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Steel. It’s a versatile material used extensively in modern car construction. Steel does have a downside though, left unprotected, the iron in the metal begins to oxidise forming what we know as rust. As the rust starts to take hold, components begin to corrode and lose integrity. Eventually, parts can fail entirely.
A Swedish insurance company recently commissioned ANCAP’s European counterpart to crash test older, rusty vehicles. The results are startling.
Engineers found that rust causes metal to lose structural integrity and become weak. So an older vehicle doesn’t perform as it did when initially crash tested. This problem is further compounded when you consider ageing models feature fewer modern safety technologies.
The Mazda6 did not perform well under the test.
In a frontal impact collision, the crash test dummy’s head made contact with the steering wheel after the airbag bottomed out. The dummy then bounced off the wheel into the door upright. The car’s body shell deformed in an unexpected manner and the floor caused lower leg injuries when spot welds failed and separated. Crash engineers noted that a weak floor could allow objects to pierce the vehicle’s underside and enter the cabin, with disastrous consequences.
Over the decade since production ceased, Mazda's sedan dropped from a weak four out of five to a weak three points. In total, it shed 8 points on NCAP’s scoring system.
Researchers concluded that in a heavily corroded vehicle, occupants had a 20% higher likelihood of dying in a crash.
The laboratory tested both cars to the same standards as when new, not to more recent and stringent evaluations.
Manufacturers apply anti-corrosion paints to crucial components at the factory, but eventually stone chips and wear cause coatings to break down. Drivers living in coastal areas will suffer accelerated oxidisation, thanks to a high salt content in the air. Boats and vehicles taken onto the beach also suffer badly with rusting.
You can identify rust by bubbling, flaky paint and a red/brown pitting. Rust generally starts small but will get worse if left untreated. If you are buying a car, take time to look underneath and examine the condition of structural metal components. If you see ragged holes and lots of loose corrosion, the car may be too far gone.
It’s possible to use a hammer to ascertain the condition of metal surfaces. If you tap the steel and it produces a sharp, defined ring, the metal should be in sound condition. If tapping makes a dull thud, the steel has most likely started corroding.
Once the rust on a part reaches a certain point, it will need replacing or repairing by a professional welder. You are far better off preventing rust by taking some simple precautions.
Research shows that newer vehicles are statistically safer. You can use our car loan comparison to find a great deal on a modern car. We’ve also written about Australia's safest cars. Use ANCAP or used car safety ratings to find out how your car performed when crash tested.
Drivers will find our article on what happens to your body in a car crash a sobering read.
Pictures: Shutterstock
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