Professional Documents
Culture Documents
This MBN 10494 consists of the following parts under the general title "Paint Test Methods":
- Part 1: General Requirements
- Part 2: Testing of Paints in Wet Condition
- Part 3: Process Engineering Tests
- Part 4: Optical Tests
- Part 5: Technical-Mechanical Tests
- Part 6: Climatic Tests
- Part 7: Resistance to Chemicals, Test Mixtures and Test Concentrates
- Part 8: Adhesion of Adhesives on the Coating
- Part 9: Special Test Methods for Electrodeposition Coats in Wet Condition
- Part 10: Special Test Methods for Electrodeposition Coats in Dry Condition
MBN 10494 can be referenced in its entirety by indicating the standard number "MBN 10494" (all parts)
without mentioning the part document, or a part document can be referenced individually as "MBN 10494-y".
The primary application is for the passenger car unit. For the commercial vehicle, bus and truck units
additional agreements may be made with the department responsible. This also applies to CKD plants.
Changes
- The following standards were included: ASTM D 714, ASTM D 661, ASTM G 154A,
DIN EN ISO 16925 and DIN EN ISO 16474-2
- DIN EN ISO 2813 supersedes DIN 67530
- Section 5.2 Abbreviated designation "SS" was changed to "NSS"
- Section 5.4.1 "Cyclical corrosion test as per DIN EN ISO 11997-1 Cycle B"
was renamed to "Corrosion cycle test 1"
- Section 5.4.2 "Cyclical corrosion test as per VDA 233-102“ renamed to "Corrosion cycle test 2"
- Section 5.5 was revised: assessable scribe mark length, scribe mark minimum length,
number of measuring points
- Section 5.5.2 "Filiform test according to Daimler" was deleted
- Section 5.6 "Cold-check test" was changed to "Cold test"
- Section 5.7 "Natural weathering using salt (outdoor weathering)", abbreviated designation "FB",
was changed to "Outdoor weathering of coatings – testing the corrosion behavior"
- Section 5.9.3 "QUV device" was included
- Section 5.10 "Function test: VDA 233-102…" was revised and renamed to "Function test:
corrosion cycle test, salt spray test and CASS test"
- Section 5.11.3 Code "Value (S value)" was changed to "Quantity (0-5); size S(0-5)"
- Section 5.11.4.2 "Edge corrosion on aluminum wheels, KR" was included
- Section 5.11.11 "Subsurface corrosion stemming from the edge, code Uk" was added
- Section 5.12 "Description of the test position" was included
NOTE: This translation is for information purposes only.
The German version shall prevail above all others.
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Contents
1 Scope................................................................................................................................................ 2
2 Normative references .......................................................................................................................2
3 Terms and definitions .......................................................................................................................4
4 General requirements .......................................................................................................................4
5 Climatic tests .................................................................................................................................... 4
5.1 Condensation atmosphere with constant humidity (code CH)..........................................................4
5.2 Salt spray testing, abbreviated designation NSS..............................................................................5
5.3 CASS test ......................................................................................................................................... 6
5.4 Corrosion cycle test ..........................................................................................................................6
5.5 Filiform test on painted aluminum parts as per Daimler ...................................................................7
5.6 Cold test.......................................................................................................................................... 11
5.7 Outdoor weathering of coatings – testing the corrosion behavior ..................................................11
5.8 Resistance to weathering ...............................................................................................................12
5.9 Artificial weathering.........................................................................................................................14
5.10 Function test: corrosion cycle test, salt spray test and CASS test..................................................14
5.11 Assessment of results of climatic tests ...........................................................................................16
5.12 Description of the test position........................................................................................................22
1 Scope
This MBN describes test methods for the examination of the quality and specific properties of paints,
varnishes and coatings
- at the time of delivery for further processing in plants of the Daimler Group
- in coated condition in the body and major component area as well as for plastic
and other functional parts
The requirements for the test methods are specified in the material-specific DBL.
2 Normative references
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any changes) applies.
