Automotive Corrosion Evaluation from Simulated Salt-Treated Gravel Damage

Automotive underbodies in cold regions are exposed to severe corrosion conditions caused by deicing salts and gravel impingement. This preliminary study presents a controlled laboratory methodology for evaluating how simulated gravel-induced surface damage influences the subsequent corrosion behavior of automotive materials under accelerated chloride-rich exposure. Controlled surface conditions were produced using commercially available blasting media as laboratory surrogates to simulate varying levels of gravel-impingement severity. Surface morphology was characterized using 3D optical profilometry, and specimens were then exposed to a 23-wt.% sodium chloride spray using an accelerated corrosion chamber. The results show corrosion severity is influenced by the surface conditions.