Salt spray test

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The salt spray (or salt fog) test is a standardized and popular corrosion test
method, used to check corrosion resistance of materials and surface coatings.
Usually, the materials to be tested are metallic (although stone, ceramics, and
polymers may also be tested) and finished with a surface coating which is intended
to provide a degree of corrosion protection to the underlying metal. Salt spray
testing is an accelerated corrosion test that produces a corrosive attack to coated
samples in order to evaluate (mostly comparatively) the suitability of the coating
for use as a protective finish. The appearance of corrosion products (rust or other
oxides) is evaluated after a pre-determined period of time. Test duration depends
on the corrosion resistance of the coating; generally, the more corrosion resistant
the coating is, the longer the period of testing before the appearance of
corrosion/ rust. The salt spray test is one of the most widespread and long-
established corrosion tests. ASTM B117 was the first internationally recognized
salt spray standard, originally published in 1939. Other important relevant
standards are ISO9227, JIS Z 2371 and ASTM G85.

Contents
1 Application
2 Testing equipment
3 Modified Salt Spray Tests
4 Standardization
5 Uses
5.1 Bibliography
5.2 See also
6 Further reading
7 References
Application
Salt spray testing is popular because it is relatively inexpensive, quick, well
standardized, and reasonably repeatable. Although there may be a weak correlation
between the duration in salt spray test and the expected life of a coating in
certain coatings such as hot-dip galvanized steel, this test has gained worldwide
popularity due to low cost and quick results. Most Salt Spray Chambers today are
being used NOT to predict the corrosion resistance of a coating, but to maintain
coating processes such as pre-treatment and painting, electroplating, galvanizing,
and the like, on a comparative basis. For example, pre-treated + painted components
must pass 96 hours Neutral Salt Spray, to be accepted for production. Failure to
meet this requirement implies instability in the chemical process of the pre-
treatment, or the paint quality, which must be addressed immediately so that the
upcoming batches are of the desired quality. The longer the accelerated corrosion
test, the longer the process remains out of control, and larger is the loss in the
form of non-conforming batches. The principal application of the salt spray test
is, therefore, enabling quick comparisons to be made between actual and expected
corrosion resistance. Most commonly, the time taken for oxides to appear on the
samples under test is compared to expectations, to determine whether the test is
passed or failed. For this reason, the salt spray test is most often deployed in a
quality audit role, where, for example, it can be used to check the effectiveness
of a production process, such as the surface coating of a metallic part. The salt
spray test has little application in predicting how materials or surface coatings
will resist corrosion in the real world, because it does not create, replicate or
accelerate real-world corrosive conditions. Cyclic corrosion testing is better
suited to this.

Testing equipment

A salt spray cabinet

[1]

The apparatus for testing consists of a closed testing cabinet/chamber, where a

salt water (5% NaCl) solution is atomized by means of spray nozzle(s) using
pressurized air. This produces a corrosive environment of dense salt water fog
(also referred to as a mist or spray) in the chamber, so that test samples exposed
to this environment are subjected to severely corrosive conditions. Chamber volumes
vary from supplier to supplier. If there is a minimum volume required by a
particular salt spray test standard, this will be clearly stated and should be
complied with. There is a general historical consensus that larger chambers can
provide a more homogeneous testing environment.

Variations to the salt spray test solutions depend upon the materials to be tested.
The most common test for steel based materials is the Neutral Salt Spray test
(often abbreviated to NSS) which reflects the fact that this type of test solution
is prepared to a neutral pH of 6.5 to 7.2. Results are represented generally as
testing hours in NSS without appearance of corrosion products (e.g. 720 h in NSS
according to ISO 9227). Synthetic seawater solutions are also commonly specified by
some companies and standards. Other test solutions have other chemicals added
including acetic acid (often abbreviated to ASS) and acetic acid with copper
chloride (often abbreviated to CASS) each one chosen for the evaluation of
decorative coatings, such as electroplated copper-nickel-chromium, electroplated
copper-nickel or anodized aluminum. These acidified test solutions generally have a
pH of 3.1 to 3.3

Some sources do not recommend
NSS tests, due to the risk of
cleaning of the cabinet after
this issue, but ISO 9227 does
thorough cleaning.
using ASS or CASS test cabinets interchangeably for
cross-contamination, it is claimed that a thorough
CASS test is very difficult. ASTM does not address
not recommend it and if it is to be done, advocates a

Although the majority of salt spray tests are continuous, i.e.; the samples under
test are exposed to the continuous generation of salt fog for the entire duration
of the test, a few do not require such exposure. Such tests are commonly referred
to as modified salt spray tests. ASTM G85 is an example of a test standard which
contains several modified salt spray tests which are variations to the basic salt
spray test.

