Which Chinese cars are galvanized. Highest quality galvanized cars and bodywork methods. Hot Dipped Galvanized Auto Body

The surface has high adhesion, so the paintwork is applied quite reliably. List of cars Now let's consider which cars are coated with the classic electroplating method:

• Alfa Romeo.
• Mitsubishi
• Skoda (Octavia, Fabia).
• Toyota.
• Honda (Legend).
• Lexus
• Renault (Logan).
• Peugeot.
• Chrysler (model 300).
• Cadillac.

Toyota car models deserve special attention. Since the company previously paid little attention to anti-corrosion treatment, now a zinc layer in nodes, sills and doors is present in most cars. Domestic cars In terms of the domestic automotive industry, everything is somewhat simpler. If galvanized cars were produced, then they were made from foreign sheet steel.

Which cars have a galvanized body: a list

The fact is that the Audi corporation, back in 1986, formed a certain corrosion protection technology, which today is known as hot or thermal galvanizing of the body. More or less correctly, this process is carried out on all Audi cars, on most of the expensive Volkswagen and Seat cars.
Also, Chevrolet Expica and Opel Astra are galvanized in a similar way. The transport receives very high-quality protection, but sometimes the galvanizing is performed not according to the criteria that are necessary.

List of cars with galvanized body

The second side (inner) is painted and primed using traditional methods. This approach allows manufacturers to save money and produce budget-class cars designed for the mass consumer.

Anti-corrosion coating technologies have been known for a long time. But do not pay attention to the loud statements of manufacturers.

Cars with galvanized body

Accord, CR-V, Legend, Pilot models.

Therefore, the machines, galvanized by the galvanic method, are more affordable. However, the effectiveness and service life of such a coating is lower.

A body with a thermally applied anti-corrosion coating will resist moisture for much longer. BMW and Mercedes are among the leaders among automakers that galvanize their vehicles.
Partial galvanizing Many manufacturers use only partial galvanizing, passing it off as complete. This applies primarily to Chinese, Russian brands, as well as some Korean manufacturers. For example, Lada Granta and Lada Kalina are partially galvanized. The bodies of these cars are covered with a protective anti-corrosion layer by 40%, but this is not bad either.

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Test Coating without galvanizing Galvanic treatment method Galvanic treatment of the body with zinc differs from the previous method in lower cost. More often this method is found in American and Japanese cars, a little less often in European ones.

By reducing the cost of processing, the reliability of such processing has also significantly decreased. The coating did not provide a 100% guarantee of protection. European manufacturers decided to go their own way, using the developed new technology.

List of technological operations carried out by BMW and Mercedes concerns:

• For the manufacture of the body, high-alloy steel is used, harmful impurities are excluded as much as possible.
• The galvanic method is applied from 9 to 15 microns of zinc.
• A thick layer of primer and paint is placed on top.

Galvanized car body - list of brands and models

It is much easier to add zinc elements to the soil or paint and assure the buyer that the body will not be afraid of rust in the next three decades. For this, of course, the manufacturer charges a certain fee, as for a very high-quality and effective anti-corrosion preparation of the body.

When choosing cars with a galvanized body, remember that cars only in the expensive segment can have really high-quality galvanizing. Remember that the Skoda Fabia has only a galvanized underbody, but cars of the Octavia level and higher in the VW Group are completely galvanized.

True, it is simply impossible to compare the quality of modern preparation and protection of the body with those processes that were carried out ten years ago. Today, manufacturers make a car for 7 years - then it must be sent for recycling.

Full galvanizing of a car body: truth or advertising gimmicks of manufacturers?

If we put aside the biased attitude and look at the situation soberly, it was the Korean manufacturers who were the first to show that quality can be saved for the sake of greed (thrift). Further, European automakers (Renault, Volkswagen, Opel) joined this, flooding the market with models that some call "cans". Assembly-stage workmanship, in which a manufacturer can proudly declare that their vehicle body is galvanized and corrosion-free, have evolved to combine good advertising with good consumable savings. However, in a few years everything will be revealed in any case and car owners will draw conclusions about the quality of the offered goods.

What cars with a galvanized body will not make you remember about corrosion?

Corrosion damages the most dangerous places and begins to spread quickly, which renders the car body unusable. You need to understand that the troubles that are hidden in the corrosion process are extremely difficult to stop. As soon as the body is welded or treated with other means, corrosion will spread even faster. Galvanized bodies need to be processed and "treated" from chips and scratches in a certain way, which is known to specialists at the workshop. Galvanized Galvanizing - Mercedes and BMW Cars Almost the entire model range of Mercedes and Bavarian BMW cars has received high-quality galvanizing. But the eternal rivals Volkswagen and Audi decided not to use the rival's technology, inventing their own options for galvanizing the body.

Which cars have a galvanized body and how is the coating applied?

Peugeot Porsche Ravon Renault Saab Skoda SsangYong Subaru Suzuki Toyota Volkswagen Volvo Vortex VAZ GAZ ZAZ ZIL KAMAZ Moskvich

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Any car is repairable. Not only standard consumables are subject to replacement, but also key components designed for long-term operation. Therefore, sometimes not only the oil and filters are changed on the car, but also the motors and gearboxes.

There are a number of elements that are not difficult to replace as needed. But the same cannot be said for the body parts. Conventionally, the easiest to replace are the doors, hood and trunk lid. It is quite another matter when you have to change the bottom or racks. This is almost impossible to do.

At the same time, the body is exposed to the strongest influence of various provoking factors, including mechanical damage, contact with aggressive chemical substances, water, moisture, snow, sand, etc. The formation of even a small focus of corrosion over time can lead to a significant growth of rust throughout the car. It is imperative to provide the body with a high level of protection. Paintwork with such tasks does not cope well.

The most effective way to combat corrosion is rightly considered to be the coating of the metal with a layer of zinc. This procedure is called galvanizing. Moreover, the highest quality zinc plating takes place in a factory industrial environment. The level of galvanizing is largely reflected in the durability of the machines. Some rust literally in 5-10 years, others are quietly operated for 30-40 years, without forcing their owner to invest a lot of money in the fight against corrosion and body repair.

