IssueD JUNE aos SURFACE SARL eee VEHICLE & INTERNATIONAL STANDARD {360 Cammorweaih Div, Wanerle, PA TERI0-001 Sune te recognition a an Amaticam Noon Standeré Foreword—This cosmatic corrosion lab test procedure is based on field correlated lab test procedure parameters as determined by a Design of Experiment process conducted by the SAE Automotive Corrosion and Prevention ‘Committee (SAE/ACAP) and the Aulo’Stael Partnership (A/SP) Corrosion Task Force. Riesults from this test wil provide excelent correlation to severe corrosive isk! environments with respect to cosmetic corrosion @j_ eter 2Nc0. For historical information on the development ofthis test, refer io 2.14 A typical automotive paint system was used to develop this test. See 2.1.4, 1 te 5, 1 dilforant type of coating system is used, fold correlation rust be determined. 1. Scope—The SAE J2334 tab tast procedure should be used when dotermining cosmetic corrosion Performance for a particular costing system, substrate, process, or design. Since i isa Heid corelated tost, i can be Used as a validation tool as wel as a development tool, If corrosion mechanisms other than cosmetic or {general corrosion are to be examined using this tet, field coreation must be established. @) 2 rcterences 2.1 Applicable Publications—-The folowing publications form a part of this speciation to the extent specitied herein. Uniess otherwise indicated, the latest version of SAE publications shall apply. 2.1.1 SAE PuauceTion Availabe irom SAE, 400 Commonweatth Drive, Warrendale, PA 15096-0001. ‘SAE J1869—Guidelnes for Laboratory Cyclic Corrosion Test Procedures for Painted Auomotve Parts @| 212 ASTM PuDIcations—Availebie trom ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19426-2968. ASTM D 1199—Specifcation for Reagent Water ASTM D 1654—Moihod for Evaluation of Painted ot Costed Specimens Subjected to Corrosive Environments ASTM D 1738—Practce for Testing Water Resistance of Coatings Using Water Fog Apparatus ASTM D 2247—Practce for Testing Water Resistance of Coatings in 100% Relative Huricity ‘ASTM E 70.90—Test Method for pH of Aqueous Solutions withthe Giass Electrode ASTM G 1—Recommended Practice for Preparing, Cleaning, end Evaluating Corrosion Test Specimens AE socal Sand Soar Pandata hey SAE nar ha to eid md egoncng wigan. Th a tA ory ‘ourny ore agnor asaby wy prea, hg oat Pg mg bert ae oe pene eat” 5 reve 86 Weel el wey yur hc en Se ed cara Ani arn Ona aM, ‘Questions necanowa ies cocuMeNT 26 7724612 FAX: (721) 176 2068 e TOPLAGEA DOCUMENT ORDER, (2) TTeABTOPAX (TED. “SAE Wen ADDRESS np teen oe, Seg et Some Atom cee ns ee2.41.3 GENERAL MoTOARS PUBLICATIONS—Avalabie from Global Engineering Documents, 15 lmemess Way East, Englewood, CO 201 12 GM 9540P 2.1.4 OTHER PuauicaTions 1. Townsend, H, ., “Development of an Improved Laboratory Corrosion Test by the Automotive and Stee! Indusities." in Advanced Coatings Technolocy Proceedings of the fourth Annuel, ESD Advanced ‘Coatings. Gonierence, The Engineering Society, Ana Arbor, MI, 1994, pp. 29-49. 2 Roudabush, LA, Townsend, HE. and McCune, 0.C., “Update on the Development of an Improved Gosmete Gorrasion Test by ihe Aulomotve and Steel Indusiies,” Automolve Conosion an Prawsation Conforence Procaedings. P-268, Socety af Automotive Engineers, Warrendale, FR, 7883, Pp. 53-83, 3. Tounsend, HE. “Recelerated Corrosion Testing: A Cooperative Etort by the Automotive and Stee! Industries, * Proceedings of the Sympasium on. Carosion-Pesistant Aulomatve Sheet Stools, ASM Materials Congress, ASM international, Metals Park, OH, 1988, pp. 55-67. 