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How can you make automotive electronics more resistant to corrosion and wear?

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Corrosion and wear are common challenges for automotive electronics, especially in harsh environments and under frequent use. They can degrade the performance, reliability, and safety of electronic components and systems, leading to increased maintenance costs and customer dissatisfaction. Fortunately, there are some effective ways to make automotive electronics more resistant to corrosion and wear, both in design and in operation. In this article, we will explore some of these methods and how they can benefit your embedded systems design.

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Daniel Morais

Coordenador de Manuten??o | Engenheiro de Confiabilidade | Especialista de Confiabilidade | Analista de PCM |

1 Choose suitable materials

One of the first steps to make automotive electronics more resistant to corrosion and wear is to choose the right materials for your components and circuits. Different materials have different properties, such as conductivity, thermal expansion, corrosion resistance, and wear resistance. You should select materials that match the requirements and specifications of your design, as well as the expected operating conditions and stresses. For example, you may want to use stainless steel, copper, or gold for connectors and terminals, as they have high conductivity and corrosion resistance. You may also want to use ceramics, plastics, or composites for housings and casings, as they have low thermal expansion and wear resistance.

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Daniel Morais

Coordenador de Manuten??o | Engenheiro de Confiabilidade | Especialista de Confiabilidade | Analista de PCM |
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Ao fortalecer a resistência à corros?o e ao desgaste na eletr?nica automotiva, a sele??o criteriosa dos materiais para componentes e circuitos é um passo inicial fundamental. Diversos materiais apresentam propriedades distintas, como condutividade, expans?o térmica, resistência à corros?o e resistência ao desgaste. A escolha deve estar alinhada n?o apenas com os requisitos específicos do projeto, mas também com as condi??es operacionais e as tens?es esperadas. Por exemplo, a preferência por a?o inoxidável, cobre ou ouro para conectores e terminais é fundamentada em sua alta condutividade e resistência à corros?o.

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2 Apply protective coatings

Another way to make automotive electronics more resistant to corrosion and wear is to apply protective coatings to your components and circuits. Protective coatings can provide a barrier against moisture, oxygen, chemicals, abrasion, and other factors that can cause corrosion and wear. They can also improve the electrical and mechanical properties of your components and circuits, such as insulation, adhesion, and lubrication. There are various types of protective coatings available, such as paints, varnishes, lacquers, resins, epoxies, silicones, and polyurethanes. You should choose a coating that is compatible with your materials, design, and application.

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3 Implement proper sealing

A third way to make automotive electronics more resistant to corrosion and wear is to implement proper sealing for your components and systems. Sealing can prevent or reduce the ingress of contaminants, such as dust, dirt, water, oil, and gas, that can cause corrosion and wear. It can also protect your components and systems from vibration, shock, and thermal stress. There are different methods of sealing, such as gaskets, o-rings, washers, plugs, tapes, adhesives, and soldering. You should use a sealing method that is suitable for your design, assembly, and installation.

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4 Monitor and control environmental factors

A fourth way to make automotive electronics more resistant to corrosion and wear is to monitor and control the environmental factors that can affect your components and systems. Environmental factors include temperature, humidity, pressure, acidity, salinity, and exposure to sunlight, rain, snow, and salt. These factors can accelerate the corrosion and wear processes, as well as induce thermal cycling, galvanic corrosion, and electrochemical reactions. You should monitor the environmental factors using sensors, indicators, and feedback loops, and control them using heaters, coolers, fans, filters, regulators, and switches.

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5 Perform regular maintenance and testing

A fifth way to make automotive electronics more resistant to corrosion and wear is to perform regular maintenance and testing for your components and systems. Maintenance and testing can help you detect and correct any signs of corrosion and wear, such as discoloration, cracks, loose connections, or faulty operation. They can also help you extend the lifespan and optimize the performance of your components and systems. You should follow the manufacturer's recommendations and guidelines for maintenance and testing, as well as use appropriate tools, equipment, and procedures.

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Michael Nixt

Mechanical Engineer at Naval Air Systems Command (NAVAIR)
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Treating corrosion early in its development will prevent it from spreading to the rest of the components and causingmore serious damage. Minor corrosion is often times expected, but regular maintenance to treat and attack corrosion will slow the process down and lengthen the lifespan of automotive components.

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6 Follow best practices and standards

A sixth way to make automotive electronics more resistant to corrosion and wear is to follow the best practices and standards for embedded systems design. Best practices and standards can provide you with proven and reliable methods, techniques, and principles for designing, developing, and deploying automotive electronics. They can also help you comply with the regulatory and safety requirements for your industry and market. You should consult the relevant sources and authorities for best practices and standards, such as the International Organization for Standardization (ISO), the Society of Automotive Engineers (SAE), and the Automotive Electronics Council (AEC).

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Michael Nixt

Mechanical Engineer at Naval Air Systems Command (NAVAIR)
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Give them to the Marines/Navy in shoreside or shipboard application. They will follow maintenance procedures, but the assembly will also be exposed to salt fog in a very corrosive environment. Despite using appropriate materials and coatings, parts are going to corrode. Examining failures and corrosion from the operational environment will highlight weak points. Some weak points will be easy to resolve, such as alllying a surface coating (paint/finish), while others will take more effort, such as a material change to a COTS component. Changes to COTS items are not always easy or straightforwards, but it can be worth the added cost and necessary synergy.

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How can you make automotive electronics more resistant to corrosion and wear?

1

2

3

4

5

6

7

1 Choose suitable materials

2 Apply protective coatings

3 Implement proper sealing

4 Monitor and control environmental factors

5 Perform regular maintenance and testing

6 Follow best practices and standards

7 Here’s what else to consider

Mechanical Engineering

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How can you make automotive electronics more resistant to corrosion and wear?

1

2

3

4

5

6

7

1 Choose suitable materials

2 Apply protective coatings

3 Implement proper sealing

4 Monitor and control environmental factors

5 Perform regular maintenance and testing

6 Follow best practices and standards

7 Here’s what else to consider

Mechanical Engineering

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