ASTM G 154A Standard Practice for Operating Fluorescent Ultraviolet (UV) Lamp
Apparatus for Exposure of Nonmetallic Materials
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DIN EN ISO 2813 Paints and Varnishes – Determination of Gloss Value at 20°, 60° and 85°
DIN EN ISO 4628-1 Paints and Varnishes – Evaluation of Degradation of Coatings – Designation
of Quantity and Size of Defects, and of Intensity of Uniform Changes
in Appearance – Part 1: General Introduction and Designation System
DIN EN ISO 6270-2 Paints and Varnishes – Determination of Resistance to Humidity – Part 2:
Procedure for Exposing Test Specimens in Condensation-Water Atmospheres
DIN EN ISO 9227 Corrosion Tests in Artificial Atmospheres – Salt Spray Tests
DIN EN ISO 16474-2 Paints and Varnishes – Exposure to Artificial Light or Weathering in Devices –
Part 2: Xenon-Arc Lamps
DIN EN ISO 17872 Paints and Varnishes – Guidelines for the Introduction of Scribe Marks
through Coatings on Metallic Panels for Corrosion Testing
DIN EN ISO 21227-3 Paints and Varnishes – Evaluation of Defects on Coated Surfaces Using Optical
Imaging – Part 3: Evaluation of Delamination and Corrosion Around a Scribe
ISO 3574 Cold-Reduced Carbon Steel Sheet of Commercial and Drawing Qualities
VDA 233-102 Cyclic Corrosion Testing of Materials and Components in Automotive Construction
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4 General requirements
For safety requirements, homologation (in particular, exhaust emissions), and quality, the existing
statutory requirements and laws shall be complied with. In addition, the relevant requirements of
the Daimler Group apply.
All materials, procedures, processes, components, and systems shall conform to the current statutory
requirements regarding regulated substances and recyclability. For the relevant information with regard
to prohibited and declarable substances, refer to DBL 8585 and DBL 6714.
With regard to all coating materials, care shall be taken to ensure the lowest possible odor and smallest
possible content of volatile matter (e.g. solvents, plasticizers etc.).
Preparations/coating materials shall be marked in accordance with statutory regulations and provided
with the necessary information for transportation and use. In the event of use abroad, the regulations
and rules applicable to those countries shall also be observed.
5 Climatic tests
Preliminary remark
These tests can either be performed on test panels in accordance with Sampling, test panels of MBN
10494-1, on coated parts, or on vehicle bodies, unless noted or agreed otherwise. The paint structure
of the test specimens shall conform to that of the relevant place of application.
Test conditions
The test shall be performed in accordance with DIN EN ISO 6270-2-CH
(Condensation atmosphere with constant humidity).
Air temperature + 40 °C ± 3 °C rel. humidity 98 % with condensation on samples
Exposure period 240 h (changes depending on material-specific DBL specifications
documents and as per agreement)
Quality assurance shall be carried out as per DIN EN ISO 9001.
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Test procedure
The test specimens shall be arranged in the usable chamber space so that they do not touch each other.
Plastic retainers can be used for adequate storage.
Test position: as per the section "Description of the test position" of this MBN
During the prescribed or agreed test duration, the prescribed default values are monitored and regulated
in the spray cabinet by means of automatic control units.
Evaluation
The number and time of any intermediate examinations and the kind of evaluation of the final assessment
of the samples are indicated in the material-specific DBL.
At the end of the test period, the samples shall be conditioned at room temperature.
The assessment of blistering shall be done as per DIN EN ISO 4628-2, see section "Blistering, degree
of blistering" in this MBN. In addition, the adhesion of the paint structures shall be tested after 1 h / 24 h
in accordance with section "Scratch test" of MBN 10494-5.
Test procedure
The samples shall be marked with a straight scribe mark down to the metal substrate parallel to the
longitudinal side. For comparative examination, 2 scribe marks which are parallel to each other can
also be applied. For tests relevant for approval, only 1 scribe mark shall be applied. With regard to
scribing and assessment, see "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
Test position: see section "Description of the test position" of this MBN
The supports for the test specimens can be made of resistant non-conductive material.
Spraying shall not be interrupted during the prescribed test period. The chamber shall
only be opened at the specified times.
During the prescribed or agreed test period, the specified temperature in the test cabinet
shall be monitored and controlled by means of automatic control units.
