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Mercedes-Benz MBN 10494-6

Company Standard Date published: 2016-03

Total no. of pages (including annexes): 22


Person in charge: Irina Moreno de Struwe
E-mail: irina.de_struwe@daimler.com
Plant: 050; Dept.: TF/VBT
Date of translation: 2016-06 Phone: +49(0) 7031/90-2647

Paint Test Methods –


Part 6: Climatic Tests
Foreword
This Standard describes the test methods for paints, varnishes and coatings.
This edition supersedes the previous edition of this Standard dated 2013-10.

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.

The paint test methods are used for


- laboratory tests, e.g. for basic examinations, initial tests, retests,
tests in the case of operational complaints
- process control of the coating in Daimler Group plants.

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 D 714 Assessment of the Degree of Blistering of Coating Materials

ASTM D 661 Ascertaining the Degree of Cracking of an Exterior Coating Material

ASTM G 154A Standard Practice for Operating Fluorescent Ultraviolet (UV) Lamp
Apparatus for Exposure of Nonmetallic Materials

DBL 5555 Finished Parts and Semi-Finished Products Made of Organic


Polymer Materials – General conditions and test methods

DBL 6714 Negative List – Constituents of Process Materials

DBL 8585 Negative Substance List for the Selection of Materials

DIN 55665 Paints and Varnishes – Natural Weathering of Coatings –


Determination of Corrosion Protection Performance

DIN EN ISO 2409 Paints and Varnishes – Cross-Cut Test

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DIN EN ISO 2810 Paints and Varnishes – Natural Weathering of Coatings –


Exposure and Assessment

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 4628-2 Paints and Varnishes – Evaluation of Degradation of Coatings –


Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance – Part 2: Assessment of Degree of Blistering

DIN EN ISO 4628-3 Paints and Varnishes – Evaluation of Degradation of Coatings –


Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance – Part 3: Assessment of Degree of Rusting

DIN EN ISO 4628-4 Paints and Varnishes – Evaluation of Degradation of Coatings –


Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance – Part 4: Assessment of Degree of Cracking

DIN EN ISO 4628-8 Paints and Varnishes – Evaluation of Degradation of Coatings –


Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance – Part 8: Assessment of Degree of Delamination
and Corrosion around a Scribe or other Artificial Defect

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 9001 Quality Management Systems – Requirements

DIN EN ISO 9227 Corrosion Tests in Artificial Atmospheres – Salt Spray Tests

DIN EN ISO 11997-1 Paints and Varnishes – Determination of Resistance to Cyclic


Corrosion Conditions – Part 1: Wet (Salt Fog)/Dry/Humidity

DIN EN ISO 16474-2 Paints and Varnishes – Exposure to Artificial Light or Weathering in Devices –
Part 2: Xenon-Arc Lamps

DIN EN ISO 16925 Determination of the Resistance of Coatings to Pressure Water-Jetting

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

MBN 10494-1 Paint Test Methods – Part 1: General Requirements

MBN 10494-4 Paint Test Methods – Part 4: Optical Tests

MBN 10494-5 Paint Test Methods – Part 5: Technical-Mechanical Tests

VDA 233-102 Cyclic Corrosion Testing of Materials and Components in Automotive Construction

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3 Terms and definitions

CASS Copper-accelerated acetic acid salt spray test


CCT Cyclic corrosion test
CED Cathodic electrodeposition (e-coat)
MB Mercedes-Benz
NSS Neutral salt spray test
RR Red rust
WR White rust

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.

5.1 Condensation atmosphere with constant humidity (code CH)


Equipment and auxiliary materials
- Climatic chamber in accordance with DIN EN ISO 6270-2. Deviating from DIN EN ISO 6270-2,
a test chamber with steam humidifier without pan may be used provided that the specified humidity
of 98 % with condensation on the specimens is maintained.

Scope and application


When paints of motor vehicles are exposed to condensation water over a prolonged period, adhesion
between coating and the substrates or between the individual layers of a paint structure can be reduced
or completely lost. The sample coatings are exposed to condensation water atmospheres to examine
whether visible surface and adhesion changes occur under that exposure.
The test sheet indicates conditions which shall be observed during the testing of motor vehicle paint
coatings in addition to standard DIN EN ISO 6270-2. The simulation of condensation water exposures
according to the test sheet does not, however, allow direct statements to be made about the life of the
tested parts during practical operation.