What zinc is used for

It is also a thermal treatment method, but it already requires less resources and financial costs for implementation. Therefore, the method has become the most widespread, and it is much easier to find cars with such a body.

Mostly Japanese and American automakers have switched to electroplating. They are much less common among European companies. Given the low efficiency compared to hot-dip galvanizing, leading car manufacturers are developing improved methods for applying zinc, thereby modernizing the galvanic principle. In particular, these are companies such as Mercedes and BMW.

In order to improve the quality and efficiency of galvanizing, the following steps are used:

• In the production of the body parts themselves, it is high-alloy steel grades that are used. Their advantage is that the amount of impurities in such steel is minimal.
• A thicker layer of zinc itself is applied. The thickness can be from 9 to 15 microns.
• In addition to galvanizing, the body is additionally primed with a thick layer and the layer of paintwork applied on top of the zinc is made thicker.
• The adhesion properties of surfaces are increased, providing a stronger and more durable bond between all layers.

Before publishing, which have a galvanized car body, it is worth noting one regularity. Japanese cars were initially inferior to European ones in terms of the quality of galvanizing and durability of the body. But then the situation began to change, and they went to about the same level. This was due to the fact that the Japanese began to use zinc for the production of machines somewhat later.

The highest quality cars are considered Toyota and Lexus. They exhibit excellent corrosion resistance properties. Largely due to a fairly thick layer of protective coating.

The galvanic method of galvanizing car bodies was used in the production of such cars:

• Alfa Romeo (after 1993 only).
• Audi A4.
• Mitsubishi Lancer 9.
• Mercedes W124.
• Mercedes W201.
• Lexus (all models).
• Volkswagen (all cars after 2000).
• Toyota lineup (after 1991).
• Skoda Fabia.
• Skoda Octavia.
• Peugeot.
• Honda Legend.
• Renault Espace 3 generations.
• Renaul Logan.
• Chrysler 300M.

The same Renault Logan has far from exemplary paintwork quality. But due to a good level of protection through galvanic galvanizing, their body can be under attack of moisture and chemical reagents for a long time, preventing the appearance of foci of corrosion.

The situation with the domestic auto industry

Many motorists are naturally interested in domestic cars that come with a galvanized body. Some even question whether they even exist.

The overall picture with the galvanizing of domestic machines looks pretty bad. Previously, cars of the AvtoVAZ family were assembled on the basis of ready-made elements that were imported from other countries. At the same time, some of the components, it is likely, were made by preliminary galvanizing of the metal, but this was not mass production.

Even in the absence of anti-corrosion factory coating, ordering parts from foreign suppliers turned out to be unprofitable, the production cost of the machines was high. To reduce prices for Russian cars, it was decided to switch to domestic steel.

If we return to the question of what kind of cars in Russia are available with a body galvanized from the factory, then we can say the following. Galvanizing began to be used everywhere. The only question is which method was used. And the technique was used cold. As you already know, in terms of efficiency, this is the weakest option for galvanizing. Plus, only individual components were galvanized. This is the answer to which cars in Russia were fully processed. There are virtually no fully galvanized cars among the Russian car industry. There is simply nothing to make a list of them.

At present, in the manufacture of machines, the so-called cataphoresis method of anti-corrosion treatment can also be used, in which zinc is not used at all.

Galvanizing Machine at Factory

Alas, it is impossible to say exactly where there is or where there is no zinc layer. This information is usually hidden or partially disclosed. This also does not allow us to say which Chinese cars can have a galvanized body. Surely all machines have partial processing. If we talk about, then here we can cite the following facts:

• On cars VAZ 2110 and its family (VAZ 2111, VAZ 2112), about 30% of body elements were galvanized.
• Niva or Lada 4 × 4 has an exclusively cataphoresis primer layer. Zinc compounds are not used here.
• Lada Kalina in the first generation used about 52% of galvanized elements.
• On the second generation Lada Kalina, conditionally full galvanization is used, since there is no corresponding layer on the hood, side members and on the roof.
• Lada Priora initially had 29% of galvanized body parts, and since 2009 zinc has been applied to all metal elements.
• Lada Granta in the body of a liftback boasts galvanized doors and fenders. In the sedan body, galvanizing is not provided at all.
• Lada Vesta was conditionally completely galvanized. After all, a special protective compound was not applied to the bottom and sills. Plus, for some reason, the sedan did not protect the roof.
• Lada Xray, like Xray Cross, is almost completely galvanized. The only exception was the roof.

Among domestic automakers, until 1999, such a concept as galvanizing in the manufacture of cars did not exist at all. Only since 2009 have companies switched to the zinc cold working method. Moreover, in the overwhelming majority of cases, only some of the components were covered. The partial processing method is used not only by AvtoVAZ plants, but also at UAZ, GAZ, etc. Therefore, on domestic cars, when damage to the paintwork appears, the oxidative process starts quickly enough, followed by the formation of rust, if this is not noticed in a timely manner and nothing is done.

Is it possible to find out about the presence of galvanized on the body

Car enthusiasts are rightly interested in buying a car with a high-quality and corrosion-resistant body. Be prepared to overpay right away for such an advantage, since a processed machine with the same characteristics and equipment will cost more.

There is no major obstacle to knowing if a new or used car was coated and what method was used. You definitely cannot trust the sellers, even if they assure you of and exclusively in the use of hot-dip galvanizing. Everything needs to be checked.

The simplest and at the same time available method is to study the technical characteristics. Information can be found in the owner's manual, or simply study the history of a particular model in a particular body. If the concept of galvanizing is not mentioned anywhere, there are probably no processed elements, or their minimum amount. Others write that the body is galvanized, but do not say which specific components were processed. You need to look for a car where they claim it is full galvanizing. This makes it possible to assume that such a car was processed at the factory in whole, and not partially.

In the overwhelming majority of cases, you will come across a partial galvanizing of the body. Moreover, most often it is a galvanic method.

There are no tools or methods that allow you to determine the degree and type of factory anti-corrosion coating with your own hands. Some car services, which have the appropriate expensive equipment, offer a car inspection service for galvanizing. But meeting such service stations is quite problematic, especially in Russia. Plus, the service is too expensive, and few people are interested in buying it.