4, Townsend, HE. “Status of a Cooperative Effort by the Automotive and Steel Indusiies to Develop a ‘Standard Acceleraied Corsion Tes,” Automotive Corrosion and Prevention Conietence Preceestoga, 228, Socieiy of Automotive Engineers, Warrendale, PA, 1989, pp. 139-145, 5. Townsend, H.E., Granata, R.0,, McCune, 0.C., Schumacher, W.A. and Nevile, RJ, "Progress by tne Aitomotve and Steel Incusiries Toward an Improved Laboratory Cosmetic Corrosion Test” ‘Automotive Congsion and Prevention Conference Proceedings, P-250, Society of Automotive Enginears, Warrendale, PA 181, pp. 7387. '& Stephens, M.L., “SAE ACAP Dvision 3 Project: Evaluation of Corrosion Test Methods,” Automat Corpslon and Prevention Conference Proceedings, P.228, Society of Auomotive Engineers, Warrendale, PA, 1989, pp. 157-164. 7. Lutze, FAW. and Shatter, A. “Accelerated Atmospheric Corrosion Testing of AISI Panels,” Automate ‘Sortosion “and Prevention Conference Proceasings. P-250, Society of Automotive Enginoere, Warrendale, PA, 1901, pp. 116-127, 8, Petschel, M, “Statistical Evaluation of Accolarated Corrosion Tests anc Correlation with Two-Year On- Vehicle Tests” Automotive Cormsion anc Prevention Conference Proosedings, P-250, Society of ‘Artomotive Engineers, Warrendale, PA, 1997, pp. 179-203, 8. Davidson, B.D. and Schumacher, W.A., “An Evaluation and Anaiysis of Commonly Used Accelerated Cosmet Corrosion Tests Using Direct Comparison witn Actua Field Exzesure,”Autornative Corrsion ang Preyantion Conference Proosedings. P-250, Society of Automotive Engineers, Warrencale, PA, 1081, po. 205.218. 10. Ostermiter, MF, anc Townsend, H.E., “On-Vehicle Cosmetic Corrosion Testing of Coated! and Cold- Rled Stee! Shee,” Automotive Corrssion and Prevention Conference Proceedings, P-268, Soctety of ‘Automotive Engineers, Warendale, PA, 1993, pp. 65-83. 41. Granata, F.D. and Moussevi-Madany, M., “Charectenzation of Corrosion Products and Corrosion Mechanisms on Automotive Coated Stosis Subjected to Field and Laboratory Exposure Tests,” Leigh University Report to the ASP Corrosion Task Force, Januavy 10, 1898. 12, ASTM E 601-02, “Standare Prectice for Conducting an Inoraboratory Study to Detormine the Precision of a Test Method," Annual Book of Standards, American Society for Testing and Materials, ‘West Conshohockon, PA. 13. ASTM E 177-908, “Siancers Practice for Uso o the Tormé Precision and Blas in ASTM Test Methods” ‘Anewal Book of Standards, American Society for Testing and Materials, Nast Conshohocken, PA. Towmeond, HE. and McCune D.C. *Round-oin Evauaion of Now Standard Laboratory Tet fr Society ot Aomatve Engingers, Warencale PA, 997, pp. 50-68 2.1.41 Reproducibility and Repeatability information concerning this test method is discussed in SAE Paper 970734. Soe Roforenco 14,SAE 42834 Issued JUNDS Definitions Cosmetic corrosion—Corrosion thai ocours ag a result of the breakdown or damage to @ coating system, ‘Tplealy,. this type ot earrosion does not impact function but does compromise appearance. General corroston—Corrosion of a component that is typically bare (no organic coating). Corrosive attack is Uniform in nature and distributed over"large” areas. ‘Soribe ereepback—Coating creepback resulting fom corrosion and undercutting from the sere fine. A scribe is a controlled simulated damage sito designed to represent soratch or chip, Corrosion coupons—Coic-rolled size! samples used to contro! anc correlate corrosion lab tests by means of mass loss data. ‘Test controls—Compononis (.2., last panels, coupons, parts, etc) whion have been previously tested ansior Correlated. They can be used io control the test conduc! and compare the test resuls (algo aseie in evaluating reproducibility and repeatability), Equipment and Test Materials ‘Test Cabinete—Test cabinet(s) with the abilty to obtain and maintain the folowing environmental conditions (Reference SAE J1563, ASTM D 1735, and