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.

5.2 Salt spray testing, abbreviated designation NSS


In accordance with DIN EN ISO 9227 NSS.

Equipment and auxiliary materials


Test cabinet in accordance with DIN EN ISO 9227
Scratch stylus, see: section "Subsurface corrosion around a scribe mark" of this MBN.

Scope and application


The salt spray test is an environmental simulation method for testing industrial materials and coatings
for their resistance to corrosion in atmospheres containing salt. Salt spray tests are generally appropriate
as corrosion protection tests for ascertaining weak points, pores and imperfections quickly. They do not
normally allow statements to be made about the long-term behavior of different systems in the field.
In addition, test specimens can be compared for quality monitoring purposes which are provided with
the identical coating or plating. However, salt spray tests are only suitable as comparison tests if the
types of coating or plating are similar.

Test conditions analogous to ISO 9227


Air temperature: (35 ± 2) °C
Average collection rate for a horizontal collection area of 80 cm2: (1,5 ± 0,5) ml/h
Concentration of sodium chloride (collected solution): (50 ± 5) g/l
pH (collected solution): 6,5 – 7,2
Normal test duration: 240 h (changes as per material-specific DBL and by agreement)
Possible test durations are 2 h, 6 h, 24 h, 48 h, 96 h, 168 h, 240 h, 504 h, 720 h, 1000 h, 3000 h

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.

The following can be assessed in addition:


- Visible surface finish changes, e.g. dulling, staining
- Surface corrosion Ri (see section of this MBN)
- Degree of blistering S (see section of this MBN)
- Edge rust KR (see section of this MBN)
- Adhesion K (see section of this MBN)

5.3 CASS test


In accordance with DIN EN ISO 9227 CASS in the case of aluminum as substrate.
Deviating from standard DIN EN ISO 9227 CASS, the pH value shall be adjusted from 3,1 to 3,3
by adding acetic acid.
The exposure time is indicated in the material-specific specification documents (DBL).
The type of evaluation of the final assessment of the test specimens at the end of exposure is indicated
in the material-specific DBL. Bare aluminum cut edges shall be protected before testing by means
of an appropriate adhesive tape (JaBand 92402 adhesive polyester tape) or wax (Pfinder 611/8).

5.4 Corrosion cycle test

5.4.1 Corrosion cycle test 1


As per DIN EN ISO 11997-1 Cycle B.

Equipment and auxiliary materials


- Scratch stylus, see section "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
- Condensation water test chamber in accordance with DIN EN ISO 6270-2-AHT
(Heating test (AHT): Condensation climate with alternating humidity and air temperature)
- Salt spray cabinet in accordance with DIN EN ISO 9227-NSS, or variable climate chamber
- Temperature and humidity check integrated into cabinet by means of data logger

Scope and application


The static corrosion test in accordance with this test instruction is intended to test the corrosion protection
and the behavior of vehicle coatings and substrates under cyclic exposure. The intention is to simulate
corrosion processes and failure patterns in a time-lapse mode allowing statements about the behavior
of the tested process and service products, paints and substrates during driving operation to be made.
The assessment criteria of the test include, in particular, simulated damage to the coating and corrosion
creep around that damage, and the determination of edge and surface corrosion using special corrosion
test panels / parts.

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.

Cyclical sequence of the test as per DIN EN ISO 11997-1 Cycle B

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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.

5.4.2 Corrosion cycle test 2


In accordance with VDA 233-102 Cyclic Corrosion Testing of Materials and Components in Automotive
Construction.

Scope and application


The purpose of the corrosion test is to provide an accelerated test procedure for the assessment of the
corrosion behavior of materials and components and of the corrosion protection provided by coating
systems. The accelerated test covers in particular the delamination/corrosion creep around a defined
artificial defect in a coating as well as surface and edge corrosion on special test panels, bonding
specimens or components. Compared to tests with a higher humidity availability a decreased aging rate
of adhesive is to be expected. This laboratory-scale cyclic corrosion test is also suitable for assessing
perforation corrosion in flanged areas or gaps and of unpainted surfaces, but without aluminum substrates.

