A SEMINAR REPORT

ON

‘Salt spray test’

Prepared by:

Shashank Agrawal (06BMTR002)

Achit Gautam (06BMTR012)

Vishal Soni (06BMTR056)

 Contents

1. Introduction

2. Testing equipment

2.1 Salt Spray Testing Equipment

3. Standardization

4. Salt Spray Test Procedure

5. Uses & Application

6. References
 Abstract
Quality control of corrosion test results implies the validation of the corrosion test
method and estimation of the uncertainty of corrosion rate measurement. The corrosion
test in an artificial atmosphere of the salt spray mist needs evaluation of corrosivity of
the test cabinet by reference specimens. Such calibration of corrosion environment
raises very strict requirements for the method description and details of all procedures
and used specimens. Reliable corrosion measurements by spray tests require validation
of the experimental device together with the experimental procedure and determination
of corrosivity uncertainty of the test cabinet environment.

Corrosion tests have been conducted for a long time but there are only a few cases of
corrosion data quality assessment or inter laboratory comparisons for such
measurements. Each test method when used in different laboratories gives different
results, as it is impossible to perform the whole procedure exactly in the same manner.
Therefore, a very essential parameter of the method is its robustness. A proper
validation of the corrosion test method means the evaluation of the impact of various
environmental features and performance variations on the uncertainty of the test result.

Our aim was to present an experimental evaluation of the corrosivity of the salt spray
corrosion test cabinet, to indicate the gaps in the description of the corrosion test
method according to ISO 9227 and to estimate the main components of the uncertainty
of the corrosivity measurement.

The validation results require changes in the salt spray test method description and
maybe in the performance.
 History
The basic salt spray test reportedly dates back to 1914, with roots in the National
Bureau of Standards (NBS) in the United States (now known as NIST). The neutral salt
spray procedure was formalized as an ASTM B117 specification in 1939. (ASTM itself
was founded in 1898.)

This specification reportedly changed considerably in the early years, compared with its
present form. Concerning the early years of changes, Thomas Doppke has commented:
"Even the salt concentration varied from 20% to as low as 3.5%."

F.D. Timmins reportedly was one of the pioneers in shifting salt spray tests away from
the simplistic ASTM B117 approach, to accelerated cyclical (wet/dry) testing. The
solution used in the ASTM G85 Annex A5 and ASTM D5894 cyclical test procedures is
still referred to as "Timmins solution".
 1. Introduction
The salt spray test is a standardized test method used to
check corrosion resistance of coated samples. Coatings provide corrosion
resistance to metallic parts made of steel, zamak or brass. Since coatings can
provide a high corrosion resistance through the intended life of the part in use, it
is necessary to check corrosion resistance by other means. Salt spray test is an
accelerated corrosion test that produces a corrosive attack to the coated
samples in order to
predict its suitability in
use as a protective finish.
The appearance of
corrosion products
(oxides) is evaluated after
a period of time. Test
duration depends on the
corrosion resistance of
the coating; the more
corrosion resistant the
coating is, the longer the
period in testing without
showing signs of
corrosion.

Salt spray testing is popular because it is cheap, quick, well standardized and
reasonably repeatable. There is, however, only a weak correlation between the
duration in salt spray test and the expected life of a coating, since corrosion is a
very complicated process and can be influenced by many external factors.

(a salt spray cabinet )

Nevertheless, salt spray test is widely used in the industrial sector for the
evaluation of corrosion resistance of finished surfaces or parts.

2. Testing equipment
The apparatus for testing consists of a closed testing chamber, where a salted
solution (mainly, a solution of sodium chloride) is atomized by means of a
nozzle. This produces a corrosive environment of dense saline fog in the
chamber so that parts exposed in it are attacked under this severe corroding
atmosphere. Typical volumes of these chambers are of 15 cubic feet (420 L)
because the smallest volume accepted by ASTM-B-117, ISO 9927 (400 litres)
and now discontinued DIN 50021 (400 litres). It has been found very difficult to
attain constancy of corrosivity in exposure regions within the test chambers
below 400 litres. Chambers are available from sizes as small as 9.3 cu ft (260 L)
up to 2,058 cubic feet (58,300 L), most common machines range from 15 to 160
cubic feet (420–4,500 L).

