Automotive Engineering
Automotive Construction

Light-weight metals are gaining popularity throughout the automotive industry. Bimetallic corrosion problems associated with the steel / aluminum interface may be successfully eliminated by galvano-aluminum coating. For riveted systems, the excellent corrosion resistance provided by galvano-aluminum in combination with the high ductility offers a perfect solution. The favorable corrosion protective properties are maintained even at elevated temperatures.

Requirements

Modern automotive engineering is facing stringent requirements regarding metallic anticorrosive systems. These stipulations are expected to increase even more in the near future. In some cases, the automotive industry has extended warranty periods regarding corrosion resistance to as long as ten years. New engine technologies will give rise to increasingly higher temperatures inside the engine compartment, which means that coatings will be exposed to various types of corrosive attack, at temperatures that may exceed 130 °C. Chromatized zinc layers, for instance, are no longer functional under these conditions.

Additional aggregates on light-weight metal engine blocks may be exposed to extreme bimetallic corrosion conditions. This effect may be controlled by using aluminum coatings, where other metals will fail very soon.

Galvano-aluminum, due to chromium-VI-free passivation, already meets the requirements of the EU Used Car Regulation regarding anti-corrosion layers today.

In addition, aluminized surfaces may be refined by suitable passivation, giving rise to surfaces in a variety of colors.

Differently colored anodized plastic door handles

Image 2. Differently colored anodized plastic door handles

To an increasing extent, today's production engineering is relying on screwless squeezing techniques, which may later cause corrosion of the machined parts because of top layer damage.

In many cases, due to the high ductility of the galvano-aluminum surface, squeezing techniques may be used for joining purposes without damaging the surface.


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