fuel tank technical developments, market research, and establishing a global network for steel fuel tankmanufacturing. The need to create such an alliance became critical as the market for steel fuel tanks was impactedby the growth of plastic fuel tanks.

Today, the same environmental issues that are driving automakers to increase fuel efficiency, reduce emissions(exhaust and evaporative), and optimize end-of-life recycling are also affecting the competition between plastic fueltanks and steel fuel tanks. The impermeable nature of steel facilitates compliance to demanding evaporativeemission standards. In fact, all of the gasoline-powered vehicles certified to meet the California Air Resources Board(CARB) Partial Zero Emission Vehicle (PZEV) standards in 2005 have steel fuel tanks. In addition, steel tanks arefully recycled, at no cost to the automaker or consumer, using an existing infrastructure. When the environmentalbenefits of steel fuel tanks are combined with steel's improvements in design flexibility, manufacturability, durability,cost competitiveness, and support services, today's steel tanks truly offer "performance with environmentalresponsibility.”

We invite you to learn more about how steel fuel tanks can benefit your team by contacting AISI, SASFT or any ofthe member companies profiled in this brochure.

Sincerely,

Andrew G. Sharkey, III Dr. Peter MouldPresident and CEO Program ManagerAmerican Iron and Steel Institute Strategic Alliance for Steel Fuel Tanks

Introductory Message

The Strategic Alliance for Steel Fuel Tanks (SASFT) is an international alliance ofcompanies specializing in the various areas of fuel tank production and possessing acommon interest in the development, optimization and application of steel fuel tanks forautomobiles.

SASFT was organized by the American Iron and Steel Institute (AISI) in 2000 to bringtogether the diverse business disciplines involved in designing, manufacturing andsupplying steel fuel tanks in the automotive market.

SASFT’s global reach recognizes that different business and technological issues impact thetypes of fuel tanks produced in different regions of the world. By understanding these issues,rational, optimized approaches can be fully deployed for steel fuel tanks.

- 3 -- 2 -

Optimizing Fuel Tank Capacity by Efficient Use of Engineering SpaceThe engineering space that accommodates a fuel tank is becoming increasinglyrestricted and complex. Steel has the advantage of utilizing this space moreefficiently compared with plastic tanks, where allowances must be made forthermal expansion and warpage. Additionally, the variable wall thickness ofplastic tanks (ranging from 2 to 15 mm) restricts the fuel volume compared with aconstant thickness (typically <1 mm) steel shell. New joining techniques are emerging allowing a reduced flange,enabling the steel shell to be expanded further. It is estimated that fuel capacity increases up to 10% or more can berealized by reducing or eliminating the weld flange.

SafetyVehicles equipped with steel tanks have demonstrated the ability to meet all current and future governmentregulations and requirements for fuel system integrity after front, rear and side impacts.

Summary of the Benefits of Steel Fuel Tanks

Best material for PZEV applications thanks to inherent impermeability to hydrocarbons.

Cost competitive with current co-extruded blow-molded plastic fuel tanks.

Corrosion resistant to road environments (15-year life minimum or 150,000 miles).

Compatible with all fuels.

Good design flexibility (complex shape/saddle tank capability).

Readily manufacturable by well-proven, conventional, low cost, widely available processes.

Over 100 years of proven performance and safety.

100% recyclable. Nearly 15 millions tons of steel are recycled annually from automobiles.

Steel fuel tanks have been widely used since the early days of the automobile's develop-ment. Thus, a strong history of performance, safety, low cost, and recyclability of steelfuel tanks has been established. Despite the growth of plastic fuel tanks in recent years,steel tanks are better suited to today's demanding environmental and engineeringperformance requirements.

Attractive CostAs the environmental restrictions on evaporative emissions increase, the manufacturing costs for producing ultra-low evaporative emission plastic tanks are increasing. In contrast, steel fuel tanks continue to be an attractive meansof achieving emission targets at affordable cost. The worldwide steel industry has developed a variety of steelsystems to meet the specific approaches favored by automakers (e.g., pre-painted, post-painted and bare steels).These advanced systems are durable and have improved formability and weldability.

Technical Assistance and Support to AutomakersThe global steel tank manufacturers have the ability to assist automakers in tank design, meeting specific perfor-mance needs and in assurance testing. Furthermore, the SASFT network of steel fuel tank manufacturers,equipment suppliers and steel companies can be utilized to facilitate development and application of new technolo-gies.

Ultra-Low Evaporative Emissions CapabilityEvaporation of gasoline from automotive fuel systems is a major contributor toward air pollution and its attendanthealth hazards. This has led national and regional government agencies to restrict the amount of automobileevaporative emissions. Steel's inherent impermeability is ideal for limiting evaporative emissions. In fact, steel isnow the material of choice for meeting the California Air Resources Board's (CARB) Partial Zero Emission Vehicle(PZEV) requirements. In the 2005 model year, 29 PZEV-certified vehicles use steel fuel tanks. In contrast, plasticfuel tanks are still struggling to demonstrate PZEV capability.

RecyclabilitySteel fuel tanks have been, and continue to be, fully recyclable through an existing infrastructure of dismantling,shredding and re-melting at steel mills. The steel recycling infrastructure is a profitable industry and, hence, noend-of-life vehicle costs are incurred by vehicle makers or consumers. In contrast, the absorption of gasoline in thewalls of plastic tanks complicates their end-of-life treatment and no fully developed recycling infrastructure is inplace anywhere in the world. Plastic tanks must be either landfilled or incinerated at a significant cost. Landfillingdepletes valuable land resources and together with incineration creates additional environmental concern for toxinsin the soil or air.

