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Technical Paper

Development of an Improved Cosmetic Corrosion Test for Finished Aluminum Autobody Panels

2007-04-16
2007-01-0417
Since 2000, an Aluminum Cosmetic Corrosion task group within the SAE Automotive Corrosion and Protection (ACAP) Committee has existed. The task group has pursued the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. A cooperative program uniting OEM, supplier, and consultants has been created and has been supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Prior to this committee's formation, numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels. However, correlations between these laboratory test results and in-service performance have not been established. Thus, the primary objective of this task group's project was to identify an accelerated laboratory test method that correlates well with in-service performance.
Technical Paper

Development of an Improved Cosmetic Corrosion Test By the Automotive and Aluminum Industries for Finished Aluminum Autobody Panels

2003-03-03
2003-01-1235
The Automotive Aluminum Alliance in conjunction with SAE ACAP founded a corrosion task group in 2000 with a goal to establish an in-laboratory cosmetic corrosion test for finished aluminum auto body panels, which provides a good correlation with in-service performance. Development of this test involves a number of key steps that include: (1) Establishing a reservoir of standard test materials to provide a well-defined and consistent frame of reference for comparing test results; (2) Defining a real-world performance for the reference materials through on-vehicle tests conducted in the U.S. and Canada; (3) Evaluating existing laboratory, proving ground, and outdoor tests; (4) Conducting statistically designed experiments to evaluate the effects of cyclic-test variables; (5) Comparing corrosion mechanisms of laboratory and on-vehicle tests; and (6) Conducting a round robin test program to determine the precision of the new test. Several of these key steps have been accomplished.
Technical Paper

Elimination of Electrocoating on Aluminum Intensive Vehicles

1999-03-01
1999-01-0352
Due to the inherently superior corrosion resistance of aluminum compared to steel and galvanized steel, electrocoating is not an absolute necessity for aluminum intensive vehicles. Therefore the possibility exists to eliminate electrocoating and thereby reduce overall finishing costs for aluminum body structures. Previous work has shown that selected powder primer/surfacers applied to non-chrome pretreated aluminum panels resulted in adhesion, corrosion and appearance characteristics equal to or better than conventionally phosphated, electrocoated and finished material. To demonstrate this concept on a complicated automotive body structure, a corrosion test piece was devised that incorporated the features of a body-in-white. The test piece included both adhesively bonded AA5754 components and AA6111 mill finished sheet. Distribution of the powder coating on these specimens, adhesion, cosmetic and galvanic corrosion performance were evaluated.
Technical Paper

Development of an Improved Cosmetic Corrosion Test for Finished Aluminum Autobody Panels

2005-04-11
2005-01-0542
A co-operative program initiated by the Automotive Aluminum Alliance and supported by USAMP continues to pursue the goal of establishing an in-laboratory cosmetic corrosion test for finished aluminum auto body panels that provides a good correlation with in-service performance. The program is organized as a task group within the SAE Automotive Corrosion and Protection (ACAP) Committee. Initially a large reservoir of test materials was established to provide a well-defined and consistent specimen supply for comparing test results. A series of laboratory procedures have been conducted on triplicate samples at separate labs in order to evaluate the reproducibility of the various lab tests. Exposures at OEM test tracks have also been conducted and results of the proving ground tests have been compared to the results in the laboratory tests. Outdoor tests and on-vehicle tests are also in progress. An optical imaging technique is being utilized for evaluation of the corrosion.
Journal Article

Development of an Improved Cosmetic Corrosion Test for Finished Aluminum Autobody Panels

2008-04-14
2008-01-1156
A task group within the SAE Automotive Corrosion and Protection (ACAP) Committee continues to pursue the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. The program is a cooperative effort with OEM, supplier, and consultant participation and is supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels, but correlations between laboratory test results and in-service performance have not been established. The primary objective of this project is to identify an accelerated laboratory test method that correlates with in-service performance. In this paper the type, extent, and chemical nature of cosmetic corrosion observed in the on-vehicle exposures are compared with those from some of the commonly used laboratory tests
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