Tests performed with a standardized 5% solution of NaCl are known as NSS

(neutral salt spray). Results are represented generally as testing hours in NSS
without appearance of corrosion products (e.g. 720 h in NSS acc. to ISO 9227).
Other solutions are acetic acid (ASS test) and acetic acid with copper
chloride (CASS test), each one chosen for the evaluation of decorative coatings,
such as electroplated copper-nickel-chromium, electroplated copper-nickel or
anodizedaluminium.

Some sources do not recommended to use ASS or CASS test cabinets

interchangeably for NSS tests, as it is claimed that a thorough cleaning of the
cabinet after ASS or CASS test is very difficult. ASTM does not address this
issue, but ISO 9227 does not recommend it and if it is to be done, advocates a
thorough cleaning.
 2.1 Salt Spray Testing Equipment
The Salt Spray cabinet is made of acrylic or PVC top cover acrylic with removable lid
and handle. It is a complete standard unit together with atomizing nozzle, air pressure
indicator, solution inlet and drain outlet, etc.

The Salt Spray Test Chamber comes with accessories:

Digital temp controller: 1

Glass holder: 1

Pt. 100 Ss 316L Sensor: 1

Time tantalizer range 9999.9hrs: 1

The Salt Spray Test Chamber has sizes: 450x250x250 mm approx and 910x510x310
mm approx.

Extra include:

Air compressor

Auto dosing pumps

Humidity chamber
 3. Standardization

Chamber construction, testing procedure and testing parameters are

standardized under national and international standards, such as ASTM B 117
and ISO 9227. These standards describe the necessary information to carry out
this test; testing parameters such as temperature, air pressure of the sprayed
solution, preparation of the spraying solution, concentration, pH, etc.

Daily checking of testing parameters is necessary to show compliance with the

standards, so records shall be maintained accordingly. ASTM B 117 and ISO
9227 are widely used as reference standards.

Testing cabinets are manufactured according to the specified requirements here.

However, these testing standards neither provide information of testing periods
for the coatings to be evaluated, nor the appearance of corrosion products in
form of salts.

Requirements shall be agreed between customer and manufacturer. In the

automotive industry requirements are specified under material specifications.
Different coatings have different behaviour in salt spray test and consequently,
test duration will differ from one type of coating to another.

For example, a typical electroplated zinc and yellow passivated steel part lasts
96 hours in salt spray test without white rust. Electroplated zinc-nickel steel parts
can last more than 720 hours in NSS test without red rust (or 48 hours in CASS
test without red rust) Requirements are established in test duration (hours) and
coatings shall comply with minimum testing periods.
 3.1 International Standards
• ASTM B 117: Standard practice for operating salt spray (fog) apparatus

• ASTM B 368: Standard Test Method for Copper-Accelerated Acetic Acid-Salt

Spray (Fog) Testing (CASS Test)

• ASTM B 380: Standard Method of Corrosion Testing of Decorative

Electrodeposited Coatings by the Corrodkote Procedure

• ASTM D 1735: Standard Practice for Testing Water Resistance of Coatings

Using Water Fog Apparatus

• ASTM D 2247: Standard Practice for Testing Water Resistance of Coatings in

100 % Relative Humidity

• ASTM D 870: Standard Practice for Testing Water Resistance of Coatings Using
Water Immersion

• ASTM G 85 A1-5: Standard Practice for Modified Salt Spray (Fog) Testing

• ASTM G 87: Standard Practice for Conducting Moist SO2 Tests

• JIS Z 2371: Methods of salt spray testing (Foreign—Japanese standard)

 3.2 Telecom Standards (NEBS GR-CORE)
• GR-487-CORE: General Requirements for Electrical Equipment Cabinets

• GR-950-CORE: Generic Requirements for Optical Network Unit (ONU) Closures

• GR-3108-CORE: Generic Requirements for Network Equipment in the Outside

Plant (OSP)