Summarizing

From all that has been said before, we can say that most often on the market there will be cars with a galvanic method of anti-corrosion body treatment. The thermal or hot method is much less common. Although the German auto giants are actively working to reduce the cost of hot-dip galvanizing. It really is gradually approaching the price of high-quality electroplating.

Nothing was said about one method of protection. This is the zinc-metal method. But there is no need to talk about high characteristics and properties. Only a few manufacturers use this method. The most famous of these is the South Korean brand Kia.

Advice for those buying a relatively new car. Each car manufacturer issues a warranty card, which specifies the warranty period for the appearance of through holes in the body caused by oxidative processes (corrosion). If such defects appeared earlier than the manufacturer foresaw, you can officially demand compensation from him in the form of free repairs. Sometimes companies take more serious steps, replacing a defective car with a new one. After all, a factory defect cannot be ruled out either, and not all cars of the same model and even release dates have a completely identical level of anti-corrosion protection.

Those who understand at least a little about cars know that one of the most expensive elements in a car (and maybe the most ...) is the body. In most cases, when buying a car, we pay attention to the body, and only then to everything else (interior, etc.).

It is the appearance of the car that plays the most important role, since if the appearance is damaged by some defect, for example, a dent or rust, then it does not matter how many "horses" this car has under the hood and what equipment it has. Often, under a layer of paint, which, at first glance, looks perfect, there is a layer of putty or, even worse, a corrosion center, which, some time after purchase, will cause a lot of inconvenience and will pull a lot of money out of your pocket.

It is for these reasons that the galvanized body, as well as the all-aluminum body of the car, is so valued among buyers and is the standard of resistance to damage and corrosion. The problem is different, it is rather difficult to find out which cars have this very galvanized or aluminum body. At the bazaar or somewhere on the Internet, they can "hang" you and convince you that the body is really covered with a protective coating and in the future you will never have a question of what to do with a rotten sill or arch. Today I want to talk about cars that really deserve attention, because they really have a galvanized body that has all the advantages of this type of protection, and also briefly touch on the topic of the technology for applying this coating.

How is a galvanized body made?

Galvanized vehicles have a phenomenal body life. The manufacturer gives a very impressive warranty period - from 5-6 to 30 years.

There are several methods for applying a protective coating:

• Galvanic;
• Hot dip galvanized;
• Cold galvanized.

Galvanic galvanizing - video

The most stable during operation is considered to be the thermal galvanizing method. Anti-corrosion protection lasts for 15-20 years, and even longer with careful use. The coating is up to three times more resistant than the galvanized method. Even under mechanical stress, the body is not subject to corrosion.

If you are wondering about galvanizing and want to know for sure which cars have a galvanized body there are some tricks to know. The fact is that some automakers, in order to improve the ratings of their cars and improve sales, indicate that the body is galvanized, although in reality this is not the case. More precisely, not quite so, the body was really galvanized, just not entirely, but only partially, that is, some parts of the body (fenders, sills, bottom) most susceptible to rotting during operation were covered with a protective zinc layer.

Galvanized car (hot method)

This method, as I have already said, is highly stable and durable, but at the same time this technology is very costly, therefore, as a rule, famous brands use it on expensive flagship models. For example, the hot-dip galvanizing method processes such car brands as:

• VolksWagen;

Note! If anyone is not aware, all of the above brands belong to Volkswagen, or rather to the Volkswagen Group corporation.

All of these brands of cars demonstrate excellent resistance to corrosion, both during tests in a salt chamber, and over many years of operation.

It is not by chance that Audi was in the first place in the rating. The fact is that it was this company that was the first to take care of the protection of the bodies of its cars, on its account there are a lot of developments and research, including double-sided zinc protection of welded joints, and not just body parts. The first production car "Audi" with a galvanized body, which rolled off the assembly line in 1986, became the Audi 80. Without exception, all surfaces of the body of this model were covered with an anti-corrosion layer.

Among the model range of the Swedish auto giant, there are also models that can boast of body protection in the form of galvanized, and the "hot" method. Besides the fact that Volvo cars are recognized as the safest in the world, they are also resistant to corrosion, partial or complete galvanizing together with aluminum body elements make these cars resistant to moisture and corrosion.

In addition to Volvo, the following cars have hot-dip galvanized bodies:

• Opel Vectra,;
• Sierra, Ford Escort;
• Chevrolet Epica;

Cars with galvanized body (electroplating method)

This technique works well only in combination with protective methods. In this technique, the German auto giants, eternal competitors: Mercedes and BMW, have succeeded. The latter has created his own formula for success, which is not inferior in efficiency to the technologies of the pioneer Audi.

The recipe for success for the Bavarians was as follows:

• For the production of body parts, high-alloy steel was selected, purified from harmful inclusions and impurities;
• Then the metal was subjected to the galvanic galvanizing procedure by applying a zinc layer (~ 9-15 microns);
• Then a perfectly flat surface was covered with a thick layer of paint.

Such a sandwich gives an answer to the question why the old "Germans" still have not lost their former beauty and are still popular among buyers. Moreover, there are often cases when cars half the age of these German cars with a galvanized body simply crumbled along the road, unable to withstand the harsh Russian climate and aggressive reagents that are generously sprinkled on our roads in winter.

What about Japanese cars?

The "Japanese", although they can compete with the "Germans" in terms of speed, popularity and beauty, rarely occupy the first positions in the matter of body protection. Among all Japanese automakers, Honda can be distinguished, whose cars, since 2005, have become more resistant to corrosion. If you want to buy a Honda with a galvanized body, you should pay attention to the following models:

• , Legend, CR-V as well.

In recent years, the equally popular Toyota brand has begun to pay more and more attention to the protective coating of the body. Cars began to receive a zinc-containing layer on the parts most susceptible to corrosion. However, the hidden cavities remain vulnerable as before and still rust after a few years.

What about the rest of the automakers

Koreans and Chinese in most cases create only the illusion of protection, as a rule, it all comes down to simple marketing and a desire to compete with eminent brands. Even if such a car really will have galvanizing, then be sure that it will be nothing more than an ordinary catophoresis soil with some zinc admixture.