Evaluation
The number and time of any intermediate examinations and the kind of evaluation of the final assessment
of the test specimens shall be subject to the respective specification documents and other agreements.
At the end of the test period, the test specimens shall be removed from the cabinet and rinsed with clear
flowing water (DI water) so that any salt residues are removed completely. The test specimens may then
be dried superficially in a stream of compressed air.
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To determine the corrosion creep, the damaged surface coating can be removed using, for example,
steam cleaning or a knife blade held at an oblique angle; then measure the average overall width
of the corrosion creep zone in mm, see section "Subsurface corrosion around a scribe mark,
code U/2" of this MBN.
Test conditions
The normal test period shall be 10 cycles corresponding to 10 weeks;
depending on the DBL requirements, other test periods are also permissible.
Test position: see section "Description of the test position" of this MBN
For parts used on the underbody, the underside of the parts in the vehicle installation
situation is the upper side in the test chamber.
Flat specimens shall be stored at suitable distances to each other – at least 50 mm.
Parts of vehicles shall be tested according to the requirements in installation position
or modified position (main exposure side on vehicle = main exposure side during test)
When changing over from the salt spray apparatus to the condensation water apparatus, the specimens
shall not be allowed to dry off. In the optimum case, the test specimens shall be stored in the apparatus
such that the scribe marks run vertically.
Parts or assemblies of a vehicle, components or special corrosion test panels can also be used as
test specimens.
The test shall only be interrupted for a short time before the next salt spray phase, which shall also
be used as the assessment period.
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Test procedure
The test panels shall be marked with a straight scribe mark down to the metal substrate parallel to
the longitudinal side. Alternatively several scribe marks running parallel to each other may be applied.
For scribing, see section "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
Evaluation
After the test is completed, rinse the test panels with clear, flowing water; if necessary, blow dry the
surface using compressed air and inspect for visible changes. The visible corrosion creep originating
from the scribe towards both sides is measured. In general, the width of the metal surfaces adjacent
to the scribe damaged by corrosion is easily visible as blister or corrosion track on the paint surface.
In addition, steam cleaning as per DIN EN ISO 16925 or an inclined knife blade can be used to carefully
remove the subsurface corrosion of the paint film through to the zone where there is still firm adhesion.
For evaluation, measure the average total width of the subsurface corrosion zone in mm; see section
"Subsurface corrosion around a scribe mark, code U/2" of this MBN.
Test procedure
Evaluation
After the test is completed, rinse the test panels with clear, flowing water; if necessary, blow dry the
surface using compressed air and inspect for visible changes. The visible corrosion creep originating
from the scribe towards both sides is measured. In general, the width of the metal surfaces adjacent
to the scribe damaged by corrosion is easily visible as blister or corrosion track on the paint surface.
In addition, steam cleaning (DIN EN ISO 16925) or an inclined knife blade can be used to carefully
remove the subsurface corrosion of the paint film through to the zone where there is still firm adhesion.
For evaluation, measure the average total width of the subsurface corrosion zone in mm; see section
"Subsurface corrosion around a scribe mark, code U/2" of this MBN.
This test is used for all painted aluminum parts, e.g. wheels.
Filiform corrosion is a thread-like corrosion phenomenon which occurs during customer use of the vehicle
under real environmental conditions on painted aluminum parts, generally starting from edges or local
damage of the coating.
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The intention of the test is the assessment and measurement of the filiform corrosion creep starting from
edges and a predetermined pre-damage (scribe).
The filiform corrosion creep shall be evaluated purely optically at the end of the test without mechanical
removal of the coating affected by the subsurface corrosion, as the corrosion creep is clearly visible due
to color and/or geometrical (arching of the coating) changes.
Measurements using digital imaging are only possible on flat surfaces.
Specimen preparation
Before applying the damage, measure and document the layer thickness of the specimens using
an appropriate method (eddy current).
In the case of wheels, appropriate measuring points are, for instance, adjacent to bolt holes on the visible
wheel side (additional measuring points depending on wheel design); see Figures 4 to 6.
A straight scribe mark that reaches through to the metal substrate shall be applied to the test specimens.
Several scribe marks may be applied. For wheels, at least one scribe mark shall be applied in the high
sheen/polished area with the dimensions given below.