Equipment and auxiliary materials


Programmable corrosion test chamber
Temperature and relative humidity monitoring using a data logger
Monitoring of constant testing conditions by means of mass-loss specimens
Measuring cylinder plus funnel
pH meter

Test procedure

Test conditions - test procedure


To be performed according to the standard.

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.

5.5 Filiform test on painted aluminum parts as per Daimler


In contrast to DIN EN ISO 4623-2, the Daimler filiform test requires an immunization by means of a 24 h
CASS test.

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

Figure 1. Determination of the arithmetic mean of filiform subsurface corrosion:


Example of a calculation (Figure 1): UF = (d – d0) / 2 (the distance between the
individual measuring points shall always be the same)

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

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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

Figure 5. Rim base (tire-side)

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11

12

13

14

15

Figure 6. Inner wheel side (brake side)

5.6 Cold test


This test is intended to determine whether stress occurs in the case of a sudden change in temperature.
The test specimens shall be heated to +50 °C and maintained at this temperature for 1 hour, then cooled
down to -40 °C immediately by placing them in the freezer cabinet for 1 hour.
The cycle consists of 1 hour hot storage, 1 hour cold storage, repeated 25 times.
Cracks, hardness and any surface changes at room temperature are assessed. In addition, the paintwork
structure shall be examined as per the manual scratch test of MBN 10494-5.

5.7 Outdoor weathering of coatings – testing the corrosion behavior


Testing of corrosion protection of vehicle paint coats by outdoor weathering using salt as per DIN 55665

Equipment and auxiliary materials


- Open space (ideally not in the direct vicinity of chimneys and other climate-influencing constraints)
in accordance with DIN 55665
- Weathering grids / cover boxes in accordance with DIN 55665
- Scratch stylus, see section "Subsurface corrosion around a scribe mark, code U/2" of this MBN.
- Climate recording instrument, e.g. weather station

Scope and application


The testing of vehicle paint coats/substrates in natural tests, so-called outdoor weathering, is intended
to determine the corrosion behavior under the influence of natural weather conditions and additional
exposure of the samples by spraying them with saline solution (severe outdoor weathering). Due to the
climatic conditions which are unchanged compared with the "field", this test results in corrosion processes
and corrosion patterns which are comparable to those occurring in practice. In addition, a time-lapse effect
of the processes is achieved by using saline solution. This test simulates the corrosion creep starting from
a defined coating damage, surface corrosion and edge corrosion.

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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The test can be carried according to two test types:


1. Outdoor weathering with salt, without light protection
For test pieces with a complete top-coat structure
2. Weathering with salt, with light and rain protection
Protection against direct sunlight irradiation by means of a roof and air-permeable side walls
For coatings without a top coat and other layers, which also in practical use are not exposed
to sunlight.

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.

The following can be assessed in addition:


- Visible surface changes
- Surface corrosion Ri (see section of this MBN)
- Degree of blistering S (see section of this MBN)
- Edge rust KR (see section of this MBN)
- Adhesion K (see section of this MBN)

5.8 Resistance to weathering


To test the resistance of the coating to atmospheric influences. For long-term weathering, coated test
pieces shall be stored on large exposure racks at a defined angle to the solar irradiation.
After the specified exposure period, assess the hue, gloss, cracks and chalking and compare with the
values for the unexposed paint coat.

5.8.1 Florida test


Before a coating material is approved for vehicle bodies, the test panels with the complete paint
structure shall be subjected to a weathering test in Florida. For the exposure time, test type,
positioning angle and time of the intermediate assessments, refer to the material-specific DBL.
This test shall be performed in analogy with DIN EN ISO 2810 on the initial test specimen.

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.

Preparation and shipment of the test panels


• Measurement of gloss of unexposed test specimens as per DIN EN ISO 2813
• Shipment of panels in such a way that the panel surface cannot be impaired,
e.g. by using special shipment boxes.

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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

Clear coat exposure


Total duration: at least 10 years
Assessment: at least after 3, 5 and 7 years
Intermediate 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:

• Gloss measurement: as per DIN EN ISO 2813:


a) high-gloss surfaces: measuring geometry: 20°
b) Matt body paint: measuring geometry 60°

• 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

• Cracking: in accordance with DIN EN ISO 4628-4

• 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.