ASTM D 2247) @ $0 °C +2°C and 100% Humidity (water fogicondensing)—Waler fogicondensing humidity can be obtained by using atomized water, steam (vapor) generator, etc. Tho test samples and controls are required to be wsiby roistwat b. 60°C =2 Cand SO. Relive Humidity 25%, Addtional equipment wil be required to maintain the 50% relabve wumidty eondtion. ‘ir circulation must 08 sufficient to pravent temperature staification and allow drying of test paris during the {dryaff portion of he test cycle Air creulation can be obtained through the use of a fan or foreed ai. ‘Sslt Solution—Tne satt solution's a compiex mixture involving 3 salts on a weight pereent basis as folows: 5% NaCl 0.1% Cah 0.075% NaHCO NOTE 1—Eithe the CaCl, of NaHCO, material musi be dissolved separately in DI water (Reterence ASTM D 11499 Type IV) and then added to the solution of other materials. Ital solid materiale ere added at the same time in a “dry” state, an insoluble precipitate may result. 1! @ sight preciptate sti forms fend a spray application is used to apply the solution, it wal be recossary to remave the precipitate to ‘avoig clogging of nazzies (i.e, fiter or siphon solution). Do not attemp: to diesolve the praciptate by adding act. NOTE 2—Messure and record pHi of tha salt soliton prior to the stat of test and on a weekly basis thereafter (Reierenes ASTM E 70-90). Do not attemet to adjust the pH with any forrn of butlers,‘Test specimens are to be immersed inthe salt solution for a 16-min interval each test cycle, Other method ot appiying the salt. euch as hand spraying or direct application by a mist within the tost chamber may be ‘adequate but this variable has not deen analyzed with respect to correlation, repeatability, or reproducibility Impact. A spray that completely wets the part with sokiton fr the 16 min (continuously) should be adeauek, Howover, avoid a high intensity (pressure) spray (with respect to impact on the test spacimen). IW & spray oF ‘Mist application of ie satt solution is used instead of an immersion application, resulis must be demonetrated {0 be equivalant to immersion or they are only val! for relative AB comparisons. Furher esearch regarcing spray vereus immersion salt application tecbriques are underway. Resuits wil be used to update Ins Drocedure as they become available [tis recommenied that the test solution be changed weekly and that agitstior/stiing of the solution be done prior to the salt solution application 5 Test Procedure 5.1 Teat Cyole—The test oyce is outined in Figure 1 (5 day/week —_manual operation) and Figure 2 (7 daylweek - ‘automatic operation). " consists of tee basic siagon 41. Humid Stage—50 °C and 100% Humidity. 6h in duration, 2. Salt Application Stago—15 min duration conducted at ambient conditions 3. Dry Stage—60 °C and 60% RH, 17 h end 45 minin durailon The test cyole is repeated daily. Fuly automatic cabinets have the option of tunning during the weekends or programming in @ dry stage soak for the weekends (typically it would be desired to run on weekends end holidays to complete the test Sooner). fin exception io tis rule would be Hf comparisons fo other laboratories Who do ot have fuly automatic canabities 1s desired (for manual operations, the weekend exposure is ‘ypically maintained at dry stage condtions unless 7 day operations are avatable). Total test duration and {eekend condions must be documontod in the tes results. If two or mare laboratories wil be conducting {ests on similar pars, tis recommended theta constari/comman weekend condivon be dened betoe testing besins Ramp time between the salt application stage (2) and dry stage (3) are part of te dry stage time, Similarly, ramp time between tne dry stage (3} and humid stage (1) are