Modified Salt Spray Tests

ASTM G85 is the most popular global test standard covering modified salt spray
tests. There are five such tests altogether, referred to in ASTM G85 as annexes A1
through to A5.

A modified salt spray chamber in use

[2] Many of these modified tests originally arose within particular industry
sector, in order to address the need for a corrosion test capable of replicating
the effects of naturally occurring corrosion and accelerate these effects.

This acceleration arises through the use of chemically altered salt spray
solutions, often combined with other test climates and in most cases, the
relatively rapid cycling of these test climates over time. Although popular in
certain industries, modified salt spray testing has in many cases been superseded
by Cyclic corrosion testing (CCT) The type of environmental test chambers used for
modified salt spray testing to ASTM G85 are generally similar to the chambers used
for testing to ASTM B117, but will often have some additional features, such as an
automatic climate cycling control system.
Graph showing the temperature & humidity steps required during modified Salt Spray
Test ASTM G85 Annex 1
ASTM G85 annex A1 � Acetic Acid Salt Spray Test (non-cyclic) This test can be used
to determine the relative resistance to corrosion of decorative chromium plating on
steel and zinc based die casting when exposed to an acetic acid salt spray climate
at an elevated temperature. This test is also referred to as an ASS test. Test
specimens are placed in an enclosed chamber and exposed to a continuous indirect
spray of salt water solution, prepared in accordance with the requirements of the
test standard and acidified (to pH 3.1 to 3.3) by the addition of acetic acid. This
spray is set to fall-out on to the specimens at a rate of 1.0 to 2.0ml/80 cm�/hour,
in a chamber temperature of +35C. This climate is maintained under constant steady
state conditions. The test duration is variable.[3]

Graph showing the temperature & humidity steps required during modified Salt Spray
Test ASTM G85 Annex 2
ASTM G85 annex A2 � Acidified Salt Fog Test (cyclic).

This test can be used to test the relative resistance to corrosion of aluminium
alloys when exposed to a changing climate of acetic acid salt spray, followed by
air drying, followed by high humidity, all at an elevated temperature. This test is
also referred to as a MASTMAASIS test. Test specimens are placed in an enclosed
chamber, and exposed to a changing climate that comprises the following 3 part
repeating cycle. 0.75 hours exposure to a continuous indirect spray of salt water
solution, prepared in accordance with the requirements of the test standard and
acidified (to pH 2.8 to 3.0) by the addition of acetic acid. This spray is set to
fall-out on to the specimens at a rate of 1.0 to 2.0ml/80 cm�/hour. This is
followed by 2.0 hours exposure to an air drying (purge) climate. This is followed
by 3.25 hours exposure to a high humidity climate which gradually rises to between
65%RH and 95%RH. The entire test cycle is at a constant chamber temperature of
+49C. The number of cycle repeats and therefore the test duration is variable.[3]

Graph showing the temperature & humidity steps required during modified Salt Spray
Test ASTM G85 Annex 3
ASTM G85 annex A3 � Seawater Acidified Test (cyclic)

This test can be used to test the relative resistance to corrosion of coated or
uncoated aluminium alloys and other metals, when exposed to a changing climate of
acidified synthetic seawater spray, followed by a high humidity, both at an
elevated temperature. This test is also referred to as a SWAAT test. Test specimens
are placed in an enclosed chamber, and exposed to a changing climate that comprises
the following 2 part repeating cycle. 30 minutes exposure to a continuous indirect
spray of synthetic seawater solution, prepared in accordance with the requirements
of the test standard and acidified (to pH 2.8 to 3.0) by the addition of acetic
acid. This spray is set to fall-out on to the specimens at a rate of 1.0 to
2.0ml/80 cm�/hour. This is followed by 90 minutes exposure to a high humidity
climate of above 98%RH. The entire test cycle is at a constant chamber temperature
of +49C (may be reduced to +24 to +35C for organically coated specimens). The
number of cycle repeats and therefore the test duration is variable.[3]