5.8.2 Weathering in central European climate


Unless specified otherwise in the material-specific DBL, coated test panels shall be placed on suitable
racks at an angle of 5° from the horizontal facing southwest, on an exposure site with central European
climate. Comparison panels for the exposed test panels shall be stored in dark conditions. Wash the
exposed coatings at quarterly intervals using clear water and, if agreed, polish half of them using
a specified polish (MB polish). Cover half of the exposed / polished surface of the coating with the
comparison panel and assess for changes in gloss and color. Specific phenomena on the coatings
such as staining, cracking or blistering shall be reported in the findings.

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5.9 Artificial weathering


Before a coating material is approved for use on car bodies, the test panels with the complete
paint structure shall be subjected to an artificial weathering test. The exposure time, test type
and the positioning angle shall be agreed with the department responsible.

5.9.1 CAM 180


This test shall be performed for coated metal specimens based on DIN EN ISO 16474-2.
Before a coating material is approved for use on car bodies, the test panels with the complete
paint structure shall be subjected to an artificial weathering test.

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.

5.9.2 Artificial weathering for coated and uncoated plastics


According to DBL 5555

5.9.3 QUV device


As per test specification ASTM G 154A: Spectral irradiation of UVA-340
Test cycle: UVA lamp with irradiation 0,89 W/m2/nm, alternating moistening/illumination 4 h / 4 h:
4 h UV at 50 °C
4 h moistening at 50 °C

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.

The pickling durations are specified in Table 1.

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.

Weighing of test specimens


The test specimens shall be weighed to ±10 mg prior to beginning the test and after removal
of the corrosion products.

Evaluation of the results

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)

The target values are stated in Table 1.

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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]

VDA 233-102 1 week 20 min 290 – 360 g/m2

DIN EN ISO 11997-1 1 week 20 min 125 – 170 g/m2

DIN EN ISO 9227 CASS 24 hours 2 min 40 – 70 g/m2

DIN EN ISO 9227 NSS 48 hours 2 min 50-90 g/m2

5.11 Assessment of results of climatic tests

5.11.1 Subsurface corrosion around a scribe mark, code U/2


In analogy with DIN EN ISO 4628-8

Introduction of the scribe mark (pre-damage)

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.

Recommended scribe mark assessment length: 10 cm

Figure 7: Scratch stylus, scratch width 1,0 mm, as per SIKKENS model 463, Erichsen

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Assessment of subsurface corrosion

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

Figure 8. Manual evaluation of subsurface corrosion around a scribe

5.11.2 Surface corrosion, code Ri


Assessment and evaluation in accordance with DIN EN ISO 4628-3.
No accumulation/clustering exceeding the limit value indicated in the relevant DBL shall occur.

5.11.3 Blistering, degree of blistering, code Quantity (0-5); size S(0-5)


Assessment and evaluation in accordance with DIN EN ISO 4628-2.
If the coating is assessed as having blisters of the quantity 3 and size 2, for example,
the results shall be stated as follows: blistering; degree of blistering 3 (S2).
No accumulation/clustering exceeding the limit value indicated in the relevant DBL shall occur.

5.11.4 Edge corrosion, code KR


In addition to DIN EN ISO 4628-1, edge corrosion shall be assessed as follows:

1. The whole edge is assessed according to Figure 9.


2. Surface corrosion does not start from the edge.
3. If corrosion starting from the edge exceeds the value of 1,0 cm according to Figure 14,make
a separate reference to this effect with the note: "Surface corrosion starting from the edge"
4. In special cases such as perforated panels, a differentiated edge assessment shall
be carried out.
5. The edge corrosion assessment refers to the edge area defined previously.
6. In the case of complete parts, all edges shall be assessed and mean values formed based
on the overall impression. Particularly striking areas shall be documented separately.

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1,0 cm
1
Edge area
Plate

Figure 9. Assessment of edge corrosion

Assessment according to Table 2.

Table 2: Ratings for the assessment of the intensity of edge corrosion


Rating Intensity of edge corrosion
KR 0 Edges without rust
KR 1 Isolated rust spots on edges / up to 5 %
KR 2 Rust spots on less than 1/3 of edges / up to 30 %
KR 3 1/
3 to ½ of edges covered by rust / up to 50 %
KR 4 ½ to ¾ of edges covered by rust / up to 80 %
KR 5 More than ¾ of edges completely covered by rust

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.