The scribe mark shall have a total length of 12 cm and run perpendicular to the turning grooves
(in the case of high-sheen wheels) or any grinding grooves in the case of plates or transverse to the
direction of rolling.
If a scribe mark of 12 cm is not possible, for wheels the scribe marks shall have no less than 3 cm spacing
from each other and have a total assessable scribe mark length of 10 cm. For scratch stylus and scribing,
see section "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
Test pieces can include test panels, panel sections or complete parts of vehicles or supplier parts
(whole or sawn into pieces). To reach a meaningful result, a test piece close to production shall be used,
and in the case of wheels a wheel or wheel segment. As the evaluation is also carried out along the edge,
care shall be taken when using parts of components to ensure that these are not too small (e.g. in the case
of aluminum disk wheels not smaller than ¼). Ensure that at least one complete bolt hole and one complete
track measurement hole are included in the segment to be tested.
Bare aluminum cut edges shall be protected before testing by means of an appropriate adhesive tape
(e.g. JaBand 92402 adhesive polyester tape) or wax (Pfinder 611/8).
Test procedure
1. Immunization: CASS test in accordance with DIN EN ISO 9227, 24 hours:
Test position: see section "Description of the test position" of this MBN
Position the test specimens in the test cabinet at an angle of 70°(± 5°) from the horizontal.
Wheels and wheel segments shall also be exposed at this angle in the CASS cabinet. The scribe
marks should run vertically.
Other positions (e.g. vertical in installation position on the vehicle) shall be agreed in exceptional
cases. For other components, the location and position in the test cabinets shall also be agreed.
2. Filiform test: 28 days at 60 ± 1 °C / 82 ± 2 % rel. humidity in storage;
Important: Wheels shall be taken out of the CASS test unrinsed and immediately put into
the filiform chamber. Plates at 70° (± 5°), wheels and wheel segments horizontally (lying down).
Evaluation
After the test is completed, the test panels shall be rinsed with clear, flowing water and, if necessary,
blown dry using compressed air.
For evaluation (after 2 days at the latest), measure the average total width of the filiform subsurface
corrosion in mm.
To do so, the width shall be measured at a minimum of 20 locations (uniform distance between
the measuring points), since the filiform corrosion results in very uneven subsurface corrosion,
and the arithmetic mean calculated; see Figure 1.
Carry out the relevant measurements at the specified measuring points (mark on the test piece)
perpendicular to the scribe; see Figure 2.
To determine the measuring points, the existing scribe mark shall be evenly subdivided, whereby it shall
be ensured that no measurements are taken right at the ends of the scribe marks but at a distance
of at least 10 mm from the ends.
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The filiform subsurface corrosion (UF) in mm shall be calculated according to the following equation:
UF = (d – d0) / 2
Where: d - total width of the zone affected by subsurface corrosion
(arithmetic mean) in mm
d0 - width of the original scribe mark in mm
The longest filiform thread, l.F., (maximum thread length) shall additionally be determined; see Figure 2.
mm
Measuring point 1 5
Measuring point 2 8
Measuring point 3 18
Measuring point 4 4
Measuring point 5 6
Measuring point 6 7
Measuring point 7 16
Measuring point 8 6
Measuring point 9 6
Measuring point 10 6
Measuring point 11 6
Measuring point 12 15
Measuring point 13 5
Measuring point 14 6
Measuring point 15 6
Measuring point 16 7
Measuring point 17 5
Measuring point 18 18
Measuring point 19 6
Measuring point 20 6
Total 162 Divided by the number of measuring points (20) = arithmetic mean:
d = 8,1 mm
Subtract scribe width:
(d - d0) = 8,1 – 1 mm = 7,1 mm
Divide by 2:
7,1 : 2 = 3,55 mm
Meaningful indication in test report:
UF = 3,6 mm
10 mm 10 mm
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Assessable scribe mark length 10 cm
11.
with 20 measuring points
12.
13.
14.
15.
16.
17.
18.
19.
20. 10 mm 10 mm
Copyright Daimler AG
Figure 2. Determination of the longest filiform thread. (Important: Take care that no measurements
are taken right at the ends of the scribe marks, but at a distance of at least 10 mm from the ends.)
