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Historically, accelerated cyclic corrosion test protocols utilized by original equipment manufacturers (OEMs) have been developed based on a great knowledge and abundant vehicle field data of primarily steel-containing vehicle components. Laboratory-accelerated cyclic corrosion tests with repeated cycles of wet, dry, humid, and/or corrosive media application have been developed both separately and in partnerships, such as in the case of SAE J2334, to simulate a severe corrosive field environment for evaluation of cosmetic corrosion performance of painted steel. With the interest in lightweight metals such as aluminum alloys and magnesium alloys in automotive applications, the validity and confidence of these accelerated test protocols with vehicle field data of lightweight metals is valuable to further increasing the usage of these metals.

With rapid growth of magnesium alloy applications in automotive industry, especially for external components, corrosion prevention is becoming increasingly important. It is necessary to evaluate coating systems that are applied on magnesium prior to component assembly. Furthermore, the interaction between coating systems and methods for galvanic corrosion prevention should be considered carefully. The present paper discusses the methodology for corrosion protection of external automotive components and demonstrates some examples of technical solutions.