Automotive Corrosion Research Articles

Corrosion Simulations for Automotive Applications

Digitisation is making huge progress, and it is not stopping at automotive corrosion either. Within the entire automotive material life cycle, computer-aided approaches can already assist corrosion engineering and management today. From constructive corrosion protection on galvanically active hybrid constructions to the virtual design of active or passive corrosion protection systems, everything is possible. We are already very close to the goal of a continuous and realisable digital corrosion twin, but the complete integration into existing value chains is far from complete. This article provides an insight into current research and development and discusses the bottlenecks that still exist. The role of data or data collection and the smart combination of data- and physics-based modelling approaches are discussed. The possibilities and scope of applications of artificial intelligence methods for automotive corrosion topics are addressed. Concrete application scenarios are outlined by using examples, and the next work steps are derived.

<i>In-Situ</i> Observation of Initial Stage Cosmetic Corrosion Behavior under Wet and Dry Conditions

It is well known that the types of automotive corrosion can be divided into perforation corrosion and cosmetic corrosion. Although the mechanism of perforation corrosion has been studied extensively, the mechanism of cosmetic corrosion has not yet been clarified. The authors investigated the cosmetic corrosion behavior of cold-rolled steel sheets without galvanizing with an in-situ observation device. After coating the samples by cathodic electrodeposition (ED), the sample surface was scribed with a cutter. Corrosion resistance was evaluated under cyclic corrosion test. It was found that the progress of under-film corrosion consisted of 3 steps. The 1st step occurs in the initial stage of the dry process in the 1st cycle. In this step, red rust gradually changed to black rust. The 2nd step occurs in the latter stage of the dry process, and under-film corrosion progressed from the scribed part. The 3rd step occurs in the wet process, and in this step, the tip of the under-film corrosion displayed swelling behavior. In the 2nd cycle, the 2nd step and 3rd step of the 1st cycle were repeated. Under-film corrosion progressed at almost the same rate as in the 1st cycle.

Automotive Corrosion and Accelerated Corrosion Tests for Zinc Coated Steels

Automotive Corrosion and Accelerated Corrosion Tests for Zinc Coated Steels

Eurocorr 2012: ‘Safer world through better corrosion control’ - part 2

The 2012 Eurocorr meeting was held at the Sheraton Maslak hotel in Istanbul from 9–13th September 2012. The focus of the meeting was ‘Safer world through better corrosion control’. The meeting attracted over 650 delegates and over 360 oral presentations and 125 posters were presented during the 27 sessions and workshops. Part 1 reviewed opening and plenary lectures and technical sessions on corrosion and scale inhibition, corrosion by hot gases and combustion products and coatings. Parts 2–5 will review the remaining technical sessions with; high temperature coatings, mechanisms of environmentally assisted cracking, mechanisms and methods, microbial corrosion, automotive corrosion and corrosion of archaeological and historic artefacts covered in this report.

Surface and Coating Analysis of Press‐Hardened Hot‐Dip Galvanized Steel Sheet

AbstractThe use of continuous galvanized steel sheet as feedstock material for press hardening leads to components of very high strength levels with classical cathodic corrosion protection. The present work provides an insight into this technology with special focus on surface oxidation and intermetallic phase formation during the austenisation process. For that reason hot dipped galvanized 22MnB5 steel sheets, with a blank thickness of 1.5 mm and an average coating weight of 70 g m−2, were annealed in a temperature range of 400–900°C in steps of 50°C without soaking before quenching in water. Surface and cross‐cuts were analyzed by SEM, EDX, and XRD to illustrate the phase formation and the surface changes during thermal treatment. Corrosion behavior was also studied based on electrochemical investigations and an accelerated, cyclic, automotive corrosion tests called VDA, which is a mixture of salt spray test and alternating climate test. It was found that austenisation of galvanized steel sheet causes a significant change of the coating. The generated coating still offers cathodic protection for the steel substrate and has higher corrosion resistance than standard galvanized steel sheet. Surface oxidation also occurs during the press hardening process leading to a surface covered with successively arranged layers of Al2O3 and ZnO, containing also further oxidized alloying elements.

Eurocorr 2009: 'Corrosion from the nanoscale to the plant' – part 5

Last year’s Eurocorr conference took place at the Acropolis Convention Centre in Nice from 6 to 10 September. The focus of the meeting was ‘Corrosion from the Nanoscale to the Plant’. The meeting attracted 800 delegates and over 360 papers and 200 posters were presented during the 25 sessions and workshops. Part 1 of the report, published in the December issue, covered the opening session and plenary lectures. Part 2, published in the February issue, reviewed technical sessions on automotive corrosion, corrosion of archaeological and heritage artefacts, organic coatings and cathodic protection and marine corrosion. Part 3, published in the April issue, reviewed technical sessions on inhibitors, oil and gas, polymeric materials, metallic and inorganic coatings and pretreatments. Part 4 published in the June issue reviewed corrosion and corrosion protection in drinking water systems, recent advances in surface analytical techniques and applications to corrosion research, simulation, modelling and life prediction, environmental sensitive fracture and corrosion mechanisms and methods. The fi nal part of the report reviews technical sessions on nuclear corrosion, including corrosion issues in future high temperature nuclear systems, microbial corrosion: biomolecules and biofi lms on surfaces – impact on the corrosion resistance and biotribocorrosion, corrosion by hot gases and combustion products, and corrosion of steel in concrete.

