corrosion in the car body

presented to: Prof. Gala Attia

Presented by: Fady Gamal
The case study
CONTENT

 Introduction.

 The Mechanism.

 Factors affecting.

 Prevention.
INTRODUCTION
Corrosion is a significant concern in the automotive
industry, particularly when it comes to the car body.
The car body's coating serves as a protective barrier
against environmental factors that can lead to
corrosion, such as moisture, oxygen, and
contaminants.
However, when the coating is intentionally or
unintentionally removed, it exposes the underlying
metal surface to these corrosive elements, increasing
the risk of corrosion.
INTRODUCTION
Once the coating is removed, different types of
corrosion can occur, such as surface corrosion
(Rust), crevice corrosion, or under coating
corrosion.
Surface corrosion can manifest as discoloration,
roughness, or the formation of small patches of rust.
Crevice corrosion can develop in gaps or crevices
where moisture and contaminants collect, accelerating
localized corrosion.
Under coating corrosion may develop beneath intact
coatings due to moisture penetration along the
exposed metal surface.
The mechanisms

Surface corrosion

Crevice corrosion

Under coating corrosion

 The surface corrosion

• The protective coating on the car body is scratched or damaged, exposing the bare metal surface.
• Moisture, oxygen, and contaminants in the environment meet the exposed metal surface.
• An electrochemical reaction takes place, where moisture acts as an electrolyte and forms an electrolytic
solution on the metal surface.
• This leads to the flow of electrons, with metal atoms losing electrons and forming metal ions (oxidation),
while oxygen or other substances gain electrons (reduction).
• The metal ions combine with oxygen from the air, forming metal oxides or hydroxides, commonly known as
rust.
• The accumulation of rust results in discoloration, roughness, or the formation of small patches of corrosion on
the metal surface.
The surface corrosion mechanism
 The Crevice corrosion

• The removal of the coating creates gaps, crevices, or tight spaces between the car body and other components
or within the body structure itself.
• Moisture and contaminants, such as dirt or road debris, can accumulate in these crevices, creating a localized
and stagnant environment.
• The restricted airflow and trapped moisture create a corrosive microenvironment.
• Electrochemical reactions occur within the crevice, like surface corrosion, where metal ions are formed, and
oxidation and reduction reactions take place.
• The confined space hinders the dissipation of reaction products, allowing corrosion to progress more rapidly.
• Crevice corrosion can lead to the formation of pits, cracks, or weakening of the metal in and around the
crevice area.
The crevice
corrosion
mechanism
 The under-coating corrosion

• The removal of the coating exposes the metal surface, but the surrounding coating remains intact.
• Moisture or corrosive substances can penetrate the exposed metal surface and migrate beneath the intact
coating.
• This can occur through capillary action, diffusion, or other means.
• The moisture or corrosive agents create a corrosive environment between the metal surface and the coating.
• Corrosion reactions take place at the metal-coating interface, like surface corrosion, resulting in the formation
of rust or corrosion products.
• Under film corrosion is often not immediately visible, as it occurs beneath the intact coating.
• Over time, the corrosion products can cause the coating to lift, bubble, or delaminate, leading to visible signs
of corrosion.
The under-coating corrosion Mechanism
 • Exposure to moisture: Moisture acts as an electrolyte,
facilitating corrosion.

• Oxygen availability: Adequate oxygen levels promote

corrosion by supporting oxidation reactions.

Factors affecting • Contaminants: Pollutants and chemicals can

the corrosion rate accelerate corrosion by catalyzing reactions or
increasing conductivity.

• Coating integrity: Damaged or incomplete coatings

allow moisture, oxygen, and contaminants to reach the
metal surface, initiating corrosion.
 • pH levels: Highly acidic conditions can accelerate
corrosion processes. (carbon steel)

• Temperature and climate: Higher temperatures and

corrosive environments like coastal areas can speed up

Factors affecting corrosion.

the corrosion rate

• Design considerations: Design features like crevices or
inaccessible areas can facilitate localized corrosion.

• Material properties ( The potential): Different metals

have varying degrees of corrosion resistance.
 Reapply efficient protective coating.

Regular cleaning and maintenance.

Minimize crevices in design.

Prevention Use coatings that penetrate crevices effectively.

Maintain coating integrity.

Use corrosion-resistant primers or sealants.

Use corrosion inhibitors ( zinc sulphate can be applied as a

coating or added to paints and primers)
THANK YOU