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MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
TITLE: MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES. Keyword: Edge corrosion, Edge protection, Rust on edges, Corrosion mitigation. Objective: A major challenge to automotive industry is to protect the vehicle from corrosion in varying environment with respect to different service conditions. One of the main types of corrosion that affects aesthetic look is edge corrosion on sheet metal. Mostly edge is acting as starting point of corrosion due to unprotected metal exposed to environment. A special attention to be given to exposed edges to protect from rust formation. Methodology: To mitigate corrosion in visible area, various solution proposed in manufacturing process, material usage, sealer application, BIW design. Samples were prepared as per design of experiments with respect to manufacturing process condition and subjected for testing. Results: Proposed solutions were validated in manufacturing process line and reports are discussed. Improvements observed in controlled lab testing were furnished with observations and recommendations. Limitation of this study: On high volume passenger and commercial segment, corrosion mitigations are linked with high cost impact where high-end corrosion protection like aluminium alloy and stainless-steel alloy have limitations. What does the paper offer that is new in the filed in comparison other work by the authors? A holistic approach in various area like BIW design suggestions, sealer application best practices, process operation, manufacturing, etc required to mitigate are discussed with validation and result observations. Conclusion: Burr is a raised edge of the sheet metal parts due to inherent limitation of blanking, piercing, shearing, and trimming operation of sheet metal parts. As burr formation is inevitable, however suitable edge rust mitigation plan is vital to sustain customer perceived quality.