Eurocorr 2009: 'Corrosion from the nanoscale to the plant' – part 4

Last year’s Eurocorr conference took place at the Acropolis Convention Centre in Nice from 6 to 10 September. The focus of the meeting was ‘Corrosion from the Nanoscale to the Plant’. The meeting attracted 800 delegates and over 360 papers and 200 posters were presented during the 25 sessions and workshops. Part 1 of the report, published in the December issue, covered the opening session and plenary lectures. Part 2 of the report, published in the February issue, reviewed technical sessions on automotive corrosion, corrosion of archaeological and heritage artefacts, organic coatings and cathodic protection and marine corrosion. Part 3 of the report, published in the April issue, reviewed technical sessions on inhibitors, oil and gas, polymeric materials, metallic and inorganic coatings and pretreatments. Parts 4 and 5 will review the remaining technical sessions with corrosion and corrosion protection in drinking water systems, recent advances in surface analytical techniques and applications to corrosion research, simulation, modelling and life prediction, environmental sensitive fracture and corrosion mechanisms and methods covered in this report.

Eurocorr 2009: 'Corrosion from the nanoscale to the plant' – part 2

This year’s Eurocorr conference took place at the Acropolis Convention Centre in Nice from 6 to 10 September. The focus of the meeting was ‘Corrosion from the Nanoscale to the Plant’. The meeting attracted 800 delegates and over 360 papers and 200 posters were presented during the 25 sessions and workshops. Part 1 of the report, published in the December issue, covered the opening session and plenary lectures. Parts 2 – 5 will review the technical sessions over four issues with automotive corrosion , corrosion of archaeological and heritage artefacts, organic coatings and cathodic protection and marine corrosion covered in this report.

Development of an Improved Cosmetic Corrosion Test for Finished Aluminum Autobody Panels

A co-operative program initiated by the Automotive Aluminum Alliance and supported by USAMP continues to pursue the goal of establishing an in-laboratory cosmetic corrosion test for finished aluminum auto body panels that provides a good correlation with in-service performance. The program is organized as a task group within the SAE Automotive Corrosion and Protection (ACAP) Committee. Initially a large reservoir of test materials was established to provide a well-defined and consistent specimen supply for comparing test results. A series of laboratory procedures have been conducted on triplicate samples at separate labs in order to evaluate the reproducibility of the various lab tests. Exposures at OEM test tracks have also been conducted and results of the proving ground tests have been compared to the results in the laboratory tests. Outdoor tests and on-vehicle tests are also in progress. An optical imaging technique is being utilized for evaluation of the corrosion. This paper summarizes the analyses of the results from the laboratory tests and the OEM test track exposures.

錆解析による車体腐食評価方法の開発

錆解析による車体腐食評価方法の開発

Fuelling the debate on automotive corrosion: a view on a changing industry from Bundy

Legislation and consumer demand are two of the main driving froces behind the decision by vehicle manufacturers to look to their suppliers to carry out research and development work in the complex area of corrosion. With fluid carrying systems, like the brake lines, now expected to last the “life of the car” and with emissions from fuel lines needing to be contained to minimum levels, how are suppliers responding? Bundy, a world‐leader in automotive fluid carrying systems, is at the forefront of identifying solutions in this field. Claims that the results of the company's work are innovative solutions which meet environmental standards and higher quality systems which ultimately offer greater value for money to motorists. Looks in detail at some of the issues now facing the industry.

What is a “rust bucket”?

Examines the environmental cause and effects of automotive corrosion. Lists the four categories of this corrosion. Reports on British Steel's anti‐corrosive coatings, plus its Zodiac hot‐dip galvanizing line, Llanwern, and its electro‐galvanizing line, Shotton. Comments on R&D into coatings for strip products at British Steel's Welsh Laboratories, Port Talbot. Discusses under‐bonnet corrosion protection.

Behavior of Painted Steel and Aluminum Sheet in Laboratory Automotive Corrosion Tests

Abstract Cold-rolled steel, electrogalvanized steel (60 g/m2 coating), and three aluminum alloy sheet products (Al 2036, Al 5182, and Al 6111 [UNS A92036, A95182, and A96111, respectively]) were pa...

環境による構造物の劣化とその対策 自動車工業における環境汚染対策 （２） 融雪剤による錆劣化とその対策

環境による構造物の劣化とその対策 自動車工業における環境汚染対策 （２） 融雪剤による錆劣化とその対策

Environmental Engineering Within the Automotive Component Development Process

This paper discusses a test engineering philosophy and the development of knowledge-based tests for automotive components. To ensure success in the product delivery process, accurate measures of total product quality comprised of quality, reliability, durability, performance (QRDP) must be provided to the product development team. Accuracy in environmental testing for automotive components involves the integration of customer-usage, geographic, and application data into the test specifications. Discussion of the inputs required for knowledge-based tests are provided for the automotive vibration, thermal, corrosion, and dust environments.

自動車部品の腐食試験のための実験室的試験と実地暴露試験の相関性に関する研究

自動車部品の腐食試験のための実験室的試験と実地暴露試験の相関性に関する研究

Topic of the Month—Automotive Corrosion Resistance—Past and Present

Abstract The corrosion resistance of automobiles has increased in the past 30 years despite their exposure to generally more corrosive environments. Factors responsible for this longer life include the development of more durable materials, improved machining and surface finishing, and changes in over-all design. 8.9.2