Design FlexibilityNewly developed steels and steel systems have improved formability. As a result, complex shaped tanks can bereadily manufactured by conventional stamping processes. Many 'saddle shaped' tanks are routinely produced todayfrom steel. A recent SASFT design feasibility study showed that a current in-production plastic saddle tank could beproduced from steel with 4% increased fuel capacity and a proportional increase in weight.

DurabilityIn addition to meeting ultra-low emission standards, CARB stipulates that fuelsystems shall meet a 15-year or 150,000 mile life. SASFT, in an extensive two-year test program, has demonstrated that 10 steel systems will meet bothexternal corrosion resistance to road environments and internalcorrosion resistance to aggressive fuels.

Benefits of Steel Fuel Tanks

...The weight of steel fuel tanks can be competitive with plastic using today's new lightweight and highly formable sheet steels...

- 5 -- 4 -

A two-year corrosion test program sponsored by SASFT, conducted by an independent test laboratory, hasdemonstrated that multiple commerically available steel systems will achieve 15-20 year corrosion durability in fueltank applications. Ten steel systems throughout the world were tested in the program. The steel systems wererepresentative of three principal approaches used by automakers for their fuel tanks: pre-painting with minimalpost-painting, post-painting after tank fabrication, and bare steels (such as stainless steels).

Steel systems selected for external and internal (fuel) corrosion testing

Test specimens were specially designed to reflect the unique corrosion conditions of a fuel tank affixed to a vehicle.The External Corrosion specimens incorporated a scribe line to simulate a scratch exposing the bare steel, adome simulating forming strains, a weld flange with a clip to simulatea crevice corrosion site, and an area exposed to gravelimpact which simulates stone chipping conditions.

To assess the External Corrosion resistance, twosimulative bench-scale procedures were used: theNeutral Salt Spray test (ASTM B117) with exposuresup to 2000 hours and the Cyclic Corrosion test (SAEJ2334) with exposures up to 120 and 160 cycles. Thelatter exposures were selected to simulate road livesof 15 years and 20 years, respectively. Perforation wasadopted as the criterion for failure. However, the progress ofcorrosion was assessed qualitatively by visual observation andphotographs, and quantitatively by measuring pit depths over theentire specimen, assessing coating integrity by creepback at thescribe line and determining chip ratings after gravel impact.

To determine the Internal Corrosion resistance, deep drawn cups andflat lids were assembled to contain an aggressive fuel (CE10A), whichwas chosen on the basis of prior experience by automakers and their recommendations toSASFT. The fuel-cup assembly was sealed by an inert gasket and clamping rings.

The fuel cup assemblies were held at 45 + 2°C for 39weeks to simulate a 15-year tank exposure. The fuelwas changed every four weeks to simulate repeatedfuel tank filling and to replenish contaminant ions andminimize oxygen depletion (per the test fluid specifica-tions of SAE J1747). The extent of corrosion wasevaluated qualitatively by recording the extent andlocation of corrosion and quantitatively by weight changesand pit depths.

The following key findings were obtained from the two ExternalCorrosion tests:

- No perforation was observed at any location for any of the steel systems. Corrosion pit depths wereobserved at isolated locations for only two steels. In the two samples, the maximum depths of the pitswere 0.2 to 0.4 mm, representing about 20 to 40 percent of the original steel thickness.

- The extent of corrosion (red and white rusting) varied by location on the specimen and from materialto material. In most samples, slight (<15% surface area) or moderate (15-30%) rusting wasobserved; pronounced rusting (>30%) occurred only in a few instances. The variations in theextent of corrosion were not of such significance to rate one steel system as clearly superior to any other.

- The integrity of the paint systems, as indicated by resistance to gravel impact and creepback, varied inproportion to the thickness of the paint films as follows:

- Those pre-painted systems having thin organic resin films (about 9 thick) and one stainless steel,having an inorganic paint film (about 17 thick), showed small amounts of paint chip loss after initialgravel impacts. However, subsequent gravel impacts did not progressively increase the paint chip loss.

- Those post-painted systems having thick coatings (up to 370 ) showed no paint chip loss orcreepback at the scribe line.

The results for the Internal Corrosion (fuel) tests showed:

- Very minor weight losses (<0.13%) for all the specimens after the maximum 39-weekexposure.

- Some variations in the extent of a white residue occurred between the samples. The white residueoccurred primarily at the liquid-vapor interface. However, the quantity of the residue was insufficientto conduct any post-exposure analysis.

- No perforation occurred and, in fact, no pits deeper than 0.1 mm were observed in any of the cups orlids.

The results demonstrate that all of the steel systems tested in this bench-scale study resist external and internalcorrosion (in the severe environments that can be experienced by automotive fuel tanks) for up to 20 years. Thus, itis fully expected that the systems will exceed the 15-year durability requirements of CARB.

As a result of the SASFT corrosion studies, automakers are encouraged to conduct their own tests (includingproving ground tests) to validate on-vehicle corrosion durability. Steel companies can provide additional informa-tion on the availability, manufacturability and cost of specific systems.

Proven Corrosion Resistance

- 7 -- 6 -

Global Map of Steel Fuel Tank Manufacturers

...Steel is the material of choice for low evaporative emission (PZEV) vehicles in California - all 29 PZEV-compliant vehicles in 2005 have steel tanks.Green steel for clean automobiles...

