Corrosion concerns in vehicle exports from India: Causes, risks and solutions

India has rapidly emerged as a major hub for automobile exports, with Indian-made vehicles reaching markets across Africa, Southeast Asia, the Middle East, and Latin America.

- By Dr Prakul Rakesh

Introduction

In FY 2023 (ended March 2024), India exported 672,105 passenger vehicles, which represented about 13% of its domestic production.¹ In FY 2024–25, exports surged to 755,000–765,000 units, a 12–14% rise from FY24.

The rising trend of vehicle export shows clear market in future, however, one persistent challenge for exporters is corrosion – the silent enemy that can damage the vehicle's structural integrity and aesthetics during transit. This feature explores the causes, risk factors, and preventive measures for corrosion in vehicles being exported from India.

Why corrosion occurs during export

Corrosion is a natural electrochemical reaction where metal reacts with moisture, oxygen, and salts, leading to rust formation.

During export, the conditions are highly conducive for corrosion due to:

1. High humidity in coastal ports

Most Indian ports (e.g., Mumbai, Chennai, Kochi, Vizag) are located in humid, salty coastal areas. Vehicles stored in open yards for even a few days may begin to show signs of corrosion.

2. Long transit times

Shipping to distant markets (such as South America or Africa) may take 2-6 weeks, during which vehicles are exposed to:
☐ Salt-laden sea air
☐ Condensation in containers or ship decks
☐ Fluctuating temperatures

3. Poor packaging or protective measures

Vehicles exported without adequate protection (e.g., shrink wrapping, rust inhibitors, or VCI) are more vulnerable to surface oxidation, especially on exposed parts like:
☐ Brake discs
☐ Undercarriage and suspension
☐ Wheel hubs
☐ Fasteners and battery terminals