ACCELERATED CORROSION TESTING

by Cynthia L. Meade
National Exposure Testing, Sylvania. Ohio

Accelerated corrosion testing has been u\ed since the early 1900s as a means for
evaluating the performance of coatings when exposure to actual conditions is neither practical
nor available. An accelerated corrosion te\t is u\uall~ defined as any test method from which
results are obtained in a shorter period of’ time than trom natural exposure. More specifically.
however. it commonly refers to a cahmet test method during which a specimen IS exposed to
a stress or combination of strebycs for a given period of time. After exposure. the specimen
is examined for rust, blisters, pitting, etc. Some commonly used tests include ASTM B II7
(salt spray). ASTM B 368 (CASS). ASTM D 2247 (100% humidity). and ASTM GXS
(modified salt spray). Newer cyclic corrosion te\ts, such as GM954OP, CCT-IV. and SAE
52334 (pending), are gaining acceptance in the coatings market.
Accelerated corrosion tests. in particular ASTM B 117, have been under attack hy
industry groups for their lack of correlation to field results. What is often not taken into
consideration. however, is that while the B II7 test procedure has remained constant, the
coating industry has undergone significant changes occr the last IO year<. For example:
Environmental regulations to reduce the level of volatile organic content ha\ resulted in
the increased use of waterborne coatings. These coatings have shown good service
performance, while performing poorly under salt spray testing.’
In the automotive industry. the widespread use of two-sided. precoated sheet metal and
longer consumer warranties (up to IO years) have driven the need for improved
corrosion protection.’

The growth of powder coating as a finish has replaced some traditionally painted and/o1
electroplated finishes.
Shorter research and development to market times hardly allow for long-term testing.
Some of the changes that have occurred in accelerated corrosion tests to keep pace with
the changing coating and automotive industries include:
ASTM B 117 changes from a test method to a practice. Since a test method specifies the
duration and expected results. B I I7 was changed to a practice describing the
operation of a salt fog chamber.
The appropriate use of a salt fog test i\ more clearly defined within B I I7 to discourage
users from using the test results alone a\ a means of evaluating one coating versus
another. B I I7 recommends that results should he correlated with actual field
exposure results when tejting new materials.’
A move from static atmosphere to cyclic environments, which include the use of wet and
dry test cycles. controlling relative humidity, adding corrosive elements. such as
sulfur dioxide. and the USC of varied electrolyte solutions.
Recognizing thus, industry groups such as the American Society for Testing and Materials
(ASTM). the Society of Automotive Engineers (SAE). Federation of Societies for Coatings
Technologies (FSCT), and others have formed task groups to develop a more realistic
accelerated test method. Each group must take into consideration the materials being used. the
end product being painted or coated. and the dominant service environment and then compare
this information to actual field corrosion. customer, or end-user expectations. and the available

540
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test methods. In some cases where no suitable test method exists, a new test method may be
needed. With the wide variety of coatings, applications, and exposure conditions, however. it
is unlikely that a single test will meet the needs of all concerned.

STATIC ATMOSPHERE TESTING

Static atmosphere testing is one in which a test chamber is used to create and maintain
a single environment throughout the duration of the test. The Salt Fog Test (ASTM B 117) is
the most commonly uyed corrosion test of this type. Parts are exposed to a constant
environment of 35°C and 100% relative humidity, with a 5% (by weight) sodium chloride
solution atomized for a predetermined time. The pN of the collected solution should be 6.5 to
7.2. The test duration can be 48 to 2,000 hours depending on the material being tested. In spite
of recent criticism, the salt spray test remains a viable quality control inspection tool to be
used after a baseline has been established. Figure 1 is a schematic drawing of a typical <ait
fog chamber.
The CASS test, ASTM B 368 [Copper-Accelerated Acetic Acid-Salt Spray (Fog) Test] is
a widely used means of production control and acceptance testing for decorative chromium
plating. Developed by the American Electroplaters Society as an alternative to the salt fog test,
the CASS test may be run in equipment similiar to a salt fog chamber hut, due to the nature
of the solution, should be done in a dedicated chamber. The solution consists of a 5% (by
weight) salt solution with the addition of 0.25 g/L of copper chloride. The test is performed
at 49°C; typical exposure times vary from 6 to 720 hrs.‘,’
Another static atmosphere test, ASTM D 2247 (100% humidity testing), is performed at
38°C and 95 to 100% relative humidity. It is used increasingly in many industries such as the

542
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Fig. 2. Humidity test chamber .schematic drawing.
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appliance, plumbing, and automotive industries. See Fig. 2 for a schematic drawing of a
typical chamber configuration3

