A car is one of the most metal—intensive mass-produced products. Weight, safety, fuel consumption and even the appearance of the car depend on the choice of alloy. Let's look at which metals and coatings are used in the body and in such small but noticeable details as emblems.
Steel remains the basis of the body. Most of the load-bearing elements of modern passenger cars are still made of steel, but not from ordinary steel. Manufacturers use high-strength and ultra-high-strength grades that make parts thinner and lighter without loss of rigidity. For the most stressed safety elements, such as racks and thresholds, hot stamping (press hardening) of boron-containing steels is used: the workpiece is heated, molded and quickly cooled in a die, after which the part acquires a very high strength.
Galvanizing protects against corrosion. To make the body last a long time, the sheet steel is coated with zinc or zinc alloys, and then primer and paint are applied. Without this layer, the metal would quickly corrode in conditions of humidity and road reagents. It is the quality of the coating that largely determines the end-to-end corrosion guarantee provided by manufacturers.
Aluminum reduces weight. Light metal is used in hoods, doors, fenders and whole bodies. A well—known example is the Audi A8 with an aluminum frame (Audi Space Frame technology, introduced in 1994). In 2015, Ford converted the body of the F-150 pickup truck to aluminum alloys, showing that such solutions also work in the mass segment. The disadvantage of aluminum is more expensive materials and difficult repairs after an accident.
Stainless steel and exotic. Rare cases are stainless steel bodywork, like the Tesla Cybertruck. Magnesium alloys are used in seat frames and steering wheel elements, and titanium is found in the exhaust systems of expensive sports cars. Such materials are too expensive for mass models.
Emblem: a small detail with a serious composition. The icon on the radiator grille seems simple, but there are strict requirements for it: it must withstand temperature changes, water, salt, sinks, and ultraviolet light. Historically, emblems were cast from zinc alloys or brass and plated with chrome. Chrome plating gives shine, hardness, and corrosion resistance, which is why chrome badges have become classics.
Modern emblems are more often plastic. Today, many badges are made of impact-resistant plastic (for example, ABS) with electroplated chrome coating. It's easier and cheaper, and the form can be made more complex. In addition, cars with adaptive cruise control often have a radar located behind the emblem. The material and coating are selected to allow radio waves to pass through, so the metal badge in this place is replaced with a special design.
Figures on the hood. Separate