As for the domestic manufacturer, unfortunately, as a rule, there can be no question of any protection. Cars at the age of 5 can already "boast" of the presence of various "teals", foci of corrosion and through holes. The bodies not only do not contain minimal protection, they are also made of thin metal, which rots very quickly from a large amount of moisture and reagents.

Well, that's all. Now you know which cars have a galvanized body and in the case of a purchase, you are unlikely to be misled. That's all for me, give your examples of protected bodies worthy of attention. If you missed something or there is a typo somewhere, please excuse me. Thank you for your attention and see you soon. Bye.

Finally, I recommend watching a video on how the galvanization and zinc coating procedure is performed

One of the worst enemies of a car is moisture. It is able to penetrate the paint on the body, as a result of which the metal begins to rot. This process is called corrosion. There are different ways to deal with car corrosion, and one of them is galvanizing. The fact is that the galvanized body prevents moisture penetration for a long time, but sooner or later even such cars rot. Let's figure out which cars have a galvanized body, what are the general methods of galvanizing.

To begin with, such a characteristic cannot guarantee complete protection against car decay. Some manufacturers (European, Japanese, Korean, American) actually produce cars in fully galvanized bodies, while others only partially galvanize some parts. Naturally, the quality will suffer in this case.

To understand how things are with galvanized cars, you must first understand the three well-known methods of galvanizing the body.

Thermal galvanized

The most reliable and efficient method is used by Group. We are talking about thermal galvanizing. This method of combating corrosion is expensive but effective. Because of it, the car greatly adds in price, but the result is worth it. More details about this method will be discussed below.

Galvanized

Galvanized galvanizing can be used for the complete treatment of the body, as well as for individual elements. This is a simpler technology to protect the vulnerable parts of the body. Often the underside of the car is subjected to galvanic galvanization, sills and arches are the most vulnerable places for corrosion. Partial anti-corrosion treatment is applied to inexpensive cars that are sold in large quantities.

Cold galvanized

The last method is cold galvanizing. This method resembles the previous one in technology, but this one is even simpler and cheaper. Some car owners can process body parts in this way in their garages. The car does not need to be immersed in a special zinc-containing solution for this. The solution itself is applied to the body using an electrode, which is connected to the positive terminal while connected to the negative terminal). Some garages offer a service for the processing of car body elements, but it will not be possible to complete processing in this way. Since this method is not used by car manufacturers, it is not worth describing in detail.

Which cars are thermally galvanized?

It is impossible to list all cars that are produced with galvanized bodies. There are a lot of them, and the list is constantly updated. At least all cars of the brands "Audi" and "Volkswagen" after the year 2000 have fully galvanized bodies. Also, the following car brands have a heat-treated anti-corrosion coating:

1. "Porsche 911".
2. Ford Escort.
3. Ford Sierra;
4. Opel Astra and Vectra (after 1998).
5. Volvo 240 and older models.
6. "Chevrolet Lacetti".

Galvanized machines

Cars that have passed the galvanic galvanizing procedure:

1. Honda. Accord, CR-V, Legend, Pilot models.
2. Chrysler.
3. "Audi" (all after the 80th model).
4. Skoda Octavia.
5. "Mercedes".

It is possible to list the brands and models of cars for a very long time, because there are many unknown or little-known manufacturers who make cars with galvanized bodies. Among experts, there is an opinion that Audi cars have the best bodywork. The concern produces galvanized galvanizing, covering the entire body with an anti-corrosion layer. However, according to reviews, it is known that such well-known cool cars as the Porsche 911 or the Volkswagen Passat have bodies that do not rot for decades. Korean manufacturers Kia and Hyundai are produced with galvanized bodies. The same can be said about many other high-quality cars that have undergone thermal or galvanic galvanization.

As for Chinese or Russian cars, here too, the application of an anti-corrosion coating takes place, but not on all models. For example, Chinese Cherry cars of the CK and MK series rot quickly enough. Sometimes manufacturers simply deceive the consumer by pretending to be a galvanized body with an ordinary cattophoresis soil with an admixture of zinc.

Generally speaking, Audi, Volkswagen, BMW, Porsche are the main manufacturers, which mainly produce models with fully galvanized bodies. In general, if in the characteristics of the car there is no word "full" next to the term "galvanized", then we can assume that there is an anti-corrosion coating only on some parts of the body. Most often we are talking about the bottom and the sill.

Now you know which car has a galvanized body, but in any case, when buying a car, you need to clarify this point, checking the technical characteristics.

Features of thermal galvanizing

Given that there are different methods of zinc, it is logical to explain how they differ from each other. As already mentioned above, heat treatment is used only by large European manufacturers. The bottom line is as follows: the car body is completely immersed in a special zinc-containing solution. After that, the composition heats up to the desired temperature, as a result of which zinc particles stick to the metal. A thin film forms on the metal surface, which does not allow moisture to pass through and prevents oxidation.

Cars with such bodies show the best results in salt chambers. Some manufacturers generally give large guarantees for bodies that have been processed in this way. Sometimes the warranty period reaches 30 years. The minimum service life of such vehicles is at least 15 years. That is, during all this time, the body will not even begin to rust.

Not every manufacturer can afford this technology. As mentioned above, this method is used in cars of the VW Group: Audi, Porsche, Volkswagen, Seat.

Also, some other manufacturers can boast of making similar bodies. In particular, the body of the Ford Escort is thermally galvanized. The new models Opel Astra and Vectra, as well as the Chevrolet Lacetti are not an exception.

All these cars are more expensive than their analogues due to the high cost of implementing such anti-corrosion treatment technology.

How is galvanized galvanizing carried out?

This method is simpler and more concise, but less effective. However, automakers still give long-term processed in this way.

The process of applying an anti-corrosion layer by electroplating is simpler:

1. The car body or any part of it is immersed in a container containing an acidic zinc solution.
2. The negative terminal is connected to the body from the power source.
3. The container itself is connected to the positive terminal.