Aethra Componentes Automotivos Ltda.

Aethra Componentes Automotivos Ltda. operates in partnership with practically allauto companies established in the country, in the development of vehicles for seriesproduction. It is the leading Brazilian supplier for its product line, which comprises the

following items: welded sets for bodies (complete chassis and floors); medium and large size stampings; shafts andcrossbeams for suspension; complete systems for fuel tanks; luggage boots; and tools developed for new vehicles.

HEADQUARTERSAethra Componentes Automotivos Ltda.Rua Carolina, 51-Morro do ValenteBetim - MG - Brazil 32686-190Phone: +55.31.3597.3020www.aethra.com.brCONTACTMarcus Andrade, Sales DirectorPhone: +55.31.3396.8097Cell: +55.31.8802.0367Fax: +55.31.3591.2765E-mail: [email protected] Lemos, Quality ManagerPhone: +55.31.3597.3019Fax: +55.31.8802.9548E-mail: [email protected]

GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS

Facility Type City, State,Province, Country

Facility Size(Sq. Ft)

Number ofEmployees

QualityCertification

R&D Eng. Div.

PrototypesTEC - Tool &DevicesChassis*

Juiz de Fora**

Vehicle Body

Hammer

Parana

Contagem/Brazil

Belo Horizonte/Brazil

Contagem/Brazil

Betim/Brazil

Contagem/Brazil

Contagem II/Brazil

Resende/Brazil

QS-16949, ISO-14000

CURRENT FUEL SYSTEM BUSINESSOEM MODEL YEAR - RANGE

Fiat

Volkswagen

Mercedes-Benz

Renault-Nissan

Palio Family

Fox

A Class

Frontier

PRODUCT AND SERVICES

PRODUCT / SERVICES PLANT

Palio Family

Fox

A Class

Chassis Division

Frontier

FULL SERVICE SUPPLIER CAPABILITIES

FUNCTION DESCRIPTION

Product EngineeringProduct DesignDesign Software- CATIA- Ideas- Unigraphics- Other

Program Management

Product Testing andValidation

CAE

1 Plant

2

CAD :• 04 Workstations SGI Octane with Software CATIA V4.2.4• 04 Workstations SGI Octane with Software Pro Engineer WF• 07 PCs with software AutoCad 2002/Mechanical 6/Inventor• 04 IBM Intellistation with CATIA V5 R10• 01 SUN Workstation ULTRA 60 with C3P IDEAS• 01 PC with Unigraphics NX

Industrial Center

Trucks

Juiz de Forz/Brazil

Parana/Brazil

800

10,880

13,272

211,367

148,245

24,610

15,336

14,800

1737

6,313

48

30

234

506

582

187

217

179

06

100

*=Fuel Tanks and Rear Axle **=Fuel Tack

Chassis Division

Chassis Division

Juiz de Fora Division

CAM :• 04 Workstations Pentium with software CAM CAMPEADOR• 01 Workstation Pentium with Mastercam• 01 Workstation Pentium with software CAM WORKNC• New products development in CODESIGN: Economical and Technical Viability

Studies; Product Design Assembly Project; Components Project; Material Project• Modifications Management• Update of mathematical drawings• Analysis of technical norms and standards• Metodologies:• QFD / DFM / DFA / VE / FMEA / CAD / CAE / CAM

• Computer Static and Dynamic Analysis• Prototypes, Pilot Production and Avant-Series Development: Project of Soft Toolings;

Construction of Soft Tollings for Draw and Trim; Laser Cutting; Models; Checking Fixtures• Laboratorial Analyses• Mechanical Tests (vibration, fatigue, pressure, bursting, etc )• Field Analyses• Product Certification• Complete Dimensional Control of Vehicle Body• Software Comparation Between Model Surface and Components in Real Time• 5 Axles CNC Machines• Tridimensional Measurement• 3 / 5 Axles Laser Cutting Machines (thickness up to 17 mm)

CAE :• 01 Workstation SGI Octane with Software PATRAN/NASTRAN• 01 Workstation IBM RS6000 with Software AUTOFORM(stamping simulation)

Steel Fuel Tank Manufacturers

DONGHEE Industrial Co. Ltd.

Over the last 30 years, DONGHEE Industrial Co. has prioritized customer satisfaction, the growth and develop-ment of its partners and affiliates through technology development and quality improvement. DONGHEE isdistinguished by its services, which range from product development to production technology. Implementation ofa six sigma campaign has increased innovation and doubled productivity.

DONGHEE Industrial Co. is consistently adopting cutting-edge technology and accumulating new production skills.DONGHEE has become a leading company in the Korean automobile industry and is gaining recognition in theworld market. The Company's promise to its clients is to be a customer-oriented and a value-oriented organizationthat provides optimal service in the digital era. DONGHEE constantly strives to nurture a dynamic corporateculture. The company also invests in fostering human resources, a key management strategy, and in securingadvanced technology to become a global company.