Figure 3. Edge corrosion starting from bolt hole for a high-sheen aluminum wheel
2
3
4
5
Figure 4. Measurement to the right of valve hole
7
8
10
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11
12
13
14
15
Test conditions
Depending on the outdoor weathering area, different weather conditions prevail. Meaningful comparisons
of test results are therefore only possible between tests in one area. In addition, the seasonal change
of the climatic conditions influences the test, and this therefore also applies to the start of an outdoor
weathering test. This is why the test according to this method should mainly be used as a comparison
test or why a known standard should also be included in the test program.
Test procedure
The test panels shall be marked with a straight scribe mark down to the metal substrate parallel to
the longitudinal side. Alternatively several scribe marks running parallel to each other may be applied.
For scribing, see section "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
Other pre-damage such as a stone impact simulation may also be applied.
Special corrosion test panels, part components, add-on parts or complete BIW bodies may also
be used as test pieces for testing.
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Store the corrosion test pieces on racks at an angle of approx. 5° inclination to the horizontal.
The scribes should run "vertically" if possible. They shall be generously sprayed once a week
with a 3 % NaCl solution. (For spraying, a sprayer used for pesticides has proven successful.)
Recommended test duration: 12 months
Evaluation
After the test is completed, rinse the test panels with clear, flowing water; if necessary, blow dry the
surface using compressed air and inspect for visible changes. The visible corrosion creep originating
from the scribe towards both sides is measured. In general, the width of the metal surfaces adjacent
to the scribe damaged by corrosion is easily visible as blister or corrosion track on the paint surface.
In addition, steam cleaning as per DIN EN ISO 16925 or an inclined knife blade can be used to carefully
remove the subsurface corrosion of the paint film through to the zone where there is still firm adhesion.
For evaluation, measure the average total width of the subsurface corrosion zone in mm; see section
"Subsurface corrosion around a scribe mark, code U/2" of this MBN.
For aluminum substrate, refer to 5.11.7 of this MBN, Subsurface corrosion around a scribe for filiform
corrosion, code UF.
Test panels
Substrate: aluminum as per MBN 10494-1: Sampling, test panels
Specimen size: 300 mm x 100 mm.
The paint structure and coating and baking conditions conform to the standard conditions
of the relevant place of application.
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Place of exposure
South Florida, e.g.:
- Atlas Weathering Services Group
South Florida Test Service
Miami, FL
- Q-Lab Weathering Research Service
Homestead, Florida
Exposure type
DWI – 5° south
Exposure
The panels shall be assessed after the following weathering phases:
Water-based coats
Total duration: corresponding to material DBL 2 / 3 or 5 years
Assessment: at least after 1 and 2 years
Assessment
Before each assessment (recommendation: cleaning every 6 months), wash the test surfaces using
a mild detergent and a soft sponge. To be assessed:
• Blistering: visual examination of the test surface for blistering in accordance with
a) Blistering, degree of blistering, code Quantity of blisters (S blister size)
of this MBN
b) Inspected in the USA by a service provider: blistering, washed area -
ASTM D 714, cracking, washed area - ASTM D 661
• Color deviation: as per visual color assessment and color measurement of MBN 10494-4
• Condensation
constant atmosphere: a condensate test in accordance with condensation constant atmosphere,
abbreviated designation CH; performed as per this MBN with subsequent
adhesion test according to manual scratch test and cross-cut as per DIN
EN ISO 2409 of MBN 10494-5.
The materials technology specialist department shall be informed in the form of a results report annually
and in the event of failure.
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Test panels
Substrate: aluminum as per MBN 10494-1: Sampling, test panels
Specimen size: 140 mm x 60 mm.
The paint structure and coating and baking conditions conform to the standard conditions
of the relevant place of application.
