Corrosion is a serious concern for the automotive industry. Beyond aesthetic and economic concerns, loss of function due to corrosion can lead to unsafe scenarios. Passive cathodic corrosion is a method widely used in marine vessels, oil pipes, and others. The key piece of this method is the use of sacrificial anodes that corrode instead of the structural metal. Once the anodes are exhausted, they can be replaced by new ones, which is desirable for the automotive industry to prolong the duration of corrosion protection for at least 15 years.

Business objective to achieve

Develop a competitive advantage against the company's main competitors by extending the life of the automotive structural components (frame and subframe).

Previously attempted solutions

Currently, corrosion protection on frames is implemented with the use of galvanized steel and e-coat. Both methods involve the addition of a protective layer, e-coat prevents corrosion by serving as insulation between the substrate and the electrolyte. On the other hand, in galvanized steel the zinc layer acts as sacrificial anode, effectively establishing a cathodic protection system, like sacrificial anodes in ships, but with the disadvantage that once the zinc layer oxidizes, it cannot be replaced by a new one.

Discarded solutions

• So far, the project is in an exploratory stage, thus there are no discarded solutions.

Must have

• Compatible with current e-coat and powder coat technology
• Anodes should not significantly increase weight of the vehicle
• Solution must have a low impact on the LCA ( Life Cycles Assessment ) of the automotive structures.
• Low environmental impact
• TRL level: Solution should be beyond TRL level 4 ( Laboratory Testing/Validation of Prototype Component/Process)

Nice to have

• The sacrificial anodes must be replaceable
• Solution must be cost effective

Research Collaboration Model is designed to accommodate both academic institutions (universities) and private research organizations. The company is open to exploring a variety of partnership models, tailored to the development stage of the proposed technology.

• Research Collaboration – The company will work together with universities or research institutes; within the framework of financing for undergraduate thesis, contract research, proposals for external funding or providing access to industry equipment.
• Joint-development – Both companies can work together to share technologies, develop or enhance their products, combine or integrate their technologies, or jointly commercialize a new product.
• Licensing – A business arrangement in which the applicant shall give company's permission to manufacture its product for a specific royalty fee with exclusivity.

Key elements for the proposal

• Propose the material of the sacrificial anodes
• Determine strategic zones of the automotive structural components for implementation of sacrificial anodes
• Propose a simple system for replacement of exhausted anodes
• Propose validation methodologies
• Evaluate compatibility with current paint (e.g. e-coat, powder coat) based protection processes.
• Asses compatibility of the solution with products of Light Vehicles and Commercial Vehicles
• Include simulations and 3D modelling to enhance the proposal