• GR-1209-CORE: General Requirements for Fiber Optic Branching Components

• GR-326-CORE: Generic Requirements for Singlemode Optical Connectors and

Jumper Assemblies

• GR-2834-CORE: Generic Requirements for Basic Electrical, Mechanical &

Environmental Criteria for Outside Plant Equipment

• GR-2836-CORE: Generic Requirements for Assuring Corrosion Resistance of

Telecommunication Equipment in the Outside Plant

3.3 Enclosure Standards

• NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum)

• UL 50: Enclosures for Electrical Equipment

3.4 Military Standards

• MIL-STD-810 method 509: Department of Defense Test Method Standard for
Environmental Engineering Considerations and Laboratory Tests

• MIL-STD-883 method 1009: Department of Defense Test Method Standard –

Microcircuits

• MIL-STD-202 method 101: Test Method – Standard Electronic and Electrical

Component Parts

3.5 Automotive Standards

• DIN 50017: Atmospheres and their Technical Application
• DIN 50018: Testing in a saturated atmosphere in the presence of sulfur dioxide

• DIN 50021: Salt Spray Testing

• FORD BI 104-04: Adhesion /Immersion TestFORD BJ7-2:

• GM 4298P: Salt Spray Test

• GM 4465P: Water Fog Humidity Test

• GM 4476P: CASS Test Copper – Accelerated Acetic Acid Salat Spray Test (Fog)

• GM 9103P: Standard for Automotive Relays

• GM 9110P: Procedure for Testing Switches

• GM 9505P: Automotive Environmental Cycles

• GM 9540P: Accelerated Corrosion Test

ASTM B117:

THE standard in salt spray testing:

The American Society of Testing and Materials (ASTM) test B117 is one of the
most widely adopted continuous salt spray test specifications. Its use is
internationally widespread and its provisions have been frequently re-written into
the national standards of other countries, and also appear in other industry
specific corrosion test standards.

ASTM B117 has always been and excellent reference document for the salt
spray practitioner, with many helpful hints and tips contained in its useful
appendixes. But since it is also regularly updated, by an active and broad based
ASTM sub-committee, it is a standard that is always evolving and becoming ever
more ‘user friendly’. The suffix to the main standard number indicates the year of
publication. For example, ASTM B117 – 03 indicates a 2003 publication date
(which was the latest version available at the time of writing). Please check you
are using the most up to date edition available for your application.
History of ASTM B117:

Continuous salt spray testing first became widely adopted as a corrosion test in
1939 when the American Society of Testing and Materials (ASTM) first published
their salt spray test standard, known under its reference number: ASTM B117. In
subsequent years, the use of ASTM B117 spread internationally and its
provisions have frequently been re-written into national standards such as the
UK's BSI, Germany's DIN etc., underpinning the widespread use of the standard
today. The terms salt spray, salt fog and salt mist are all in widespread use for
this type of testing and are generally interchangeable terms, as is the term
cabinet or chamber, which is used to describe the equipment in which the test is
conducted.

Test Conditions:

Can be used to test the relative resistance to corrosion of coated and uncoated
metallic specimens, when exposed to a salt spray climate at an elevated
temperature. Test specimens are placed in an enclosed chamber and exposed
to a continuous indirect spray of neutral (pH 6.5 to 7.2) salt water solution, which
falls-out on to the specimens at a rate of 1.0 to 2.0 ml/80cm²/hour, in a chamber
temperature of +35C. This climate is maintained under constant steady state
conditions. The test duration is variable.

Method:

Salt fog testing is performed by placing samples in a test cabinet that has been
designed in accordance with Paragraph 4 (Apparatus) of ASTM B117 and
operated in accordance with Paragraph 10 (Conditions) of ASTM B117.

A 5% salt solution, prepared by dissolving sodium chloride into water that meets
the requirements of ASTM D1193 Specification for Reagent Water, Type IV is
supplied to the chamber. At the time the samples are placed into test, the
cabinet should be pre-conditioned to the operating temperature of 35ºC and
fogging a 5% salt solution at the specified rate. The fog collection rate is
determined by placing a minimum of two 80 sq. cm. funnels inserted into
measuring cylinders graduated in ml. inside the chamber. One collection device
is located nearest the nozzle and one in the farthest corner.

