GROUP 8 PRESENTATION

CORROSION IN
AUTOMOBILE INDUSTRY
24TH OCTOBER, 2018.
GROUP MEMBERS
• KOMOLAFE TIMILEYIN 15CF02631
• ADIMEKWE EBUKA 14CF017084
• AMODU EMMANUEL 15CF02578
• TIJANEE SAMUEL 15CF02673
• ODIETE ARETHA 15CF02647
• ORJIAKOR CHINAZA 14CF017153
• ONOVUGHAKFOR TEGA 14CF017151
• SAM FIEFAMOKUMA 14CF017158
• OSHINAIKE FEMI 14CF017155
 A NON CORRODED VS CORRODED
AUTOMOBILE
What Is Corrosion?
Corrosion can be defined as a chemical or
electrochemical reaction between a
material, usually a metal, and its environment that
produces deterioration
and alteration of the material and its properties.
 INTRODUCTION TO AUTOMOBILE CORROSION

History of Corrosion in the automobile industry

• Before the 1950’s, automobile owners reported no evidence of
corrosion related problems. The first signs of automobile corrosion
appeared on the year 1955. As the years pass by, localized corrosion
of 430 stainless steel (1960), Galvanic corrosion (1965), Body
perforation (1970), Corrosion of anodized aluminum (1980), and
reports of 434 stainless steel marginal performance (1985) were all
gradually recorded. By the year 1990’s, regular reports of body
perforation has already evolved to become a major problem in the
automobile industry.
• The automotive industry refers to the range of companies involved in
the design, manufacture and marketing of motor vehicles.
• As at 2016, about 9 million vehicles were produced and the rate of
production is only increasing according to the Organisation
Internationales des Constructeurs d’Automobiles (OICA).
• Due to the quantity, trillions of dollars are spent trying to prevent or
manage corrosion. As such, corrosion cannot be overlooked in this
industry.
• The presentation considers the most common forms of corrosion
encountered as well as preventive measures that can be taken.
• Automobiles usually have the frame (chassis) made from alloys which
usually contain considerable amounts of iron. To be more specific, the
metals usually found are:
• Steel for the body
• Light Aluminium
• Copper for wiring
• Lead for balance
• Platinum for lustre
Types of Corrosion that Occurs in the
Automobile Industry
• Due to the large amounts of steel, iron corrosion (formation of rust) is
the most common form of corrosion encountered in the industry
according to Nerikar (2015).
• Generally, the corrosion is caused by the oxidation of the metal to
achieve the ore or ground state of the metal. This process is engaged
due to the environmental conditions such as the presence of moisture
or abundance of oxygen or the electrolytic conditions surrounding the
metals.
• This is most common in the engines, frames and exhaust pipes of
vehicles
 Atmospheric Corrosion
• When any metal surface of an automobile comes into contact with air containing some
moisture, atmospheric corrosion can occur. A thin (micron-scale) film of moisture deposited under
nonzero humidity conditions is sufficient to cause the gradual decay of iron and steel surfaces,
producing iron oxide, or rust. This in turn impairs the mechanical integrity and reduces the
lifespan of the metal. The thickness of the film depends on factors such as ambient temperature
and pressure, relative humidity, and the presence of salts.
Crevice Corrosion

• Crevice corrosion refers to electrochemical processes that occur in confined spaces such as

gaskets, seals, flanges, and spaces filled with deposits. This type of corrosion is a localized form of
attack due to the presence of a stagnant solution or an electrolyte. It is difficult to detect and can
lead to sudden failure through a phenomenon known as stress corrosion cracking.
Common Areas of corrosion in automobiles
 WAYS TO PREVENT CORROSION IN
AUTOMOBILE INDUSTRY
• DESIGN
• Corrosion control begins at the engineering stage. If the part is for use in an environment where it
is susceptible to corrosion, manufacturers should design the part with that in mind. 
• For example, parts exposed to the elements should allow water and debris to drain off instead of
collecting on the surface. To reduce crevice corrosion, designers should eliminate narrow gaps
that allow air or fluid to enter and become stagnant. For corrosive environments, such as in
saltwater, it may be wise to engineer for a degree of corrosion allowance.
Protective Coating
• Coatings can provide a layer of protection against corrosion by acting as a physical barrier
between the metal parts and oxidizing elements in the environment. One common method is
galvanization, in which manufacturers coat the part with a thin layer of zinc. 
• Powder coatings are another effective way to prevent corrosion in metal parts. With proper
application, a powder coating can seal the surface of the part away from the environment to
guard against corrosion.
Maintenance

•  Protective coatings, environmental control, and cathodic protection are effective ways of
preventing corrosion in metal parts. However, these measures are nothing without ongoing
maintenance and monitoring. Coatings can wear over time; even small nicks and scratches can
lead to corrosion. Be sure to keep parts clean and apply additional protection as necessary.
Cathodic Protection

• It is possible to prevent corrosion by applying an opposing electrical current to the metal’s

surface. One method of cathodic protection is an impressed current, using an outside course of
electrical current to overpower a corrosive current in the part.
• A less-complex method of cathodic corrosion protection is the use of a sacrificial anode. This
involves attaching a small, reactive metal to the part you wish to protect. Metal ions will flow
from the reactive metal to the less active part, reducing corrosion at the expense of the smaller
piece.
Vehicle Coating
• Many of the coatings used to prevent or slow corrosion can have
specific vulnerabilities.
• The existence of anodic and cathodic sites on the surface of vehicle
body implies that differences in electrical potential are found on the
surface. These potential differences have a number of causes.
• One important mechanism is oxygen concentration cell corrosion, in
which the oxygen concentration in the electrolyte varies from place to
place.
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