National University of Science and Technology

School for Chemical and Materials Engineering

Open Ended Lab 01

Class: ME-13
Date: 21st April 2023
Group: 01

Name Registration no.

Fiza Khan 333804

Hina Mukhtar 339291

Minahil Saif 331464

Nimra Amanullah 331529

Ramsha Durrani 342997

Safa Shahid 335337

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 Open Ended Lab for Lab IV

1. Title: To improve the production process, quality, safety, and life of the product

2. Problem Statement:

A leading automotive manufacturer was experiencing corrosion-related

problems in its production facility. The company used steel for various
components, including brake parts, suspension systems, and exhaust systems.
However, the production process involved exposure to moisture, salt, and other
corrosive agents, which led to premature corrosion and rusting of the
components. This not only affected the quality and appearance of the products
but also increased the risk of failure and safety issues.
Now the company wants us to come up with suitable proposals to improve the
production process, quality, safety, and life of the product. Write a proposal
justifying your ideas keeping in mind the given work conditions.

3. Abstract:
Due to the enormous influence, it has on the functionality, safety, and lifetime of
vehicles, corrosion resistance is of highest significance in the automotive industry. The
structural integrity and functioning of vehicle parts can be compromised by corrosion,
which can result in expensive repairs or premature replacement. To ensure the
dependability and durability of their goods, car manufacturers prioritize corrosion
resistance throughout the manufacturing process.

4. Introduction:
The body and chassis are a significant area where corrosion resistance is crucial in
automobile applications. Environmental factors that affect vehicle bodywork include
exposure to moisture, road salts, chemicals, and bad weather. The body panels, frame,
and other structural elements can sustain significant damage from corrosion,
jeopardizing the vehicle's overall safety and appearance. Automotive manufacturers can
improve the durability and aesthetics of the car by using corrosion-resistant materials
like galvanized or coated steel, aluminum alloys, or sophisticated composites.

The drivetrain and engine systems are another significant area where corrosion
resistance is essential. High temperatures, vibration, and harsh chemicals, such fuels and
lubricants, are all present in this equipment. These systems are susceptible to
catastrophic breakdowns due to corrosion, which can also affect fuel efficiency and
engine performance. Automotive manufacturers may guarantee the dependability and

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 effectiveness of these vital systems by using corrosion-resistant components, coatings,
and treatments.
Additionally, corrosion resistance is essential for electrical and electronic systems in
automobiles. Electrical connections can be damaged by corrosion, which can result in
faulty lights, sensors, control modules, and communication networks, among other
vehicle systems. Automakers may reduce electrical failures and preserve these systems'
correct operation by using corrosion-resistant connections, coatings, and preventative
measures.

5. Methodology:
 Material selection: When producing your product, use materials that are resistant
to corrosion. Use coatings or metals with excellent corrosion resistance in the
environment to which the product will be subjected. Do extensive study on
material qualities, and if necessary, confer with material engineers.

 Considerations for Design: Include elements in the design that reduce the
possibility of corrosion. Avoid regions with angular edges, cracks, and places
where moisture can collect. To avoid moisture traps, make sure there is enough
drainage and ventilation. In locations that need protection, take into account
coatings or linings.

 Before applying protective coatings or treatments, be sure the surface has been
properly prepared. Use methods like abrasive blasting, acid cleaning, or
mechanical cleaning to remove any impurities, oxides, or rust from the surface.

6. Implications of using steel for brake parts and suspension systems

 Weight: Compared to certain substitute materials, such as aluminum or carbon

fiber composites, steel is comparatively heavier. This may have an impact on the
fuel economy and total weight of the vehicle, both of which are becoming more
crucial for achieving rigorous emission regulations and enhancing energy
efficiency.

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  Steel may be quite robust, but if it is not properly maintained, it might succumb to
rust. Automobiles are subjected to a variety of environmental factors, such as
moisture, salt from the road, and chemicals, all of which can cause rust and
corrosion.

 Design Flexibility: Steel is suited for a variety of automotive applications due to

its formability and structural integrity. Comparatively to materials like aluminum
or composites, which give greater design freedom, it could be more difficult to
create detailed and sophisticated designs.

 Weight reduction is essential to maximizing range in electric vehicles (EVs),

which are becoming more and more popular. To make up for the extra weight of
batteries, several automakers choose lighter materials like composites or
aluminum. Advanced high-strength steels, which offer structural support and
crashworthiness, can still play a vital role in EVs.

7. Technique Proposals:
 Protective Coatings: Apply appropriate protective coatings to the product
surfaces. Consider using coatings such as paints, enamels, powder coatings, or
specialized corrosion-resistant coatings like galvanizing, electroplating,
anodizing, or metallizing. Follow recommended application procedures and
quality control measures during the coating process.