HEADQUARTERSDONGHEE Industrial Company, Ltd.#218 Hwang-Sung-Dong Nam-GuUlsan Metro-city South Korea 680-160Phone: (82) 52-259-0733www.donghee.co.kr

CONTACTDae Sik KimDirector, R & DPhone: (82) 31-211-3965Cell: (82) 16-9322-9380Fax: (82) 31-212-3927E-Mail: [email protected]




Number ofEmployees


Plant

Plant

Plant

Plant

Plant

Plant

Plant

Plant

Ulsan, Korea

Busan, Korea

Asan, Korea

Zhangjigang, China

Hwasung, Korea

Ulsan, Korea

Asan, Korea

Kwangju, Korea

530,000

285,000

500,000

250,000

285,000

90,000

355,000

364,725

601

194

452

116

373

332

90

95

TS-16949

QS-9000

QS-9000

--

QS-9000

QS-9000

--

--

CURRENT FUEL SYSTEM BUSINESS

OEM PROGRAM MODEL YEAR - RANGE

Hyundai Motors

Hyundai Motors

Hyundai Motors

Kia Motors

Kia Motors

Kia Motors

Ssangyong Motors

All Passenger Vehicles

All SUV, RV Vehicles

All Light Trucks

All Passenger Vehicles

All SUV, RV Vehicles

All Light Trucks

SUV

1996 - Present

1996 - Present

1996 - Present

1999 - Present

1999 - Present

1999 - Present

2000 - Present

PRODUCT AND SERVICESPRODUCT / SERVICES PLANT

Suspension Assembly - Front

Suspension Assembly - Rear

Pedal Assembly

Sunroof Assembly

Ulsan, Asan, Hwasung,Kwangju, China

Ulsan, Asan, Hwasung,Kwangju, China, Slovakia

Busan, Asan, Slovakia

Ulsan, Asan, Hwasung,Kwangju, China, SlovakiaFuel Tank Assembly

Ulsan, Asan, China


FUNCTION

Product Engineering

Product Designers

Design Software- CATIA

Program Management

Product Testing and Validation

CAE

ADDITIONAL INFORMATION

DONGHEE Industrial Co. is the representative company of DONGHEE Group.There are eight companies in DONGHEE Group, including:

- DONGHEE Industrial Co. (Ulsan) - DONGHEE Co. (Buscan)- DONGHEE ACS Co. (Hwasung) - DONGHEE Webasto (Ulsan)- DONGHEE Auto Co. (Seosan) - DONGHEE China (Zhangjigang)- DONGHEE Slovakia (Slovakia) - DONGHEE Automotive Co.

(Kwangiu)

- 11 -- 10 -

Contagem II/Brazil

Steel Fuel Tank Manufacturers

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

QS-16949, ISO-14000

Aethra Headquarters, Contagem, MG, Brazil

Elsa LLC...

ELSA Corporation, an automotive component manufacturer is located inElwood, Indiana. ELSA specializes in fuel tanks, exhaust systems, and structuralcomponents for OEM customers.

HEADQUARTERSElsa LLC1240 South State RoadElwood, Indiana 40636Phone: (765) 557-2000www.elsallc.com

CONTACTBrad StewartSales ManagerPhone: (765) 557-2078Fax: (765) 557-1547E-Mail: [email protected]




Number ofEmployees


Manufacturing

Technical

Elwood, Indiana

Sakamoto Industriesof Ota City, Japan

320,000

520,000

470

810

QS-9000

ISO-9001



Subaru

Mitsubishi

21Z

PSU, PS41

2004 thru 2008

2003 thru 2007


Fuel Tanks

Exhaust Systems

Elwood, Indiana

Elwood, Indiana


FUNCTION DESCRIPTION

Product Engineer

Product Designer

Design Software- CATIA- Ideas- Unigraphics- OtherProgram Management


CAE

Japan

Japan

Japan

Yes

Japan

Japan


Sakamoto Industries Co. Ltd. is our parent companylocated in Ota City, Japan. Our product development/validation activities are done in Japan while workingwith the Japanese OEMs.

Fuel Systems LLC

Fuel Systems LLC was acquired in 2001 by TMB Industries. All five manufacturinglocations are QS-9000 and ISO-9002 certified. They specialize in vehicular mountedfuel tanks and fuel tank modules for vehicles ranging from heavy-duty, medium-dutyand light-duty trucks to specialty vehicles with applications including military,construction, off-highway, and emergency usage. Fuel Systems manufacturing and

design functions work hand-in-hand with their customers to ensure that every tank is designed and manufactured tofit the exact customer specification. The technological capabilities, particularly in the areas of state-of-the-arttesting, metal processing, and robotic welding, ensure the highest possible quality. Combined with a second-to-nonework ethic and unparalleled pride in performance from over 400 employees, these strengths keep customerssatisfied and continually invested. Fuel Systems is a Tier-1 supplier and is the sole source for many of their OEMcustomers for their metallic fuel tank needs.

HEADQUARTERSFuel Systems LLC1950 Waldorf NWGrand Rapids, Michigan 49544Phone: (616) 735-3500www.fuelsystemsllc.com

CONTACTSteve WitherspoonVice President of Sales & MarketingPhone: (810) 794-2093Cell: (313) 706-4738Fax: (810) 794-5933E-Mail:[email protected]




