Body galvanization: which cars are better protected from corrosion

Operation / From Autoclub

• We find out which cars have a galvanized body using one of the above methods and the degree of galvanization.
  Cars with a hot-dip galvanized body.
• List of cars with galvanic body galvanization
• A little about Japanese cars
• Other manufacturers

It's no secret that the most valuable part of a car is certainly the body. Strength characteristics determine the character of the vehicle, and the properties of the material and the quality of its processing determine the degree of resistance to the occurrence and development of corrosion foci.

Full or partial processing

Corrosion is the main and very dangerous enemy of metal. First, a barely noticeable yellow coating on the parts, then swelling of the paintwork and, finally, obvious rotting of the body panels, all this occurs due to aggressive and constant exposure to water, dirt, and sand. Temperature changes, mechanical damage and chemical reagents that are sprinkled on public roads make their negative contribution.

To prevent this problem, the body is specially protected from rust at the production stage by covering it with a layer of zinc. But the vast majority of modern cars undergo only medium or minimal processing. From such partial protection, although it successfully protects the part at first, nothing remains after 2-3 years of operation. The dealers themselves recommend that on such machines, additional treatment of panels against rust, especially hidden cavities, niches, seams, and bottoms, is carried out.

A fully galvanized car body is not subject to corrosion for a long time - almost 30 years. It all depends on the type of galvanizing (this will be discussed in detail below) and the operating conditions of the car.

The main causes of corrosion

Among the reasons for the appearance of rust on the body and underbody of a car, the following unfavorable factors can be identified:

• Territorial use of the car. In other words, the region and its climate. Sudden changes in temperature, UV rays, and air humidity have an adverse effect on your iron horse.
• Reagents on the roads. In winter, in large cities, road services treat roads with a sand-salt mixture, which helps get rid of ice, but at the same time can cause serious damage to external metal parts and the body.
• Poor quality painting, unscrupulous repair work, chips and damage to the paintwork of the vehicle.
• Inadequate care.

Methods for galvanizing a car body

In mechanical engineering, there are several types of galvanization of the car body. Let's look at each of them in detail.

Hot (thermal) method

The classic and best type of treatment involves lowering a dry body into a bath of molten zinc. The temperature in the container can vary between 500-4000 degrees Celsius. The manufacturer provides a guarantee of 15 years or more for car bodies treated in this way.

Full immersion in hot zinc makes the metal panels incredibly resistant to corrosion and last forever. Even damaged areas of the body, chips and cracks, self-heal over time - they are covered with a thin layer of zinc deposits. And in general, this thermal method, although more expensive, provides a protective layer thickness of 2-15 microns.

Initially, this type of galvanizing was used in German. The first galvanized car was the Audi A80. Further, this method was adopted by Volvo, Porsche and other automakers. Today, despite the high cost of the technology, hot-dip galvanizing is carried out not only on the bodies of luxury cars. Place foreign cars Chevrolet (Corvette model) and Ford (Explorer, Focus, Fiesta and Mustang) in a hot bath with zinc.

Of course, this method is widely used by auto industry giants:

1. Audi is a pioneer in the field of body heat treatment and a world leader in this field. Cars of the German brand rarely need to be repaired due to external damage, except after serious accidents. The Ingolstadt manufacturer makes full use of hot-dip galvanizing technology - it carries out partial, complete or combined processing. For example, on A4 models, individual body parts are placed in molten zinc. And the bodies of models such as the Q5 are completely immersed in the bath.
2. This Stuttgart brand always tries to keep up with the best. Full and partial zinc treatment of the body is one of the ways to stand out among competitors. The first car from the manufacturer to receive a fully galvanized body was the Porsche 911. This happened in 1989. The body of the 911 Carrera modification was partially subjected to one-sided hot-dip galvanization. Since 1999, the same version has been completely processed using stainless steel.
3. Swedish Volvo. Like Audi, it galvanizes almost all of its models. A popular method is double-sided hot processing or immersion of the core in the melt.

Of course, such galvanized cars are an order of magnitude higher than their analogues. However, taking into account the costs of body restoration, their price is fully recouped during operation. Isn’t it true that if a car lasts more than 15 years without repair, you won’t mind spending any money on buying it?

Condition of the Audi 100 body after 23 years of operation!

Galvanic processing method

This is already bathing in a bath with zinc-containing electrolyte. Stainless steel is deposited on the surface of the metal due to the action of electricity, and not high temperature. The method, which was adopted in order to save money, is now actively used by most automakers.