CYCLIC CORROSION TESTING

The industrial maintenance coating industry has encouraged the use of the Prohesion test,
which was developed in the 1960s by British Rail4 The test cycle is as follows: one hour wet
cycle at ambient temperature; one hour dry cycle at 35°C.
The traditional 5% salt solution is replaced with a dilute mixture of ammonium sulfate
and sodium chloride at a pH of approximately 5.2. Research has shown that this test has
produced results, which for some coatings more closely correlate with actual outdoor
exposure results. This test method was recently incorporated into ASTM G 85 Modified Salt
Fog Tests as Annex 5.
The equipment required to perform the test is similar to a salt fog chamber, but includes
a programmable controller to automatically cycle wet and dry conditions. and a means for
changing the temperature within the exposure zone. See Fig. 3 for a commonly used chamber
of this type.
Since the early 1980s the SAE, Automotive Corrosion and Preventation Committee.
along with the American Iron and Steel Institute have invested considerable resources in the
development of cyclic corrosion tests that could be used to rank materials used in the
automotive environment. Beginning with approximately 20 tests ranging in complexity from
the ASTM B I I7 to multistep/multienvironment cyclic corrosion tests, IO materials were
tested and results compared to long-term exposure data from panels exposed at IO sites
worldwide. The following criteria for an acceptable accelerated corrosion test were estab-
lished?
I The test must simulate the rank order of performance of coatings in actual service.
2. The test must produce failure modes consistent with field exposure, i.e. blisters,
filiform. etc.

543
 3. The test must be reproducible. Same coatings tested under same conditions must
produce the same result.
4. The test must be reasonably rapid.
5. The test must be feasible, A significant investment in equipment or labor to run the
test must not be required.
After reviewing the various available tests, it was determined that the GM-9540P/B and
CCT-IV cyclic test methods met the above criteria. (CCT test methods originated in Japan and
usually refer to a Nissan test specification. At present there are 8 CCT test methods,
designated by CCT I CCT VIII.)
A third test. originally called Paper Champion 4 (PC4). was developed using a design of
experiments statistical analyic. Usin g a statistical design of experiments approach, it was
determined that them were seven important variables to a good cyclic test method.
These variables are:
1. Number of dryouts per cycle. 3
2. Electrolyte solution, NaCl+NaHCO,+CaCl,
3. NaCl concentration, 5%
4. Dry-sta_pe temperature, 60°C
5. Dry-stage humidity, SW
6. Humid-stage humidity, 100%
7. Humid-stage temperature, 60°C
This test method. while still in the draft stage, has been assigned an SAE designation-J
2334.

CORROSIVE GAS TESTING

Moist sulfur dioxide tests have been used in Europe for many year\ as a means of
simulating corrosion found in industrial atmospheres. The test is performed at 100% relative

544
 Table I. Corrosion Test Procedures

ASTM B 117 Practxc [or Operating a Salt Fog Aluminum. marme expo\urc\,
Chamber production controlinspection tool
ASTM B 368 Copper Accelerated Acetic Acid Tc\t IIecoratlve copper-nickel-chromium
(CASS)
ASTM D 2241 Tcsiing CoatIn:\ in 100% Humidity Water reSISta”CC or watincs
ASTM G X5 Annex I Acctic Acid (formerly B X7) Erfoliatmn testing of alun;inum
nlloy\
ASTM G X5 Annex 2 Cycltc Acldit’ied Salt Sprq Exfohation teatmg of alummum
alloy\
ASTM G 85 Annex 3 Acidified Synthetic Sea Water Aluminum
ASTM G 85 Annex 4 Salt/SO, Spray Testmg Aircraft
ASTM G X5 Annex 5 Wet/Dry Cyclic Indu\trlal ma,ntrnnnce coatmgs
ASTM G 87/DIN 5001 X Moist SO, Roofing materials, electrical contact\
CCT IV Accelerated CornGon Test P:linted steel
GM954OPIB Accelerated Corrosion Test Painted ~trel
SAE J-2334 Cyclic Laboratory Corrosion Test Painted steel

humidity and 100°F with the introduction of 0.2 or 2 L of sulfur dioxide in a 300-L chamber,
depending upon the specimen being tested. The procedure is governed by ASTM G-87.’
A number of companies have also experimented with the effects of adding corrosive
gases to their testing programs. Used alone or as part of another test, frequently salt fog or
humidity, the addition of sulfur dioxide expedites coating degradation. An important
consideration should be whether expediting the test results or simulating field service
conditions is the objective. Acid-rain te\ting can also be accomplished with additional gases
such as carbon dioxide. Sulphur dioxide tests are often used on roofing materials such as
fxteners.

SUMMARY

With the various test methods available. one should select the test method that most
appropriately suits the materials being tested. either through a near simulation of the actual
exposure conditions or by a previously established confirmation of the ability of the test
method to rank materials according to their suitability for the environment. Considerable
research is ongoing, and a growing amount of technical data is available to aid the technician
in choosing and interpreting today’s corrosion test methods. Table I list\ some available test
methods.

References
I Simpson, C.H. et al., .lr)utxa/ of‘Pvotrc,tivr Crx~tings ottd Linings, 8(5):28: 1991
2. Annual Book of ASTM Standards, Vol. 02.05, ASTM, Philadelphia
3. Annual Book of ASTM Standards, Vol. 06.01, ASTM, Philadelphia
4. Appleman, B.R., Jr)urnal of’ Cotrtiqs Technology, 62(787):57-67; 1990
5. Roudabush, L. et al., “Update on the Development of an Improved Cosmetic Corrosion
Test by the Auto & Steel Industry,” Paper #9323X4. Presented at 6th Annual Society of
Automotive Engineers Automotive Corrosion & Prevention Conference, 1993

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