Number ofEmployees


Corporate Office Grand Rapids, Michigan

Walker, Michigan

Springfield, Ohio

Charlotte, North Carolina

--

45,000

60,000

60,000

24

75

130

100

QS-9000,ISO-14001


OEM PROGRAM MODELYEAR - RANGE

FordGM

InternationalTruck & Engine

VolvoMack

Freightliner

Since 1972Since 1970

Since 1977Since 1987

Since 1962

Since 1990


Fuel Tanks/Modules

FULL SERVICE SUPPLIER CAPABILITIESFUNCTION

Product Engineering

Product Designer

Design Software- CATIA- Ideas- Unigraphics- Solid Works

Program Management


CAE

Mfg. / Technical

Mfg. / Technical

Mfg. / Technical

Fuel Tanks/Modules

Fuel Tanks/Modules

Fuel Tanks/Stampings

Chicago, Illinois

Charlotte, North Carolina

Springfield, Ohio

Walker, Michigan

QS -9000,ISO-14001

QS-9000,ISO-14001

Fuel Tanks/Modules


QS-9000,ISO-14001

- 13 -- 12 -

Fuel System engineers and manufacturing specialists assist their customers at the initialdesign stage of the product development cycle. They've seen a lot of fuel tanks over theyears, and have developed a strong sense of what works. By bringing this insight to thetable before design specifications are finalized, they help to save time and money andaddress quality issues right from the beginning. When the manufacturing process begins,they handle everything from raw stock to finished product, performing with excellenceon every element of the process, including stamping, bending, forming, piercing,trimming, welding and finishing operations. They are completely configured to handlesteel, aluminized steel or aluminum - regardless of the configuration required.

Fuel Systems offers their customers multiple types of finishes: primer paint, epoxypowder paint, aluminum cleaning and high-lustre polished aluminum. And their tankmodules arrive ready to bolt onto the vehicle - completely equipped with all necessarymounting hardware. Fuel Systems is a one-stop source - from design to delivery - fortop-of-the line fuel tanks, whether an application is for specialty vehicle, or light-duty,medium-duty or heavy-duty truck.

Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

Hino Since 2003

Fuel Tanks/Modules

Fuel Tanks/Modules

Fuel TanksFuel TanksFuel TanksFuel Tanks Fuel Tanks/Stampings Wytheville, Virginia

Wytheville, Virginia 45,000 75Mfg. / TechnicalQS-9000,ISO-14001

Chicago, Illinois 45,000 40Mfg. / TechnicalQS-9000,ISO-14001

Horie Metal CO., Ltd.

Horie Metal was established in 1942 and acquired by Toyota MotorCorporation in 1972. In 2001, a total 50 million steel tanks had beenproduced since 1961. The company has the largest market share in Japan.

Fuel system parts are produced using plated low carbon steel, stainless steel, and other metals. Horie Metal CO.,Ltd. has in-house stamping, brazing, welding (spot, seam, projection, plasma arc, MIG, etc.), bending, painting,assembling, leak testing (water sink, helium) processes.

HEADQUARTERSHorie Metal CO., LTD.2-26, Konoshu-ChoToyota, Aichi, Japan 471-8510Phone: +81-(0)565-29-2211www.asnohorie.co.jp

CONTACTJun TakeokaAssistant ManagerPhone: +81-(0)565-29-8941Cell: +81-(0)90-8158-2292E-Mail: [email protected]: +81-(0)565-29-3371


Facility Type City, State /Province, Country


Number ofEmployees


Main Plant & Tech Center Konosu-cho, Toyota,Aichi, Japan

Hirota-cho, Toyota,Aichi, Japan

Miyoshi-cho,Nishikamo, Aichi,

Japan

Tahara, Aichi, Japan

350K (Floor)650K (Land)




991

189

30

110

ISO-/QS -9000,ISO-14001


OEM PROGRAM

Toyota

Honda

Dainhatsu

HinoSuzuki (Indonesia)

Auto Alliance Thailand

Siam Nissan (Thailand)

Over 30 Models for TanksOver 40 Models for Filler Pipes

1 Model for Tanks1 Model for Tank (Indonesia)

2 Models for Filler Pipes

1 Model for Tanks and Filler Pipes1 Model for Tanks and Filler Pipes




Fuel Tanks

Hirota Plant

Miyoshi Plant

Tahara Plant

Asnohorie Thailand (Plant)

Asnohorie Indonesia (Plant)

A. Plukdaeng, Rayong,Thailand

Lemanhabang, Bekasi,Indonesia

90K (Floor)3300K (Land) 328

60K (Floor)150K (Land) 195

QS-9000ISO-9001

ISO-14001

Fuel Filler Pipes

Fuel Doors

Blanking, Slitting

Tank Straps

Plastic Components

Pump Units

Hirota, Tahara, Indonesia, Thailand

Miyoshi

Main

Hirota

Main

Hirota, Tahara

Main, Tahara, Hirota, Indonesia, Thailand

Martinrea International Inc.

A global leader in the production of quality fluid management systems, metal parts,assemblies and modules, Martinrea International Inc. is a Tier-1 automotive supplier andsupplier to other industrial sectors. Recognized for innovation in engineering solutions andthought-leadership in technologically-advanced product development and manufacturing,Martinrea’s expertise includes: fluid handling; metal forming including hydroforming,stampings, welded assemblies and multi-axis laser cutting; prototyping; and tooling.

Functional areas include fuel systems, structural & occupant safety, engine and transmission components, powersteering and brake components, and HVAC and exhaust components. As of January 2004, the company employedover 3000 people at 17 divisions in Canada, the United States, Mexico and Europe. Martinrea International Inc. isa public company with its common shares trading on the Toronto Stock Exchange under the trading symbol

“MRE.”

