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Technical Paper

Development of High Corrosion Resistant Stainless Steels for Automotive Mufflers Based on Condensate Corrosion Test and Field Investigation

Automotive exhaust gas condensate causes severe corrosion inside mufflers. Corrosive condensate became a problem following the introduction of three-way catalytic converters in exhaust systems. The authors previously established a new laboratory test method that simulates condensate corrosion. This test method contributed to the development of new stainless steels for automotive mufflers. The addition of molybdenum (Mo) and copper (Cu) to ferritic stainless steels was found to be effective in improving condensate corrosion resistance, and the effect was arranged using the index [%chromium (Cr)+3×%Mo+1.5×%Cu]. A field test was carried out to investigate the corrosion behavior of mufflers under actual conditions. Aluminized steels showed severe damage by general corrosion. On the other hand, 19%Cr-Cu ferritic stainless steel exhibited excellent corrosion resistance. The corrosion behavior in the field test showed good agreement with the results of the laboratory test.
Technical Paper

Evaluation of the Corrosion Rate of Zn Coated Steel Sheets for Automotive Body Use

The corrosion mechanism of zinc coated steel sheets in automotive bodies was studied in field vehicle tests and several types of accelerated tests. Perforation corrosion starts in unpainted areas of lapped parts, and proceeds in the following steps: i) galvanic protection by the Zn coating, ii) protection by corrosion products, and iii) corrosion of the steel substrate and perforation. Although the corrosion processes were the same in all the cases tested, the corrosion rate depended significantly on the environment, such as atmospheric exposure conditions and the part of the automotive body. In accelerated corrosion environments, Zn coating is largely ineffective against perforation corrosion because galvanic protection and protection by corrosion products cannot be maintained over the long term.
Technical Paper

Corrosion Behavior of a Vehicle Submitted in Service in Subtropical Marine Environment of Okinawa Island for Eight Years

A passenger vehicle in the subtropical marine environment of Okinawa Island for eight years was submitted for corrosion investigation.The precoated sheet steels such as Zn-Ni and Zn-Fe showed excellent corrosion resistance in the door hem flange and a scribed outer panel, compared to cold rolled steel. Cosmetic corrosion of a North America vehicle was more severe than that of a Okinawa vehicle, but a similar corrosion rate for perforation was shown in door hem flange. Basic zinc chloride and β-FeOOH were observed by using micro X-ray diffraction method in the initial stage of corrosion, and then these changed to ZnO and α-FeOOH, Fe304.
Technical Paper

Corrosion Behavior of Organic Composite Coated Steel Sheet

Organic composite coated steel sheets retain their excellent corrosion resistance during cyclic corrosion tests (CCT). To clarify the corrosion behavior of these sheets during CCT, variations in corrosion products and coating components were examined. Moreover, the contribution of the corrosion products, organic composite coating, and chromate film to corrosion resistance was examined by AC impedance measurements. Formation of crystalline ZnCl2·4Zn(OH)2 and amorphous zinc carbonate were detected by X-ray diffraction (XRD) and Fourier transformation infrared spectroscopy (FT-IR). Crystalline ZnCl2·4Zn(OH)2 is formed during CCT on and under the organic composite coating. The corrosion products formed on the coating contain silicates from the silica in the organic composite coating. Consequently, the contents of zinc and silica in the coating decrease, while nickel and chromium in the chromate film and carbon in the coating remain constant during CCT.
Technical Paper

Characteristics of Al2O3 Dispersed Zn-Co-Cr

Al2O3 -dispersed Zn-Co-Cr alloy electroplated has been developed for automobile use. Optimum coating composition ranges from 0.5 to 2.0wt% for Co, 0.3 to 1.0wt% for Cr, and 0.1 to 2.0wt% for Al2O3. The coating showed excellent corrosion resistance with and without paint. Superior anti-corrosive property of the coating results from the formation of the mechanically and chemically stable corrosion products, ZnCl2 −4Zn (OH)2, and the passivation in anodic polarization. The coating also showed good stone chipping resistance as well as paintability, formability, and weldability. Accordingly Al2O3 -dispersed Zn-Co-Cr alloy electroplated is suitable for application to both unexposed and exposure parts, including interior and exterior surfaces.
Technical Paper

Properties of Precoated Galvannealed Steel Sheets for Lead-Free Automotive Fuel Tank Use

The goal of this study was to identify a pre-coated steel sheet that will satisfy press formability, seam weldability, spot weldability, brazing property, external corrosion resistance and internal fuel resistance. We established an experimental method for anti-fuel resistance measurement by applying synthetic spoiled gasoline by investigating the composition of spoiled gasoline and corrosion products in the fuel tank, which was collected in North America after 160,000 kilometers' running. Newly developed lead-free pre-coated steel sheet shows excellent anti-fuel corrosion resistance in comparison with that of usual terne coated steel sheet according to this method.