Development of an Electrical Resistance Sensor from High Strength Steel for Automotive Applications

This work focuses on a demonstration of the monitoring of corrosion processes taking place in high strength steel in automotive applications. This is performed by means of a corrosion sensor, which operates as an electrical resistance sensor. It was developed from the same type of material that is used for the high-strength steel parts produced in the automotive industry. Using the sensor, real time corrosion processes can be measured. It is attached to a location inside the vehicle’s engine and is equipped with a data logger, which enables wireless transfer of the measured data. In this study the development, operation, and evaluation of the monitoring process are presented. Corrosion estimation is verified by means of electrochemical methods. A metallographic investigation was included in order to verify the similarity between the microstructural properties of the sensor and those of the as-received high-strength steel sheet.