HEADQUARTERS30 Aviva Park DriveVaughan, OntarioCanada L4L 9C7Phone: (416) 749-0314www.martinrea.com

CONTACTRay SheffieldDirector, Fuel Tanks2319 Bishop Circle EastDexter, Michigan 48130Tel: (734) 426-4376Email: [email protected]




Technical Centers and Laboratories Troy, MI; Dexter, MI; Mississauga, ON;Lincoln Park, MI; Basildon, UK

Mississauga, ON (2 locations);Brampton, ON; St. Mary's, ON;Dexter, MI; Reed City, MI; Clare, MI;North Vernon, IN; Saltillo, Coahuila,Mexico; Hermosillo, Sonora, Mexico;Born, Netherlands; Essex, UK

75,000+

800,000+

Fluid Handling (Fuel, Vapor, Brake Tubing,Hoses and Assemblies; Fuel FillerAssemblies; Fuel Tank Assemblies;Transmission & Engine Oil Cooler Linesand Assemblies; Heater Inlet/OutletAssemblies; Air Conditioning Lines)

Metal Forming (Stamping, Hydroforming,Frames, Structural/Occupant Safety,Exhaust Components)

Vaughan, ON; Brampton, ON;Markham, ON; Corydon, IN

450,000+

- 15 -- 14 -



FUNCTION

Product Engineering

Product Design

Design Software- CATIA- Ideas

Program Management


CAE

Martinrea recently established a highly-automated fuel tank assembly facility in Hermosillo, Sonora, Mexico. This facilityfeatures the first Soudronic CONTOUR 2 welding cell in North America, as well as 100% helium leak detection forPZEV emissions compliance, enabling Martinrea to produce steel fuel tanks with unmatched flexibility and quality. At fullvolume, the plant will produce approximately 400,000 fuel tank assemblies per year, with provisions for expansion asnecessary.

Martinrea’s capability to design, develop, test, and manufacture complete near-zero emissions fuel systems is unmatched.With in-house design and testing expertise, program management, and manufacturing capabilities for Fuel Fillers, Fuel/Vapor/Brake Bundles and Fuel Tank Assemblies, Martinrea can deliver complete system solutions from concept tocustomer.



OEM PROGRAM

Ford

Fuel, Vapor, Brake LineAssemblies and BundlesFuel Filler AssembliesFuel Tank Assemblies

FULL SERVICE SUPPLIER CAPABILITIESDESCRIPTION

Product Engineering

Product Design

Design Software - CATIA (v.4 and v.5), I-Deas, Unigraphics

Program Management

Project Testing & Validation

CAE - Nastran (NX v3), LS-Dyna 3D, HyperMesh, LS-POST; Linear, Non-Linear, Dynamic, Optimization, Crashworthiness, Metal Forming AnalysisFuel Filler Assemblies

Fuel, Vapor, Brake Line Assemblies and Bundles

8

8

2

GeneralMotors

Fuel, Vapor, Brake LineAssemblies and BundlesFuel Filler Assemblies

17

1

Daimler-Chrysler

Fuel, Vapor, Brake LineAssemblies and BundlesFuel Filler Assemblies

1

8

NUMBER OFPROGRAMS

Metalsa

Metalsa, Mexico, together with its partner Tower Automotive is a leading global designer andmanufacturer of a broad range of structural components, assemblies and modules, many ofwhich are critical to the vehicle’s structural integrity. Metalsa and Tower Automotive are thelargest independent, global suppliers of stamped, formed, and welded components andassemblies. As a worldwide leader with over 12,000 colleagues in more than 15 countries,Tower Automotive is headquartered in Novi, Michigan with technical centers located inmetropolitan Detroit, Europe and Asia. With these building blocks, Tower Automotive hascreated a value-based and safety-focused company uniquely positioned to meet the needs and

challenges of their global automotive customers. From its San Luis Potosi plant, Metalsa provides the US and Mexicoautomotive industry with upper body structural stampings and metal fuel systems for passenger cars and light trucks.This Strategic Business Unit provides customers with specialized attention, point-of-use logistics services, productdesign and validation, and prototype fabrication.

HEADQUARTERSMetalsaCarretera Miguel Aleman Km 16.5Apodaca, Nuevo LeonMexico 66600Phone: +52 (81) 8369-7400www.metalsa.com.mxCONTACT IN USAAbraham TijerinaInnovation and Technology DirectorPhone: (248) 374-5046Cell: (248) 961-5000Fax: (248) 374-5049E-Mail: [email protected]




Number ofEmployees


Plant and HQ Apodaca, N.L., Mexico

San Luis Potosi, SLPMexico

Roanoke, Virginia

Novi, Michigan

340,000

170,000

200,000


2402

514

241

5

QS-9000,ISO-14001


Steel Fuel Tank Modules

Plant

Plant

Sales Office

Sales Office Cincinnati, Ohio 90K (Floor)3300K (Land)

1

TS -16949ISO-14001

VDA6.1

Upper Body Structures

Control Arms

Light Truck Chassis Frames

Engine Cradles

Rear Axles

Heavy Truck Siderails

SLP

Apodaca

Apodaca

Apodaca

Apodaca / Roanoke

Apodaca / SLP

SLP

QS-9000ISO-14000

CURRENT FUEL SYSTEM BUSINESSOEM PROGRAM ANNUAL VOLUME

Nissan

Nissan

Nissan

Nissan

GM

Ford

Ford

Ford

HS

TKGS

D21

S-CAR

P96

P131

F53

99 - 170,000/yr

03 - 40,000/yr90 - 80,000/yr

90 - 40,000/yr

95 - 80,000/yr

97 - 15,000/yr

97 - 15,000/yr

98 - 10,000/yr

FULL SERVICE SUPPLIER CAPABILITIESFUNCTION QUANTITY

Product Engineering

Product Design

Design Software- CATIA- Ideas- Unigraphics

Program Management


CAE

10

25

11

7

8

OTHER DESIGN SOFTWARE

Pro-Engineer CAE Software: Hypermesh, ANSA, Nastran,Optistruc, Hyperform, LS-Dyna, ADAMS

Spectra Premium Industries

Innovative and future-oriented, Spectra Premium Industries, Inc. (SPI), is a leading manufac-turer of steel fuel tank systems, aluminum radiators and high-pressure die cast mangnesiumalloy parts.