With this connection, electrolysis is carried out in the tank. As a result of this process, the zinc particles dissolve and adhere to the car body. This forms a protective layer, which also prevents the oxidation process and repels moisture. This method is simpler and cheaper. Therefore, the machines, galvanized by the galvanic method, are more affordable. However, the effectiveness and service life of such a coating is lower. A body with a thermally applied anti-corrosion coating will resist moisture for much longer.

BMW and Mercedes are among the leaders among automakers that galvanize their vehicles.

Partial galvanized

Many manufacturers use only partial galvanizing, passing it off as complete. This applies primarily to Chinese, Russian brands, as well as some Korean manufacturers. For example, "Lada Granta" and "Lada Kalina" are partially galvanized. The bodies of these cars are covered with a protective anti-corrosion layer by 40%, but this is not bad either. Here the thresholds and the bottom of the car are treated with an anti-corrosion compound. In this case, we are talking about one-sided galvanizing. The second side (inner) is painted and primed using traditional methods.

This approach allows manufacturers to save money and produce a class tailored to the mass consumer. But this does not prevent us from talking about anti-corrosion treatment in commercials, because it really does take place.

Conclusion

A car with a galvanized body is not new. Anti-corrosion coating technologies have been known for a long time. But do not pay attention to the loud statements of manufacturers. First of all, you need to look at the warranty period that concerns give to the bodies produced.

Body materials determine the overall weight, strength, reliability and durability of the vehicle. Manufacturers are looking for new technological solutions; they widely use aluminum alloys, new polymers, and composite materials. However, the most widespread products are made of sheet carbon steel.

The production of steel sheet for the automotive industry is well developed, it allows you to obtain a material with the desired properties, has a minimal cost. Automakers are improving designs and technologies (such as spot welding or laser welding) to improve the performance of their production models.

Body protection against corrosion.

The task belongs to the most important group. Various methods are used to solve:

• Manufactured from corrosion-resistant materials... The method is effective, but polymer structures do not have the specified mechanical characteristics, and aluminum alloys and composites significantly increase the cost of production and the finished car.
• Protection with mastics, painting... The applied mastics and paints and varnishes do not provide the required level of protection against moisture and aggressive chemicals, for example, road reagents. They do not have sufficient resistance to mechanical stress - they are subject to abrasion, crack over time, and are easily damaged by minor impacts. Damage sites turn into corrosion centers.
• Application of protective films (layers of various materials)... The method is not new, but it remains the most promising in terms of cost and efficiency. Among the technologies used, zinc coating is considered optimal (galvanizing, galvanizing, galvanizing).

Zinc as a protection for steel.

Galvanizing is the most widespread method of protecting iron and steel products from corrosion caused by natural (moisture, temperature) and artificial (aggressive chemicals) factors. In fact, more than 40% of the zinc produced annually in the world is used specifically for protective coatings.

This situation is due to the high efficiency of several protection mechanisms characteristic of galvanized steel products:

• Formation of barriers... Zinc quickly forms films of oxide or other compounds that are chemically passive to the effects of various substances. As a result, the access of reagents provoking corrosion to steel products is limited, Zn compounds perform the functions of a sealant formed on site.
• Electrochemical protection... Due to the difference in electrochemical potentials (-0.441V - Fe, -0.763V - Zn), the latter, deposited on the surface of iron or steel parts, acts as an electrochemical protector. In fact, corrosion processes take place in the protective layer without affecting the base material. Protection extends even to areas without coverage (within the radius of the protector) - if the integrity of the zinc layer is partially violated, the protective properties are retained.
• Partial regeneration... The potential difference between the materials also causes the transfer of Zn particles to the unprotected surface of the base material, allowing for the self-healing of minor defects or damage.

Problems of galvanizing technological processes:

• Ensuring the required level of adhesion - the adhesion of the zinc layer to the surface of the material.
• Obtaining a given thickness. With an annual rate of destruction of zinc plating from 0.85 (minimum) to 6 microns, for a 5-15 year warranty on the body, a thickness of 2-5 to 10-20 microns is required.
• Protection of complex configuration parts.

Technologies, properties of coatings, advantages, disadvantages.

For galvanized bodies, automakers give a solid warranty - from 5 to 30 years. The characteristics of the protective layer largely depend on the applied method of application.

Several galvanizing technologies are used in the automotive industry:

• Hot (thermal);
• Electroplating;
• Cold;
• Zincrometal.

Thermal (hot) galvanizing.

Zinc melt technology is the oldest, but provides the most effective protection. It was proposed back in 1742 by Paul Jacques Malouin, a French scientist known for his work in the field of physics and chemistry. The text of the report for the Royal Academy of France contains a description of the method of applying a Zn layer to the immersion surface of steel products in a bath with a melt, and a detailed discussion of the ongoing processes.

Thermal galvanizing is the process of coating a metal (iron, cast iron, steel) with a layer of zinc at a high temperature. The technique consists in immersing the structure in molten metal heated to 450-500 degrees. For uniform deposition of Zn on the surface, rapid filling of cavities in structures of complex shapes, penetration into places of surface defects (cracks, pores, cavities), the protected structure moves in the melt (or a current of molten metal is created relative to the structure) at a constant low speed.

Several processes are going on at the same time:

• The surface of the steel product is heated, due to which there is an intense diffusion of zinc into the near-surface layers. Provides a high degree of adhesion of the coating, reliable adhesion to the surface.
• Zinc penetrates into the domain structures of the metal, forming a pseudo-alloy with steel, which has a high mechanical strength.
• On the surface, pure Zn reacts with oxygen to form an oxide. At high temperatures, the reaction with carbon dioxide (carbon dioxide) in the atmosphere proceeds intensively. As a result, the surface is covered with a film of zinc carbonate - a solid, chemically inert material with respect to most influences, realizing a barrier protection against corrosion.