Orientation:

Unless otherwise agreed upon, the samples are placed at a 15-30 degree angle
from vertical (automotive components, however, are often tested in the "in-car"
position). This orientation allows the condensation to run down the specimens
and minimises condensation pooling. Overcrowding of samples within the
cabinet should be avoided. An important aspect of the test is the utilization of a
free-falling mist, which uniformly settles on the test samples. Samples should be
placed in the chamber so that condensation does not drip from one to another.

Test durations:

Test durations are typically in 24-hour increments and can range from 24 hours
to 5000 hours (where salt fog exposure is a part of a more complex test method,
exposure time can be as little as 15 minutes.) Except for sample rotation and
daily monitoring of collection rates, the cabinet should remain closed for the
duration of the test.
 4 Salt Spray Test Procedure

Basically, the salt spray test procedure involves the spraying of a salt solution onto the
samples being tested. This is done inside a temperature-controlled chamber. The solution is a
5% salt (sodium chloride – NaCl) solution. The samples under test are inserted into the
chamber, following which the salt-containing solution is sprayed as a very fine fog mist over
the samples. The temperature within the chamber is maintained at a constant level. Since the
spray is continuous, the samples are constantly wet, and therefore, constantly subject to
corrosion. Through the years, there have been some new twists added to better simulate
special environmental conditions, but the most common procedure by far in North America
is the test as described in ASTM B 117 Standard Practice for Operating Salt Spray (Fog)
Apparatus.

(Drawing of the tank)

The Procedure:

 Wooden racks are contained in the salt fog chamber (3’ high, 3’ deep, 5’ wide)

 Place samples on a the wooden rack at a small tilt angle

 5% NaCl in tap water pumped from a reservoir to spray nozzles

 Solution mixed with humidified compressed air at nozzles

 Compressed air atomizes NaCl solution into a fog at the nozzles

  Heaters maintain a 95°F cabinet temperature

 Test duration can be from 24 hours to 1000 hours and more for some materials

Within the chamber, the samples are rotated frequently so that all samples are exposed as
uniformly as possible to the salt spray mist.

When the salt spray test is used for testing metallic-coated steel sheet, the corrosion
performance is rated in the following ways:

• Number of hours until rusting of the steel is first evident

• Number of hours until 5% of the surface area is rusted
• Number of hours until 10% of the surface area is rusted, etc.
 5 Uses & Application
Typical coatings that can be evaluated with this method are:

 Phosphated surfaces (with subsequent paint/primer/lacquer/rust preventive)

 Zinc and zinc-alloy plating (see also electroplating). See ISO 4042 for guidance
 Electroplated chromium, nickel, copper, tin
 Coatings not applied electrolytically, such as zinc flake coatings acc. to ISO
10683
 Organic coatings

Hot-dip galvanized surfaces are not generally tested in salt spray test (see ISO 1461 or
ISO 10684). Hot-dip galvanizing produces zinc carbonates when exposed to the
environment, thus protecting the coating metal and reducing the corrosion rate. These
by-products are not produced when a hot-dip galvanized specimen is exposed to a salt
spray fog. Hence, hot-dip galvanized steel is not normally tested according to this test
method and corrosion resistance is expressed as years of corrosion protection in
different environments. See ISO 9223 for guidance.

Painted surfaces with an underlying hot-dip galvanized coating can be tested according
to this method. See ISO 12944-6.

Testing periods range from a few hours (e.g. 8 or 24 hours of phosphated steel) to more
than a month (e.g. 720 hours of zinc-nickel coatings, 1000 hours of certain zinc flake
coatings).

Examples of application of this test as an acceptance method for coated surfaces are
the automotive, construction and aerospace industries.

Application:

This test has its origins in the early 1900s. In the United States, it was well defined by
1939 with the release of the initial edition of the ASTM B117 standard. Since that time, it
has found its way into the environmental requirements of many different organizations in
such areas as general mechanical testing, automotive specifications, military
requirements, electrical enclosures, and the telecommunications NEBS (Network
Equipment Building System) requirements. The following list gives a sampling of
standards incorporating a salt fog test.