Test conditions
Accelerated weathering: CAM 180 Q/B
Optical filter: Quartz inner filter and Pyrex outer filter
Irradiance: 0,55 W/m² at 340 nm
(corresponding to 56 W/m² at 300-400 nm)
Operating mode: Continuous run
Pass cycle: 60 min spraying (light-off period) of the front and back
of the panel
40 min dry phase (light-on period)
20 min spraying (light-on period) of panel front
60 min dry phase (light-on period)
Black-panel temperature: 70 ± 2 °C
Enclosure temperature: 47 °C during light-on period
38 °C during light-off period
Humidity: 50 % r.h. during dry phase of light cycle
> 95 % r.h. during the spraying and light-off period
Clear coats shall be exposed until failure at least 1 x before initial use in production.
The exposure time and intermediate assessments are indicated in the material-specific DBL.
5.10 Function test: corrosion cycle test, salt spray test and CASS test
Function test of the corrosion cycle test 1 as per DIN EN ISO 11997-1, corrosion cycle test 2
as per VDA 233-102, salt-spray test as per DIN EN ISO 9227 NSS and CASS test as per
DIN EN ISO 9227 CASS.
Mass-loss plates made of steel CR4 as per ISO 3574, as described in DIN EN ISO 9227 2002-09,
shall be used for monitoring the chamber.
The work for plate pre- and post-processing shall be carried out under an extraction vent,
and acid-proof gloves and safety glasses worn while doing this.
Samples
Two test specimens (control panels) per week sized 150 mm x 70 mm each and (1± 0,2) mm thick
and consisting of steel CR4 in accordance with ISO 3574 shall be used.
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Plate preparation
Isopropanol and afterward butyl acetate shall be used for degreasing the plates. The plates shall
be rubbed free of smears and dirt. A lint-free paper towel – soaked with the previously mentioned
solvents – shall be used for this. The initial weights shall then be ascertained and documented.
The back of the plate shall then be taped up with a special adhesive tape (picture, name) and
the plates marked.
Testing
The test durations are specified in Table 1.
At least 2 mass-loss plates shall be respectively used per test chamber.
Plate post-processing
The rough corrosion products shall be physically removed in a water bath with a brush.
If the plates are pickled on the same day, further mechanical removal of the corrosion products
can be immediately begun. To do this, the plates shall first be bent, which more easily loosens
up the corrosive layer. Next, additional physical treatment shall be performed with a hammer.
If the plates are not pickled on the same day, they shall be dried after the water bath, packed
in cellulose cloths and heat-sealed with a bag of silica gel. On the day of pickling, the plates
shall then also be bent and processed with the hammer.
A fresh batch of pickling medium (without Fe III chloride) shall be used. Five test panels can be pickled
at the same time with a batch (2 liters) of pickling medium.
A 2 liter batch of pickling medium consists of 1 liter of concentrated hydrochloric acid (35-38 % solution),
1 liter of deionized water and 7,5 g hexamethylenetetramine. First, the water is put in and then the acid
added. The quality of the acid shall be verified prior to adding it. If it appears to be yellow, the acid shall
not be used.
The pickling solution shall be homogenized with the magnetic stirrer and maintained at approx. 40 °C.
After they have been cleaned, the plates shall be washed off with DI water and dried off with a paper
towel. Next, the dry plates shall be weighed and the mass losses documented.
After the pickling, the pickling solution shall be collected in special toxic waste containers and disposed
of in the hazardous waste disposal location.
Divide the averaged loss of mass by the area of the affected eroded metal surface in order to obtain
the loss of mass of the metal per square meter.
Loss of mass in g/m²: = (initial weight – end weight ) / surface area of the test specimen
Surface area of the test specimen = surface area of the corroded side (as the other side is taped up)
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Table 1. Test duration, pickling times and target values for the chamber monitoring
Target value
Testing Test duration Pickling time
[Loss of mass per square meter]
The scribe mark shall be produced on coated metallic panels as per DIN EN ISO 17872.
The test panels shall be marked with a straight scribe mark down to the metal substrate parallel
to the longitudinal side. The scribe mark should be made vertical to the component placement
in the chamber and have a distance of at least 3 cm from the edges of the specimen.
Scribing tool: Scratch stylus as per SIKKENS, e.g. model 463, Erichsen; see Figure 7
Scribe width: 1 mm
Scribe depth: The damage caused by the scribe shall reach down into the substrate;
this means that electroplated parts shall be scribed down to the steel substrate.