Thermal galvanizing has significant advantages:

• The simplicity of technologies for applying a layer of a given thickness (it is regulated by the temperature of the melt, the residence time of the structure in the bath, the speed of movement of the protected part in the zinc mass).
• Homogeneity of the protective coating, the possibility of using widespread methods in metallurgy for thickness control (electromagnetic, magnetic and other meters).
• Special properties of the film to improve the mechanical properties of the product. The upper soft layers extinguish the impact energy, the internal pseudo-alloy mass increases the mechanical strength. According to the testimony of representatives of concerns - car manufacturers, after processing the finished body in molten zinc, the increase in structural strength can reach 50%.
• Self-control of the surface of parts. Indeed, if the preparation of the metal surface (workpiece) is not carried out properly, the deposition of Zn in the area does not occur, the defect is detected visually or by instrumental methods.
• The quality of processing remains constant regardless of the nature of the surface - in open areas, in hidden cavities, even in the presence of invisible structural defects. In the most problematic places - corners and edges, due to the specifics of the process, the thickness of the protective layer increases (unlike other methods).
• Depending on the composition of the steel (the content of alloying components and impurities, including non-metals - phosphorus, sulfur, etc.), it is possible to change the appearance (due to the formation of various compounds), the thickness of the galvanized. Protective abilities remain unchanged.

The economic advantages of the technology should also be noted - the minimum processing time, the simplicity of the process automation, which makes it possible to achieve high productivity, low cost, the ability to work with structures of any size and shape. At the same time, the finished products do not require additional preparation before painting, and the adhesive ability ensures the quality of the paintwork application.

An additional advantage is the ease of regeneration of zinc protection. The ability to self-repair allows you not to use additional measures to repair minor defects. Large, easily removed by local treatment with zinc-containing primers, paints, repair mixtures (included in Zn is involved in chemical recovery processes).

Another important fact is that the coating does not impair the properties of the base material, for example, thermal conductivity and electrical conductivity.

Disadvantages of hot-dip galvanizing.

Despite many important advantages, the use of thermal technology and galvanizing of car bodies has not become widespread. The reason for this is the disadvantages of the method:

• Providing the productivity required for an automobile conveyor requires significant capital investments from companies to equip galvanizing lines with large baths.
• Maintaining significant volumes of melt at a given temperature level is a task requiring serious energy consumption. This affects the cost of production, worsens the environmental component. Heavy fines in the light of the current environmental legislation (for example, in Japan and Europe) also have a serious negative economic impact.
• After the completion of the process, welding, drilling holes, etc., violates the integrity of the protective coating. Accordingly, the design and manufacturing process becomes more complicated (it is required to provide for the maximum number of operations at the stages before galvanizing).
• Some types of work, for example, welding, require special technologies and equipment.
• Constructive calculation of parts must be carried out taking into account processing. Otherwise, additional surface loads can lead to mechanical failure.

As a result, despite the recognition of the reliability, quality, and economic feasibility of hot-dip galvanizing, only some manufacturers use it to protect car bodies.

Auto with hot-dip galvanized body.

Thermal technology is used by car manufacturers to obtain a protective zinc layer with a thickness of 2-100 microns on body parts (individual or entire structure). This allows:

• Ensure the corrosion resistance of body structures for 15 years or more (the owner receives appropriate guarantees);
• Get coverings that are 3-4 times superior to others;
• Increase the resistance of products to mechanical damage (with minor influences).

Manufacturing difficulties have limited the number of manufacturers using this protective technology in full.

The leader is the VW Group, which widely uses hot-dip galvanizing for cars of manufactured brands. Achievements in the field of tread methods of the Audi company are especially great.

It was the world famous Audi 80 that became the first production car model to receive a fully galvanized body. On the roads today, these cars (or no less high-quality Audi 100) are often found, the bodies of which still remain in perfect condition. Already in 1986, practically the technologies were used for all cars of the brand.

The company is constantly improving technological processes for obtaining protective coatings. The latest developments include a method of double-sided galvanizing not only of metal parts, but also of welded seam structures.

Thermal galvanizing for body elements is also used by Volvo. The complex of aluminum parts and galvanized steel products allows the brand's machines to be in the top reliability ratings for a long time.

Galvanized zinc.

Galvanizing by galvanic method is the application of a thin zinc layer on the surface of the product due to a special composition of electric current flowing through the electrolytes. The technology is used to obtain layers with a thickness of 2–40 µm.

Technologically, the process is as follows:

• An electrolyte solution is placed in the electrolysis baths - acidic, containing Zn in the form of hydrating ions (sulfates, chlorides, fluoroborates), complex ones, in which Zn is part of anions (cyanides, zincates, pyrophosphates) or cations (ammoniaates, ethylene diaminates).
• The cathode of the installation is a protected metal structure.
• The anode is a zinc electrode (or made of special zinc-containing compounds).

A direct current with a density of 1-5A / sq.dm is passed through the solution. Positively charged zinc ions are attracted to the cathode, restore the charge to neutral, forming a metal layer on the surface. The anode provides the supply of Zn ions to the solution, replenishing the losses.

Advantages and disadvantages of the method.

Electrolytic (galvanic) technology is the most widespread, due to the obvious advantages:

• high performance;
• the ability to process parts and structures of complex configurations;
• density and uniformity of the layer, filling of invisible small defects.

The galvanized coatings obtained have all the protective properties inherent in galvanizing. At the same time, the equipment for performing operations and materials can somewhat reduce the production cost, in comparison with the traditional thermal method.

Among the disadvantages of the technology are:

• The need for careful preparation (special treatment) of the protected surface.
• Lower adhesion and diffusion depth of zinc into the material in comparison with hot-dip galvanizing.
• Possibility (with inaccurate observance of technologies and process parameters) of a significant change in the electrochemical properties of steel, which may result in an increase in the tendency to develop corrosion processes.
• The manifestation of side effects, such as hydrogen saturation, causing an increase in the fragility of structures and a change in the electrochemical properties of the material.

In terms of capital costs and energy losses, galvanic technology is comparable to thermal technology (volumetric baths, powerful current sources, additional energy costs to eliminate side effects are required). The method is also problematic from the point of view of ecology - most of the solutions used are poisonous and require special measures for processing.

However, ease of implementation, process control, and accurate results have led to wider adoption in the automotive industry.

Auto protected electrolytic zinc plating.

