ABSTRACT
Automobiles are built for an internationally competitive market that is demanding not only in vehicle performance and price but also in subjective customer perception. Corrosion-resistant coatings for the body therefore have both protective and cosmetic functions. This chapter discusses the design considerations for automobile bodies including front and side panels, wheel arches, joints, and rainways. Basic protection for automobile bodies is by a paint system applied over a phosphate coating that also gives the vehicle an aesthetically pleasing appearance. Corrosion can interact with the mechanical degradation of moving parts by wear, fatigue or erosion to an extent influenced by the compositions of fuels, oils and products of combustion. The protection of recirculating water-cooling systems is complicated by the use of antifreeze additives. The integrity of exhaust systems that have hitherto been replaceable items, is now a serious concern because of widespread adoption of catalytic converters for emission control, reduced noise tolerance and a trend by manufacturers to extend warranties.