part ofthe humid siage. Fiamp times should fe documentea for each test set-up. osmetic corrosion evaluations of coatings susceptible to damage, test samples will be scribed prior io exposure (Reference ASTM D 1654) Sonbe length should be a minimum of 2 in. Scribe creepback measurements are to be taken at predetermined intervals depending on the level of corrosion resistance ‘desired, Scribe orientation, on the specimen, must be soeciied and documented (lor typical fet panel ‘specimens, i is recommencied that panels be oriented 15 degrees from the vertical such that no one pane! ‘shadows another and that the scribe line be made in a diagonal across the pane! lace), $2 Test Duration—Typically, SAE 2398 is conducted for a minimum of 60 cyoles when evaluating costed products. Longer durations may be required to observe performance aifferendee in the heavier weight metalic recoats. Diflerent test durations may be appropriate based on other materials, corrosion mochanisms of iniorest, or past history| HU%OS PUE 309 BO AiG —— anaes AtuQ spusx99,45 Sb “snoy L1) HA %OS pur :309 BO ce (sinoy 9) ERE %001 Pu dos AuprUNy ——————— nwa wade Honwsodg [enuey - yoo/cvd S- peETE AVS SapoA- 389,,. qu] UOIso1105 oyauIsOD FIGURE 1—COSMETIC CORROSION LAB TEST CYCLES—5 DAYAVEEK—MANUAL OPERATION @ 2anal (soynmtur sp ‘smoy £1) HA %O0S PUP D09O AC i Z i Uae | (samnutw 1) storpuos 4 | 48 (Aeadg 10 80, ‘diq) uonmoyddy ayeg (sinoy 9) He %6001 Pu DOS Auprumy, += + Bonvsodg spEWOMY - yaaM/AUC L - PEETL AVS S9]94- 389, LQu’] UOIs0.1107) d19IS07) Kuea wodoy, ‘SAE J2934 fesued JUNGB FIGURE 2—COSMETIC CORROSION LAB TEST CYCLES—7 DAY/VEEK—AUTOMATIG OPERATION.| @ O)« a oz s oan 5.3 Coupon Monitoring—The testing process willbe montored with bare stasl corrasion coupons. SAE 42534 lesued JUNGE ‘8. Corrosion coupons consist of 25 mm wie » 50.8 mm long pieces of bare AIS! 1006-1010 steel. The ‘coupons serve to monitar the average general bare steel corrosion produced by the test environment Each coupon shall be permanently domitied by stamping a number onte the surface. ©. Corrosion coupons shall be thoroughly cleaned to remove all forming and storage olts/tubes with & commercially available degreaser lowed by a methanol rings. Then the mass in miligrame shall be Fecorded and retained for future reteronce, The coupons shall be secured to an aluminum or nonmetallic coupon rack. The coupons shall be electrically isolated from the rack by using fasteners and washers made from a non-black plastic material, preterably nyion, © Allow & minimum § mm spacing between the coupons and the rack surface. All coupons shell be seoured at a maximum 15 degrees ftom vertca’ and must not contact each ote, |. The coupon rack shall be placed in the general vicinty of the samples being tested, such that the coupons receive the same environmental exposure. 8. Coupons shall be removed and analyzed atter a predetermined number of cycles throughout the test fo monitor conosion. Te analyze coupons, remove 1 coupon fom each endo the rack and prepare for Weighing and mass loss determination, Insure enough coupons are exposes in the test 20 monitoring frequency can be accomplished. Addtional unexposed coupons can be adkied throughout te test ‘obtain interval data in adciton to cumuiative date. h. Before weighing, clean the coupons using a mild “sand blast" (preferably glass beads) to remove all ‘corrosion by-products from the coupon surface. An altemativeequivalent cleaning method, using a chemical process, is desctibed in ASTM G1. Once clean, wipe the coupons with methanol and weigh todeiermine the coupon mass loss using Equation 1 Mass Loss = (Initial Mass) - (Ens-ot Exposure Mass) a.) Data Reporting Coupons—Coupon mass loss values ate to be