Processing and Corrosion Control of a Magnesium Body Structure Element

  1. Dr. P. J. Winkler
  1. Harald Schreckenberger and
  2. Günther Laudien

Published Online: 23 DEC 2005

DOI: 10.1002/3527606025.ch6

Materials for Transportation Technology, Volume 1

Materials for Transportation Technology, Volume 1

How to Cite

Schreckenberger, H. and Laudien, G. (2000) Processing and Corrosion Control of a Magnesium Body Structure Element, in Materials for Transportation Technology, Volume 1 (ed P. J. Winkler), Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, FRG. doi: 10.1002/3527606025.ch6

Editor Information

  1. DaimlerChrysler AG, Forschung und Technologie, Postfach 800 465, 81663 München, Germany; Tel.: 089–607 22393; Fax: 089–607 28627

Author Information

  1. Volkswagen AG, Wolfsburg, Germany

Publication History

  1. Published Online: 23 DEC 2005
  2. Published Print: 20 APR 2000

Book Series:

  1. EUROMAT 99

ISBN Information

Print ISBN: 9783527301249

Online ISBN: 9783527606023



  • transportation technology;
  • materials;
  • automotive;
  • magnesium body structure element;
  • corrosion control;
  • processing


The hatchback of Volkswagen's 3-liter car (3 l consumption per 100 km) consists of an inner component of die casting magnesium (AM50) which is covered with an aluminium panel from the outside. This hybrid design normally requires a new manufacturing process: The already pre-coated magnesium part will be bonded and folded with the bare aluminium part. The corrosion protection is provided by an organic coating system which protects both against general corrosion and galvanic corrosion as well. The corrosion of the Al/Mg sandwich has been examined at hybrid samples which are similar to the hatchback. Several powder coatings (epoxy resin, polyester resin, hybrid resin), wet paints and cathodic electro-coating paints of different degrees and compositions have been applied to the magnesium part. They show that only powder coating gives enough protection. Galvanic corrosion at the points of attachment of the hatchback might be possible (for example the bolted joint of the hinge). The resistance against galvanic corrosion has been tested at samples that had a damaged paint coat in order to simulate a defect. Furthermore different contacts (Fe, Al, Zn, etc.) have been fixed conductively. Under laboratory conditions the corrosion load has been made for all test samples with 30 cycles in the environmental corrosion testing.