Scribe mark length: at least 12 cm; 1 cm each at the beginning and end of the scribe mark shall
not be assessed. If the standardized scribe mark cannot be made due to the
component geometry, this shall be reconciled with the specialist department
and noted in the test results.
Figure 7: Scratch stylus, scratch width 1,0 mm, as per SIKKENS model 463, Erichsen
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The evaluation shall be carried out immediately following the end of the exposure in analogy with
DIN EN ISO 4628-8; the following procedure deviating from DIN is used by Daimler:
1. Delamination (loose coatings) shall be removed. Important: remove loose coatings completely.
The preferred methods of Daimler are: pressurized water-jet, knife, compressed air
and combinations thereof.
Note 1: In the case of flat sheets which are evaluated by means of imaging, the removal
of the loose coating is not absolutely necessary. This presupposes the use of an apparatus
with co-axial illumination.
Note 2: In the case of the pressure-water jet method, delamination of interlayers may occur
that is not a part of the evaluation and shall be documented separately.
Note 3: If the adhesion of the coating on the substrate is so poor that the coating no longer
adheres at all and can be easily removed up to the edge of the test specimens, this shall
be stated in the test report.
2. Evaluation shall be carried out at the earliest after a regeneration period of 24 hours
after the end of exposure. Deviations from this rule should be indicated in the test report.
3. No distinction between the corroded areas and the delamination down to the substrate
caused by this corrosion. This means that the complete delamination down to the substrate,
including the corroded area, is evaluated.
4. The preferred evaluation method is DIN EN ISO 21227-3 (use of digital imaging). In the following,
the manual evaluation is described, which can continue to be applied to non-flat test specimens.
Manual evaluation
Use a ruler to measure the width of the subsurface corrosion, if possible at 10 locations (at least 6)
at a distance of 1 cm along the scribe and calculate the arithmetic mean. Ignore the subsurface
corrosion at the beginning and end of the scribe mark (1 cm each); see Figure 8.
The following equation shall be used for the calculation of the characteristic value:
U/2 = (d – do) / 2
d= (d1+d2+d3….+d10)/10
Where
U/2: mean subsurface corrosion towards one side from the scribe
d: total width of the creep-corrosion zone of delamination down to the substrate including corrosion
(arithmetic mean), in mm
do: width of the original scribe mark, in mm
dn: width of the creep-corrosion zone per measuring point n
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Instead of the manual evaluation, evaluation using an image assessment instrument including software
is preferred in light of assessment accuracy. (e.g. VIEEW)
When indicating the characteristic value also indicate whether manual or image evaluation was used.
1 cm
d1
d2
d3
d4
10 cm
d5
(Assessable scribe mark length)
d6
d7
d8
d9
d10
1 cm
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1,0 cm
1
Edge area
Plate
Depending on the substrate type (steel/zinc), WR (white rust in the case of zinc) /
RR (red rust in the case of steel and zinc) shall be added to the value.
Blisters forming along the edge are also regarded as edge corrosion.
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Figure 11: Example of a wheel surface with systematic edge corrosion at the
wheel center holes, track measurement holes and on the wheel center hole: KR 4
Depending on the weld type, the reverse of the weld seam shall also be taken into consideration.
Rating
Intensity of the flange corrosion
FR
FR 0 No corrosion on flange surface
FR 1 Isolated rust spots on flange surface / up to 5 %
FR 2 Less than 1/3 of the flange area corroded / up to 30 %
FR 3 1/
3 to ½ of the flange area corroded / up to 50 %
FR 4 ½ to ¾ of the flange area corroded / up to 80 %
FR 5 More than ¾ of the flange area corroded
The corrosion value shall always be indicated with the addition WR (white rust in the case of zinc) /
RR (red rust in the case of steel and zinc).
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Max. Uk OK range
NOK range
Max. Uk
Figure 12: Assessment of the subsurface corrosion stemming from the edge (Uk)
The test specimens shall be arranged at an angle of 70 ° (± 5°) to the horizontal. In case of
a 3D testing geometry, the test position shall be agreed on with the specialist department.
For the NSS salt spray test, CASS test, corrosion cycle test 1 and corrosion cycle test 2,
the following applies:
- Test specimens shall not be struck directly by the spray stream of the nozzle
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