SPI is a Tier-1 full service supplier to the automotive industry for the manufacture of steel fueltank systems. They are experienced in the design, engineering, and validation of fuel systems

to meet today's stringent emission standards.

With a low-cost flexible manufacturing system and an integrated tool and die manufacturing facility, SPI offers itscustomers superior products and the best possible quality/price ratio.

HEADQUARTERSSpectra Premium Industries1421 Ampere StreetBoucherville, QuebecCanada J4V 5Z5Phone: (450) 641-3090www.spectrapremium.comCONTACTMark ChurchDirector - Fuel System ProgramsPhone: (519) 977-7013Cell: (514) 918-1366E-Mail: [email protected]: (519) 258-9461


Facility Type City, State, Province, Country Facility Size(Sq. Ft)

Number ofEmployees


Plant Boucherville, QuebecCanada

Debert, Nova ScotiaCanada

Laval, QuebecCanada

Haley, OntarioCanada

450,000

125,000

170,000

89,000

600

75

250

90

ISO-9001,QS-9000,ISO-14001


OEM PROGRAM MODELYEAR - RANGE

General Motors

General Motors

Bombardier

Service Parts

GMX281

Spyder

2004 - 2006

2007 - 2009

PRODUCT AND SERVICES

PRODUCT / SERVICES PLANT

Fuel System

Plant

Plant

Plant

Technical Center Windsor, OntarioCanada 10

Radiators

Radiator Components Debert

Laval/Stratford

ISO-9001,ISO-14001

ISO-9001,ISO-14001

QS-9000

Boucherville

--

--

Yes

----

- 17 -- 16 -


--


SPI has in-house tooling capabilities enabling the rapiddevelopment of prototype and production parts.

SPI has developed a flexible automated production linecapable of producing low volume and high volume productionwith enhanced permanent controls.

SPI is a Tier-1 full service supplier and offers completeproduct design, engineering, development and validationtesting services.


FUNCTION

Product Engineering

Product Design

Design Software- CATIA- Ideas- Unigraphics

Program Management


CAE


Low Carbon Steel (LCS) and High-Strength Steel (HSS)Stamping; Hydroforming, Roll Forming, Heat Treat-ment, Laser Cutting, Sequencing Centers, ELPO, Waxand Water Base Coating.

Boisbriand, QuebecCanada 90,000 70Plant TS-16949

DaimlerChryslerJS AWDJS PZEVJC PZEV

2007 - 20112008 - 20102008 - 2011

Die-Cast MagnesiumComponents Haley/Boisbriand

Unipres Corporation

With more than 50 years of involvement with stamping technology, UnipresCorporation has continued to build upon and refine its technical expertise. In thosefew decades, passenger car design, including car body structures and transmissions,has evolved with remarkable speed. Technologies developed exclusively by Unipreshave provided the background to the realization of high-quality components capable of

ever better performance. The history of Unipres’ technology is a history of constant exploration on the cuttingedge of the field, with new challenges being met and mastered. When you discover even a small part of thathistory, Unipres believes your concepts of press technology will be changed forever.

Unipart Eberspacher

Unipart Eberspächer is a 50/50 joint venture company, founded in 1998,between the Unipart Group of Companies (UGC), one of the UK's top 20private companies and Eberspächer GmbH, the world’s fourth largestmanufacturer of exhaust systems with a global network of manufacturing sites

supporting the automotive industry.

Unipart Eberspächer is based in Coventry, UK manufacturing steel fuel tanks, exhaust systems, catalyticconverters and fabricated manifolds with a full service supplier capability including design, development testing,and validation,and program management through to volume production.

HEADQUARTERSUnipart Eberspacher Exhaust SystemsBeresford AvenueCoventry, UK CV6 5LZPhone: +44 (0) 2476 638663www.uees.co.ukCONTACTGeoff Morris - Sales ManagerPhone: +44 (0) 2476 835029E-Mail: [email protected]

Phil North - Design EngineeringPhone: +44 (0) 2476 835024E-Mail: [email protected]



Number ofEmployees


Design and Development(Fuels) Coventry, UK

Coventry, UK

UK, Germany, USA

Global

20

280

300

2,000

TS-16949

TS-16949

TS-16949ISO-9000

TS-16949ISO-9000



Aston Martin

Aston Martin

Aston Martin

Bentley

Jaguar

Vanquish

DB9

V8 Vantage

Arnarge

XK8

2002

2004

2005

2006

2004


Steel fuel tanks / design,development & manufacture

Exhaust systems (inc.catalysts, manifolds and

DPF’s) design, developmentand manufacture

Coventry, UK

Germany, UK and otherglobal locations

Manufacturing

Design and Development(Exhausts)