Achieving a high level of protection against deposited galvanic zinc coatings is possible only with the use of a set of protective measures. This path was chosen by the leaders of the European automotive industry - BMW and Mercedes-Benz. Technologies used include:

• Manufacturing of body parts from high quality alloy steel with precise dosage of impurities;
• Galvanizing with a galvanic method (layer thickness 9-15 microns) with exact observance of the parameters of the technological process;
• The use of high-quality paint and varnish materials with special properties (adhesion, resistance to damage, ultraviolet radiation, etc.).

The result is equally impressive tread performance as compared to Audi, while reducing production costs.

Cold galvanized.

The essence of the technology is to apply zinc-containing compositions with pre-selected characteristics to the surface of the parts to be protected. The result of using the compositions is the formation of a protective coating with anticorrosive properties approaching those obtained by other methods.

The advantages of cold technology include:

• Ease of performing operations, low cost - the compositions are applied as paintwork, do not require special equipment, additional chemicals, or energy consumption.
• Minimum restrictions on use - it is allowed to work in a wide range of temperatures (-20 .. + 40 degrees), indoors and outdoors, in industrial or domestic conditions.
• High level of adhesion to metals and paintwork.
• Ability to work with structures of any geometric shapes;
• Ease of restoration of damaged protective layers.
• Minimal environmental impact.

Such a set contributes to the spread of the cold galvanizing method in the automotive industry, allowing it to be used even in the production of budget cars.

However, the quality of the product obtained can be significantly inferior to the results of the use of thermal or galvanic technologies.

• An acceptable degree of protection is achieved only with the use of high quality compounds and careful preparation of parts;
• The resistance of the layer to mechanical stress is much lower;
• Processing hidden areas and areas with limited access is difficult.

Zincrometal.

The technology differs from those described radically - it is not the finished product that is coated, but the metal (steel) at the manufacturing (rolled) stage. For this, inorganic compounds and organic polymers are used, with a high content of zinc and its oxides (soils).

The material, like most sheet steels, has excellent structural properties. It is easily supplied to forming, stamping, does not impose additional conditions during welding, is compatible with traditional primers, adhesives, varnishes and paints. The protective properties are not violated during the listed operations.

In the main - in terms of the degree of protection against corrosion, the material is significantly inferior to hot and galvanized galvanizing. Therefore, as a rule, it is used only in inexpensive car brands, the manufacturers of which, trying to stay in trend, declare about the "galvanized body".

A video about the types of galvanizing, simple and clear.

More about the types of galvanizing.

In addition to various galvanizing technologies, galvanized car bodies differ in the degree of processing:

• Full- a protective coating is applied to all parts, hidden and hard-to-reach areas, cavities, etc. are covered. One- and two-sided are used.
• Partial- the areas in the most unfavorable conditions are processed, necessarily - the nodal joints.
• Nodal connections- only critical areas are protected - welded seams, mounting parts of fasteners and the like.

As a partial, zinc-plated anti-corrosion protection of the bottom has become widespread. From the point of view of operation and cost, this method is fully justified. Full galvanizing of the body is another matter. First of all, you should consider the cost and price of a car. In addition, environmental protection problems arise - environmentally unsafe chemicals are widely used during processing, the release of which into the atmosphere and water is almost impossible to prevent. The tightening of environmental legislation is becoming the reason for the refusal of European, American, Japanese car manufacturers from full galvanizing.

Is galvanizing effective?

A lot of car owners are asking this question. Of course, the argument "for" is a guarantee against perforating corrosion of the body for 7-15 (often more) years.

However, messages on forums from car owners, opinions of service center specialists give rise to doubts. Often there are stories showing that any type of galvanizing, under certain conditions, ceases to protect structural parts. Moreover, the acceleration of the corrosion process is often observed.

Audi 80 and 100, Volkswagen are cited as examples. Passat B3 and B5. These models come from the 80s, 90s, 2000s, respectively, serve as an example of high-quality processing, reliable protection. That is why their owners today cannot make claims - in most cases, despite their advanced age and, often, the difficult operating conditions of the car body remain in perfect condition.

There are also "anti-heroes" of the process. These include, for example, Peugeot 307 (2004-2006). The galvanized bodywork of these cars rusts faster than the untreated metal of other automakers. Poor quality composition violation of technology, other reasons - to understand the experts. The conclusion for an ordinary motorist is simple - often the word "galvanized" is a good marketing ploy. To avoid the catch SHOULD REMEMBER:

• Only cars with full galvanized bodywork can be considered really protected.
• In addition to the manufacturer's statements, one can judge the degree of reliability of the coating by the warranty period - at least 5-7, ideally 15 or more years.
• Even with full galvanizing, a violation of technology can serve as a source of problems and lead to accelerated development of corrosion.
• Processes under the protective layer can develop secretly.

In a word, when buying a car, information about the type and technology of zinc coating will not be superfluous. Some details are shown in the lists below.

Galvanized car bodies (lists).

The most popular brands and models of cars on the Russian market are included in the lists by galvanizing technologies. In addition, the years of manufacture of the car, the degree of processing are indicated.

Hot dip galvanized.

• Audi all models from 2001;
• Cadillac ATS (since 2012), BTS (since 2006), Catera, DeVille, Escalade, Seville (all since 2001), CTS, DTS, SRX, STS, XLR;
• Ford Escape, Expedition, Explorer, Fiesta, Focus, Galaxy, Maverick, Mustang, Mondeo, Taurus (all since 2001), C-Max, Fusion, Kuga, Ranger, S-Max, Tourneo Connect:
• Jaguar F-Type;
• Peugeot 307 - one-way;
• Porsche - the entire model range;
• Volvo - Thermal technology is used for all models.

Partial, one-sided (unless otherwise stated):

• Audi A1, A2, A4 Allroad, TT (up to 2001);
• Cadillac Catera, DeVille, Escalade, Seville (all up to 2001);
• Ford Escape, Expedition, Explorer, Fiesta, Focus, Galaxy, Maverick, Mustang, Mondeo, Taurus (all up to 2001).

Galvanized zinc plating.