5.11.4.1 Edge rust of perforated plates


Perforated plates shall be used here.
Perforated plates according to Daimler Standard can be obtained from Chemetall.
Test procedure
The test pieces shall be subjected once with the burr side upwards and once with
the burr side downwards.
Assessment:
Each edge shall be evaluated separately according to Table 2 with no integration.

5.11.4.2 Edge corrosion on aluminum wheels, KR


The assessment shall be made as stated in Table 3; see Figures 10 and 11.

Table 3: Assessment of edge corrosion on light alloy wheels


Rating Intensity of edge corrosion

KR 0 Edges without corrosion


Isolated corrosion spots on the edges.
KR 1 With burnished wheels, one corrosion spot on the
burnished leading edge / trailing edge leads to KR 1
Systematic edge corrosion on one specific edge, with
KR 2 at least 3 affected corrosion spots per specific edge

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Systematic edge corrosion on two specific edges,


with at least 3 affected corrosion spots per specific edge
KR 3 or Systematic edge corrosion on one specific edge,
with at least 3 affected corrosion spots and isolated
occurrences of edge corrosion

Systematic edge corrosion on three specific edges, with


at least 3 affected corrosion spots per specific edge or
KR 4 Systematic edge corrosion on two specific edges, with
at least 3 affected corrosion spots and isolated occurrences
of edge corrosion
Systematic edge corrosion on four specific edges, starting
with 3 each affected corrosion spots per specific edge or
KR 5 Systematic edge corrosion on three specific edges, starting
with 3 affected corrosion spots and isolated occurrences
of edge corrosion

Rim flange Valve hole


Bolt hole Edge of vent hole
Spoke edges Burnished leading edge
Burnished trailing edge
Track measurement hole
Wheel center hole
Figure 10: Visible wheel side

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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

5.11.5 Weld corrosion, code SR


Assessment according to Table 4.

Table 4: Ratings for the assessment of the intensity of weld corrosion

Rating Intensity of the weld corrosion


SR 0 Welds without corrosion
SR 1 Isolated rust spots on welds / up to 5 %
SR 2 Rust spots on less than 1/3 of welds / up to 30 %
SR 3 1/
3 to ½ of welds covered by rust / up to 50 %
SR 4 ½ to ¾ of welds covered by rust / up to 80 %
SR 5 More than ¾ of welds completely covered by rust

Depending on the weld type, the reverse of the weld seam shall also be taken into consideration.

5.11.6 Flange corrosion, code FR


Flange corrosion is the surface corrosion occurring on an uncoated hem.
It can only be assessed after opening of the flanges.
Assessment according to Table 5.

Table 5: Ratings for the assessment of the intensity of flange corrosion

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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5.11.7 Subsurface corrosion around a scribe for filiform corrosion, code UF


As per filiform test on painted aluminum parts of this MBN

5.11.8 Filiform corrosion starting from the edge, code KRf


As per filiform test on painted aluminum parts of this MBN.

5.11.9 Scratch test on the undamaged surface, code K


As per adhesion test of MBN 10494-5. This characteristic value may be required in a material-specific
DBL with regard to an undamaged location after a defined regeneration time after the end of exposure.

5.11.10 Cross-cut on the undamaged surface, code Gt


As per cross-cut in accordance with DIN EN ISO 2409 of MBN 10494-5. This characteristic value
may be required in a material-specific DBL with regard to an undamaged location after a defined
regeneration time after the end of exposure.

5.11.11 Subsurface corrosion stemming from the edge, code Uk


Uk Subsurface corrosion stemming from the edge, see Figure 12

For steel and galvanized substrates:


In DIN ISO 11997 T1 Cycle B, examined components shall not exceed the required
maximum values on all edges for subsurface corrosion of the edges (Uk)
For aluminum:
The maximum specified value as per CASS is valid
No Uk value has been set for NSS and filiform tests.

Max. Uk OK range

NOK range

Max. Uk

Figure 12: Assessment of the subsurface corrosion stemming from the edge (Uk)

5.12 Description of the test position

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

Applicable to all corrosion tests:


- Specimens shall not contact one another; a minimum distance of 5 cm shall be maintained.
- No solution shall drip from specimens or holders onto other specimens
-The surface to be tested shall be completely exposed to the corrosive medium

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