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Coil-coated sheet has a large potential in the automotive industry. However, several shortcomings like reduced corrosion resistance due to cutting and forming processes have to be overcome to meet customers' demands. To improve the processing of coil-coated steel, there is a strong need for a better understanding of the mechanisms that lead to failure of the coating systems and the application of computer simulation of the processing itself. In this research a Finite Element Method is applied in order to simulate processing steps such as cutting and forming of coil-coated material. This computational method is combined with an advanced experimental system analysis. Modern electrochemical and surface analysis techniques will be applied to detect crucial defects in the coating after the processing step. The results obtained will be compared with those resulting from the evaluation of standard corrosion tests to generate reliable critical values and a mechanistic understanding.
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