Graph showing the temperature & humidity steps required during modified Salt Spray
Test ASTM G85 Annex 4A

An example of modified salt spray test ASTM G85 annex A4 � SO2 Salt Spray Test
ASTM G85 annex A4 � SO2 Salt Spray Test (cyclic)
This test can be used to test the relative resistance to corrosion of product
samples that are likely to encounter a combined SO2(sulfur dioxide)/salt spray/acid
rain environment during their usual service life. Test specimens are placed in an
enclosed chamber, and exposed to 1 of 2 possible changing climate cycles. In either
case, the exposure to salt spray may be salt water spray or synthetic sea water
prepared in accordance with the requirements of the test standard. The most
appropriate test cycle and spray solutions are to be agreed between parties.

The first climate cycle comprises a continuous indirect spray of neutral (pH 6.5 to
7.2) salt water/synthetic seawater solution, which falls-out on to the specimens at
a rate of 1.0 to 2.0ml/80 cm�/hour. During this spraying, the chamber is dosed with
SO2 gas at a rate of 35 cm�/minute/m� of chamber volume, for 1 hour in every 6
hours of spraying. The entire test cycle is at a constant chamber temperature of
+35C. The number of cycle repeats and therefore the test duration is variable.

The second climate cycle comprises 0.5 hours of continuous indirect spray of
neutral (pH 6.5 to 7.2) salt water/synthetic seawater solution, which falls-out on
to the specimens at a rate of 1.0 to 2.0ml/80 cm�/hour. This is followed by 0.5
hours of dosing with SO2 gas at a rate of 35 cm�/minute/m� of chamber volume. This
is followed by 2.0 hours of high humidity soak. The entire test cycle is at a
constant chamber temperature of +35C. The number of cycle repeats and therefore the
test duration is variable.[3]

Graph showing the temperature & humidity steps required during modified Salt Spray
Test ASTM G85 Annex 5
ASTM G85 annex A5 - Dilute Electrolyte Salt Fog/Dry Test (cyclic)

This test can be used to test the relative resistance to corrosion paints on steel,
when exposed to a changing climate of dilute salt spray at ambient temperature,
followed by air drying at and elevated temperature. It is a popular test in the
surface coatings industry, where it is also referred to as the PROHESION� test.
Test specimens are placed in an enclosed chamber, and exposed to a changing climate
that comprises the following 2 part repeating cycle. 1.0 hour exposure to a
continuous indirect spray of salt water solution, prepared in accordance with the
requirements of the test standard and acidified (to pH 3.1 to 3.3) by the addition
of acetic acid. This spray is set to fall-out on to the specimens at a rate of 1.0
to 2.0ml/80 cm�/hour, in an ambient chamber temperature (21 to 27C). This is
followed by 1.0 hour exposure to an air drying (purge) climate, in a chamber
temperature of +35C. The number of cycle repeats and therefore the test duration is
variable.[3]

Standardization

Electroplated and yellow chromated bolt with white corrosion

Zinc flake coated bolt with red rust after testing

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 B117 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 are agreed between customer and manufacturer. In the automotive
industry requirements are specified under material specifications. Different
coatings have different behavior 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.

Artificial seawater which is sometimes used for Salt Spray Testing can be found at
ASTM International. The standard for Artificial Seawater is ASTM D1141-98 which is
the standard practice for the preparation of substitute ocean water.

Uses
Typical coatings that can be evaluated with this method are:

Phosphated (pre-treated) 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 according to ISO
10683
Organic coatings, such as rust preventives
Paint Coating
Hot-dip galvanized surfaces are not generally tested in a salt spray test (see ISO
1461 or ISO 10684). Hot-dip galvanizing produces zinc carbonates when exposed to a
natural environment, thus protecting the coating metal and reducing the corrosion
rate. The zinc carbonates are not produced when a hot-dip galvanized specimen is
exposed to a salt spray fog, therefore this testing method does not give an
accurate measurement of corrosion protection. ISO 9223 gives the guidelines for
proper measurement of corrosion resistance for hot-dip galvanized specimens.

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).

Bibliography
Metal Finishing. Guidebook and directory issue. Published by Metal Finishing
Magazine, 1996