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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.

Ford GT 2005 vehicle was designed for performance, timing, cost, and styling to preserve Ford GT40 vintage look. In this vehicle program, many advanced manufacturing processes and light materials were deployed including aluminum and magnesium. This paper briefly explains one unique design concept for a Ford GT instrument panel comprised of a structural magnesium cross-car beam and other components, i.e. radio box and console top, which is believed to be the industry's first structural I/P from vehicle crash load and path perspectives. The magnesium I/P design criteria include magnesium casting properties, cost, corrosion protection, crashworthiness assessments, noise vibration harshness performance, and durability. Magnesium die casting requirements include high pressure die cast process with low casting porosity and sound quality, casting dimensional stability, corrosion protection and coating strategy, joining and assembly constraints.