 Corrosion Inhibitors: Implement corrosion inhibitors into the production

process. These substances can be added to coatings, fluids, or materials to
mitigate corrosion. Corrosion inhibitors work by forming a protective layer on the
metal surface, inhibiting the electrochemical reactions that cause corrosion.

 Quality Control and Testing: Establish strict quality control procedures to

identify any defects or vulnerabilities during the production process. Conduct
regular inspections, including visual inspections, non-destructive testing, or
laboratory analysis to detect early signs of corrosion or coating degradation.
Implement standardized testing methods to ensure the quality and longevity of the
product.

 Maintenance and Monitoring: Develop a comprehensive maintenance plan to

monitor the product's condition and implement preventive measures. Regularly
inspect the product for signs of corrosion or coating failure. Implement a
corrosion management system that includes corrosion rate monitoring, cathodic
protection (if applicable), and scheduled maintenance activities to address any
emerging issues promptly.

 Employee Training and Safety: Provide training to employees involved in the

production process on corrosion prevention and safety practices. Emphasize the
importance of handling materials properly, implementing appropriate safety

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 measures, and following standard operating procedures to reduce the risk of
accidents and product damage.

 Environmental Considerations: Consider the product's exposure to

environmental factors, such as temperature, humidity, chemicals, or pollutants.
Evaluate the potential impact of these factors on corrosion and incorporate
appropriate preventive measures into the production process.

 Customer Education: Educate customers on proper product handling, storage,

and maintenance to ensure the product's longevity. Provide guidelines and
recommendations for cleaning, storage conditions, and suitable environments to
minimize the risk of corrosion.

8. Results:

Implementing Aluminum Alloys and above proposals:

Aluminum alloys are substantially lighter than conventional cast iron or steel
components in terms of weight. The braking and suspension systems' total weight can be
decreased by swapping out heavier components with aluminum. By reducing weight, a
vehicle's fuel economy, handling, and wear on other parts are all enhanced.

Enhanced Performance: Compared to cast iron or steel, aluminum alloys are more
effective in dissipating heat because of their superior thermal conductivity. This
characteristic is particularly helpful for brake systems as too much heat might result in
brake fade or poor braking performance.

Aluminum alloys have a natural resistance to corrosion, especially when compared to

cast iron or steel. By extending the lifespan of brake and suspension parts, this corrosion
resistance lowers maintenance and replacement expenses.

Reduced Unspring Mass: The weight of parts not supported by the suspension system,
such as wheels, tires, and brake parts, is referred to as unsprung mass. The unsprung
mass is decreased by using lighter aluminum alloys in the braking and suspension
components. This decrease enhances the vehicle's suspension responsiveness, which
enhances handling, stability, and ride comfort.

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9. Discussion:

The usage of aluminum alloys in braking and suspension systems supports

environmental objectives including lowering vehicle emissions and enhancing fuel
economy. Aluminum components are lighter than steel, which results in less energy
being used to accelerate and decelerate the vehicle. Aluminum alloys are also recyclable,
which makes them more ecologically friendly and sustainable.

It's crucial to remember that the selection of materials for brake and suspension systems
is influenced by several variables, including performance needs, economic concerns, and
statutory restrictions. Despite the many advantages of aluminum alloys, they may have
certain drawbacks, such as greater manufacturing costs or a need for additional materials
in some applications.
Therefore, a comprehensive evaluation of the specific requirements and trade-offs is
necessary when selecting materials for these critical automotive systems.

10.Conclusion: To maintain the security, dependability, and lifetime of vehicles,

corrosion resistance is crucial in the automotive sector. Automotive manufacturers may
lessen the negative impacts of corrosion and improve the overall quality and
performance of their products by using corrosion-resistant materials, coatings, design
elements, and maintenance procedures.

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 It's crucial to keep in mind that while producing cars, a variety of elements, including
cost, performance, safety, and environmental concerns, are often traded off. Steel is still a
preferred material because of its superior strength, low cost, and established production
infrastructure. However, as manufacturers work to optimize their cars for needs,
developments in alternative materials and production methods continue to widen the
variety of possibilities open to them.

11.References:

 https://autoprotoway.com/aluminum-car-parts-guide/
 https://www.metalsupermarkets.com/aluminum-and-the-auto-industry/
 https://www.shapesbyhydro.com/en/manufacturing/why-aluminium-is-the-right-
material-for-external-car-parts/
 https://www.aluminiumleader.com/application/transport/
 https://titussteel.com/what-causes-steel-corrosion/#:~:text=The%20corrosion%20of
%20steel%20is,volume%20of%20the%20original%20steel.
 https://www.corrosionpedia.com/definition/217/steel-corrosion
 https://steelfabservices.com.au/steel-corrosion-the-basics/
 https://www.investopedia.com/ask/answers/062315/what-types-raw-materials-would-
be-used-auto-manufacturer.asp

THANK YOU