The galvanic treatment procedure looks something like this:

• the body itself or its panels are immersed in a container filled with an acidic zinc solution;
• The negative terminal from 220 V is also connected here;
• The container is connected to the positive - electrolysis begins.

The galvanizing method makes the car less resistant to rust, but ensures almost perfect uniformity of the protective coating. The result is an incredibly beautiful, smooth and shiny body. The thickness of the protective layer during galvanic treatment is 5-20 microns. The manufacturer's warranty does not exceed 10 years.

Since galvanic treatment provides comparatively worse protection against corrosion, some manufacturers thicken the layer to 9-25 microns, use high-alloy steel and add a durable primer layer.

Well-known brands that use galvanic processing:

• Chevrolet;
• Skoda;
• Toyota - almost all models;
• Mitsubishi.

The famous German giants are also fans of the galvanic method: BMW, Mercedes-Benz, Volkswagen. They use special steel and apply an impressive layer of expensive paint, thereby protecting the body almost as well as Audi with its heat treatment.

Cold galvanizing

The cheapest way to protect iron from corrosion. In recent years, it has become widespread among budget car brands. Treatment in this case is nothing more than spraying or painting metal panels with primer containing highly dispersed zinc powder. In the finished protective coating, the zinc content does not exceed 90-93%.

This method of body processing has been adopted by Chinese and some Korean manufacturers. They often use stripped-down galvanization, when the back side of the body panel is simply primed and painted. This allows you to save a lot, and the cars remain fresh for a long time. The rotting process remains invisible, as it occurs on the reverse sides of the parts.

Body parts that rot most quickly

Cars with galvanized bodies: complete list

For a list of cars with galvanized bodies, see the table below.

Russian-made cars undergoing galvanization

The bodies of AvtoVAZ models are subjected to partial cold galvanizing or cold galvanizing of node connections. Lada Priora of the latest modifications is coated with zinc better than anyone else - 80-90%. On the Lada Vesta only the sills are left untreated, on the Xray the roof is left untreated. The second generation Lada Kalina is painted with stainless steel everywhere except the hood, roof and side members. The Lada Granta is galvanized to a minimum - only the wings and doors.

Until 2014, UAZ Hunter, Pickup, Patriot, 23602-cargo were partially galvanized by cold galvanizing, just like Vases. But since 2014, they began to use full galvanic double-sided galvanization with a protective layer of 9-15 microns.

UAZ Patriot weak points
Since 2009, cars produced by GAZ (Gazel, Sobol, Siber) have been processed by partial cold galvanizing. The same method is used to protect the bodies of all modifications of Gazel Next. The remaining models on the market today are cold galvanized at their node connections.

List of cars that can last up to 30 years without corrosion

We have prepared a rating of cars whose owners need not be afraid of corrosion.

Audi A6 C4

The model was produced from 1994 to 1997. Thus, the “youngest” Audi A6 C4 is now 24 years old. Despite this, cars are still actively sold on the secondary market, and one of the main reasons for this is the almost “eternal” body, completely hot-dip galvanized.

New Audi A6 C4

A major overhaul of the engine, suspension, and brake system may be required, but nothing will happen to the body parts.

Ford Focus

The model has been produced from 1998 to the present. Perhaps the only representative of budget cars on the list treated with hot-dip galvanizing. It is extremely popular in the secondary market; many cars of the first generations are still “on the move”.

These achievements would not have been possible without the full hot-dip galvanization that Ford generously bestows on its vehicles.

Porsche Cayenne 955

The model was produced from 2002 to 2010. A premium crossover with permanent all-wheel drive, excellent interior trim, powerful engines and a body that will never rot.

How to find out if a car has undergone anti-corrosion zinc treatment

Information about this can be found in the technical documentation for the vehicle. If you couldn’t find the word “zinc” in the papers, the body is unlikely to be protected from corrosion in any way.

To determine the presence of galvanized car body without papers, you will have to spend a lot of money. In particular, seek a service from a specialized center or trust the information provided on the Internet.

Partial protection or its complete absence can be judged by the cost of the car. Budget models are rarely galvanized, especially using one of the high-quality methods. They are simply treated with inexpensive paints and materials. These cars include Asian economy class cars.

Galvanic galvanizing

Galvanic galvanization can be used for complete body processing, as well as for individual elements. This is a simpler technology for protecting vulnerable areas of the body. The underbody of the car, sills and arches are often galvanized - the places most vulnerable to corrosion. Partial anti-corrosion treatment is used for inexpensive cars that are sold in large quantities.

Table: cars with galvanized body

If you have any questions, leave them in the comments below the article. We or our visitors will be happy to answer them