Why Are Older-Model Cars More Prone to Rust?
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June 19 09:08:18, 2025
If you've ever attempted to restore a vintage, classic, or antique car, you probably encountered rust on these older models. You might also wonder why modern vehicles from the 1990s onward seem less prone to such damage. Just like how car manufacturers have integrated more computer systems into vehicles, they’ve also concentrated on enhancing corrosion resistance for both the body and its components.
As a result, newer models are increasingly constructed using galvanized steel, which is treated to resist rust, along with aluminum parts. Here's what you need to know.
**Galvanized Steel**
Starting in the 1980s, more car manufacturers began utilizing galvanized steel, an alloy that bonds steel with zinc. While you may still find non-galvanized steel cars in certain markets, American models typically use this material for the body and panels as standard.
This bonding process places pure zinc on the exterior, with another zinc layer chemically attached to the iron in the steel. Under ideal conditions, galvanized steel can last up to 70 years without corroding, which is why it’s commonly used for original equipment manufacturer (OEM) parts.
Despite its advantages, galvanized steel isn't flawless. Any bends or welds in the steel are more vulnerable to rust. To counteract this, some manufacturers apply a sealant for additional rust protection in these areas.
What makes zinc so beneficial? Unlike paint, zinc doesn't flake off as a coating. Instead, it forms an electrolytic bond with the iron in the steel. Since the zinc sits on the steel’s surface in a thin layer, it directly interacts with oxygen in the air, shielding the alloy beneath and significantly reducing the chance of corrosion.
That said, the zinc layer does wear down over time, exposing the steel. In regions with high moisture levels or where road salt is frequently used, the corrosion process accelerates, potentially causing premature rusting unless proper care is taken.
**Aluminum Parts**
Aluminum is known for its corrosion resistance, prompting car manufacturers and aftermarket part producers to adopt it more frequently. Being lighter than steel, aluminum can enhance a car's fuel efficiency. However, unlike galvanized steel, aluminum can become contaminated easily, and its delicate structure might make it more susceptible to damage.
In the mid-2000s to 2010s, some carmakers claimed aluminum was impervious to corrosion. In 2015, *Consumer Reports* debunked this idea, revealing that aluminum could suffer from premature corrosion. This led to a class-action lawsuit against Ford regarding claims about their F-150 and Explorer models.
**Other Modifications**
Design adjustments also play a role in preventing rust. The undercarriage is usually the first place rust develops, so it often receives an undercoating for comprehensive protection. Recent innovations minimize spots where mud tends to accumulate, and modern vehicles use fewer seams, as these areas are prone to corrosion. In some cases, plastic replaces metal in rust-susceptible zones.
Manufacturers also pay close attention to the metals used for exteriors. Even trim pieces favor galvanized steel over stainless steel or chrome-plated materials.
If you spot signs of corrosion or peeling paint on your vehicle, get in touch with DaSilva’s Auto Body for rust removal services. To learn more about our offerings or to book an appointment, contact our Naugatuck location today.