Manufacturing

HEADQUARTERSUnipres Corporation1-19-20 Shin-YokohamaKohoku-ward, Yokohama City,Kanagawa Prefecture, Japan 222-8581Phone: +81-45-470-8250www.unipres.co.jp

CONTACTHirohumi KondoDeputy General ManagerPhone: +81 545-62-5060Fax: +81 545-62-5125E-Mail: [email protected]




Number ofEmployees


Plant for Body Parts andFuel Tank

Tochigi City,Tochigi Pref.Japan

351,300

24,600

262,300

377,100

233

140

191

587

ISO-9001ISO-14001



Nissan

Nissan

Nissan

Nissan

Nissan

Nissan

Nissan

SKYLINE/Infinity G35

STAGEA

FAIRLADY Z/350Z

Infinity FX45

FUGA/Infinity M45

CIMA/Infinity Q45

SERENA

Since 2002

Since 2002

Since 2002

Since 2004

Since 2001

Since 2003

Since 2005


Nissan Maxima Tochigi Plant


FUNCTION

Product Engineering

Product Design


Program Management


CAE

Engineering Center

Plant for Body Parts

Plant for Body Parts

90,600 126Plant for Body Parts

Fuji City,Shizuoka Pref. Japan

Oyama City, TochigiPref. Japan

Yamato City, KanagawaPref. Japan

Yokosuka City,Kanagawa Pref. Japan

ISO-9001ISO-14001

ISO-9001ISO-14001

ISO-9001ISO-14001

ISO-9001ISO-14001

Nissan Sunny Tochigi Plant

Nissan Presage Tochigi Plant

- 19 -- 18 -



FUNCTION

Product Engineering

Product Design


Program Management


CAE

Unipart Eberspächer is currently installing a new hightechnology steel fuel tank manufacturing cell into itsCoventry UK factory. This will produce complex saddle-shaped stainless steel tanks and include state-of-the-artwelding on a Soudronic CONTOUR 2 seamwelder supportedby a new helium leak test facility.


..

Comau Pico is the innovative leader in industrial automation. As a member of the Comau GroupComau Pico is part of the largest full-service automotive supplier in the world. With over 50years of experience in automated assembly tooling, Comau Pico offers an unparalleled range ofproducts and services to the North American market. Using the latest technology Comau Picodelivers complete turnkey systems that meet and exceed the design and manufacturing needs ofits customers.

Since 1903, Harley-Davidson has produced the most enduring and recognizablemotorcycles in the world. No other motorcycle has the look, the sound and the

feel of their two-wheeled pieces of art. The motorcycle defines Harley-Davidson, but a wide range of otherproducts and services is available to increase the enjoyment of the experience or give newcomers a taste of ourworld.

Harley-Davidson, Inc. employs some 8,000 people worldwide. Corporate headquarters are in Milwaukee,Wisconsin. The company's domestic production facilities are located in the Milwaukee area, East Troy andTomahawk, Wisconsin; York, Pennsylvania and Kansas City, Missouri. Other key business operations are located inChicago, Illinois; Franklin, Wisconsin; Talladega, Alabama; Highland Heights, Ohio; Ann Arbor, Michigan; CarsonCity, Nevada and Plano, Texas. Harley-Davidson also maintains operations in strategic international markets,including throughout the continent of Europe, Brazil, and Japan, to support its worldwide dealer and distributornetwork.

ITT Industries, Inc. is a global engineering and manufacturingcompany with leading positions in the markets it serves, generating2003 sales of $5.63 billion. ITT Industries is the world's premiersupplier of pumps, systems and services to move, control and treat

water and other fluids. The company is a major supplier of sophisticated military defense systems, and providesadvanced technical and operational services to a broad range of government agencies. ITT Industries alsoproduces connectors, switches, keypads and cabling used in telecommunications, computing, aerospace andindustrial applications, as well as network services. Further, ITT Industries makes industrial components for anumber of other markets, including transportation, construction and aerospace. Based in White Plains, NewYork, ITT Industries employs approximately 39,000 people around the world.

Founded in 1974, The Magni Group has become America's fastestgrowing coating company. With customers on five continents, the

company's primary business is extending the customer's product life by eliminating corrosion. In addition tocorrosion control, Magni coatings also provide lubricity and conductivity, which can improve productperformance. Magni develops, manufactures, and applies protective coating systems for a wide variety of metalproducts. Magni manufactures both solvent and waterborne liquid coatings used for rust prevention on metalsurfaces. These coatings are sold to a great variety of industrial manufacturers including coil coaters. Theautomobile industry is the primary market for Magni Group's products. In addition to selling coatings, the groupalso applies the coatings to automobile parts and fasteners.

Strategic Partners

Soudronic automotive supports the automotive industry's efforts toproduce lighter, safer and better cars. By offering superior weldingsolutions for the manufacture of fuel tanks, tailored and tubular blanks,

patchworks and other demanding parts, the company works in close cooperation with many of the world'sleading steel converters and car manufacturers. The vast majority of the 40 million cars produced annually featurea growing number of tailored blanks. More and more car bodies are built with tailored blanks in combinationwith hydroformed steel parts made of tubular blanks. The installed base of their welding systems produce severalmillion tailored blanks, fuel tanks and tens of thousands of tubular blanks per year. Services offered include:service and maintenance, prototyping, back-up production, sampling/demonstration, system engineering,project management, training, and spare parts. The latest activity added to the project family is quality controlsystems for laser and arc welding.

Associate Members

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