Full, double-sided (unless otherwise noted):

• BMW - since 1998, all models of the body;
• Chevrolet Astro, Blazer, Cruze, Express, Impala, Malibu, Nivam Suburban, Tracker (all since 2003), Camaro of the latest generation (since 2013), Corvette (since 2000), Tahoe (since 2006), Aveo, Captiva, Cobalt, Epica, Evanda, Lacetti, Lanos, Orlando, Rezzo, Sparkm TrailBlazer;
• Chrysler 300m, Concorde Grand Voyager, Neon, Sebring (all -c 2000), Aspen, Crossfire, Pacifica, PT Cruiser;
• Citroen Berlingo, C1, C2, C3, C4, C5, C6, C8, Jumper, Xantia, Xsara Picasso (all since 2007), C3 Picasso, C4 Aircross and Picasso, C-Crosse, C-Elysee, DS3, DS4, DS5, Jumpy;
• Daewoo Evanda, Gentra, Lacetti, Matiz, Nexia, Rezzo, Sens, Winstorm (all since 2007);
• Dodge Avenger, Caliber, Caravan, Challenger, Charger, Dakota, Durango, Magnum, Neon, Ram (all since 2007), Viper (since 2000), Journey, Nitro;
• Honda Accord, Civic, CR-V, Element, Elysion, Fit, FR-V, HR-V, Insight, Inspire, Jazz, Legend, Mobilio, Odyssey, Partner, Stepwgn, Stream (all since 2005), Airwave, Crosstour , Pilot, Ridgeline;
• Infiniti EX Series, G Series, M Series (all since 2007), FX Series, JX Series, Q50, Q60, Q70, QX50, QC60, QX70, QX80;
• Jaguar S-Type, X-Type, XJ, XK (all since 2007), XE, XF;
• Jeep Cherokee, Grand Cherokee, Commander, Liberty, Wrangler (all since 2007), Compass, Patriot, Renegade;
• Land Rover Discovery, Freelander, Range Rover (all since 2007), Defender, Discovery Sport, Range Rover Evoque and Sport;
• Lexus - all models from 2007:
• Mazda - auto production since 2007;
• Mitsubishi - since 2001 all cars;
• Nissan - since 2007 all cars produced.
• Mercedes-Benz - bodies of all models since 1999
• Mini - everything:
• Opel - in 2008, the partial gave way to the complete.
• Saab 9-2x, 9-3, 9-5, 9-7x (all since 2007);
• Since 1999, Seat has been producing cars only with full galvanized galvanization;
• Skoda - from 1999 to the current moment, production cars receive full two-sided electroplated protection;
• Subaru Forester, Impreza. Justy, Traviq (all since 2002), Baja, Brz, Legacy, R1, R2, Tribeca, WRX, XV;
• Suzuki - in 2007, the manufacturer abandoned cold galvanizing on all manufactured models in favor of full galvanic.
• Toyota - since 2000, cars are produced only in galvanized galvanized bodies. The company uses only full double-sided galvanizing for all production models.

Partial:

• Chevrolet Astro, Blazer, Cruze, Express, Impala, Malibu, Niva, Suburban, Tracker (all up to 2003), Camaro (up to 4th generation inclusive), Corvette (up to 2000);
• Fiat 500, 500L, Albea, Barchetta, Bravo, Doblo, Ducato, Freemont, Linea, Palio, Panda, Punto, Scudo, Siena, Stilo, Ulysse;
• Honda Accord, Civic, CR-V, Element, Elysion, Fit, FR-V, HR-V, Insight, Inspire, Jazz, Legend, Mobilio, Odyssey, Partner, Stepwgn, Stream (all up to 2005);
• Opel up to 2008 - all models;
• Peugeot 107, 2008, 206, 207, 208, 3008, 308, 4007, 4008, 406, 407, 408, 508, 607, 807, Boxer, Expert, Partner - two-sided;
• Subaru Forester, Impreza. Justy, Traviq (all before 2002) - bilateral;

Cold galvanized.

Partial:

• Chery Amulet, Arrizo7, Bonus, Cross Eastar, Eastar , For a, Indis, Karry, Kimo, M11, QQ, QQ6, Tiggo, Very - one-sided;
• Citroen Berlingo, C1, C2, C3, C4, C5, C6, C8, Jumper, Xantia, Xsara Picasso (all up to 2007), Xsara;
• Daewoo Evanda, Gentra, Lacetti, Matiz, Nexia, Rezzo, Sens, Winstorm (all up to 2007), Kalo, Lanos, Leganza, Magnus, Nubira;
• Dodge Avenger, Caliber, Caravan, Challenger, Charger, Dakota, Durango, Magnum, Neon, Ram (all up to 2007), Viper (up to 2000);
• GreatWall, Haval - all models:
• Hyundai Accent (since 2001), Avante, Elantra, Getz, Grandeur, Matrix, Santa Fe, Sonata, Terracan, Tiburon, Tucson (all since 2005), Genesis, i20, i30, i40, ix35, ix55, Solaris;
• Infiniti EX Series, G Series, M Series (all up to 2007), I Series, Q45;
• Jaguar S Type. X Type, XJ, XK (all up to 2007);
• Jeep Cherokee, Grand Cherokee, Commander, Liberty, Wrangler (all up to 2007);
• Land Rover Discovery, Freelander, Range Rover (all up to 2007);
• Lexus - all models up to 2007;.
• Lifan (all cars);
• Mazda - until 2007;
• Nissan - everything from 2000 to 2007
• Saab 9-2x, 9-3, 9-5, 9-7x (all up to 2007);
• Ssang Yong - the manufacturer applies zinc-containing compounds to parts of body structures of all auto model range;
• Suzuki - cars manufactured before 2007;
• VAZ, GAZ - in 2009 they switched to partial cold galvanizing of all body structures;
• UAZ has been applying protective zinc-containing compounds since 1998.

Node connections:

• Fiat - almost all models produced at the end of the 20th century (until 2000);
• Hyundai - until 2005;
• VAZ, GAZ - they began to use the protection of critical connections since 1999.
• TagAZ - all currently produced models.

Zinc metal body.

• Kia Bongo, Carens, Carnival, Ceed, Cerato, Forte, Magentis, Mohave, Opirus, Optima. Picanto, Pride, Quoris, Rio, Shuma, Sorento, Soul, Spectra, Sportage, Venga;
• Renault has been producing zinc metal bodies for production vehicles from 2000 to the present.