recorded afr each set of a predetermined number of cycles (ypicaly, every 20 cycles). This willbe a cumulative value, Adsitonel unexpased coupons can be instaled and removed after the next set of cycles te obtain mtaval coupon data desired Test Samples—The test sarnplos will have sore creepback values oF corrosion rate measurements recorded at predetermined intervals (typically, 20 cycles — in a rinsed only condition). At end-ottest two sets of ‘reepback valves will be recorded (if costed samples are to bo evaluated) ane sat In a rinses only condition ‘and one set after the scrape and tape process (Reference 1989 SAE Aulomotive Corrosion and Prevention Conference P228, pages 144-5, see 2.1.4 (4)), ‘As a guideline, serie creepback measurements of average, faximmum, and minimum (total width) wil be recorded. By Denon: ‘Total Width Greeaback—A measurement of the distance between the unatiectec paint fim areas, in ‘ilimetors, on each side of the scribed line (measured across and perpendicular to the scribe line) (Loss of adhesion betwoon paint film and substrate). '. Ayerago—The mean of a set of measurements of Total Width Creepoack, at points spaced equidistant apart centered on the scribed ine. 8. Maximum—A measurement of the Total Wicth Creepback st the point with the most extensive ‘adhesion loss, discounting the areas atthe ends of the seriaed line. . Migimum—A measurement of the Total Width Creepback at the point with the least extensive adhesion 195, discounting the areas a the ends of the served fine.SAE 2984 Issued JUNOB 6.3 Test Equipment—Test equipment used shal be documented and Include the following information: |f multiple cabinets are used to conduct the test, tne folowing information must be recorded for each cabinet ‘Cabinet Manufacturer/Mode! Huriity Temperature Humiitcation Process De-humidiication Procass Hering Process Cooing Process: Alc Circulation Process Size Capacity Calibration Process Frequency of Caliration im. Ramp Time Betwoen Stages 2.1 SOLUTION INFORMATION: ‘Frequency of Salt Solution Changes (recommend weekly or sooner if contamination is a suspected concern} b. Method of Salt Application pH Measurement Method 1a recorder isin use, cycle profiles should be eubmitted with test sample data. i a recorder is net in use, writen documentation should be provided indicating typical steaay:state conditions and the ramp times botwaen steady-state conditions PREPARED BY THE SAE AUTOMOTIVE CORROSION AND PREVENTION COMMITTEEvu ‘SAE 12334 lesued JUNOB e Rationale—Not applicable. Rotatlonehip of SAE Standard to ISO Standard—Not applicable, Application—The SAE 2334 jab test procedure should be used when determining cosmetic corrosion porlormance for a particular coating system, substrate, process, or design. Since It i¢ afield correlated test, itcan be used as a validation 1001 as wail ag a development tool. If corrosion mechenisms other than cosmetic or general corrosion are to be examined using ths test, fold correlation must be established, Reference Section ‘SAE J1563—Guidelinos for Laboratory Cyclic Corrosion Test Procedures for Painted Automotive Parts ASTM D 1199—-Specification for Reagent Water [ASTM D 1654—Method for Evaluation of Painted or Coated Specimens Subjected 10 Corrosive Environments ASTM D 1735—Precice for Tasting Watar Resistance of Coatings Using Water Fog Apparatus ASTM 0:2247—Practice for Testing Water Resitance of Coetings in 100% Relatve Humiity ASTM E 70-90—Test Method for pH of Aqueous Solutions withthe Glass Electroce ASTM.G {—Recommendes Precice fot Prepanng, Clearing, ané Evaluating Corrosion Test Specimens ‘om as4oP “Townsend, H. E., "Development of an Improved Laboratory Corrosion Tast by he Automotive and Stee! Industries.” in Advanced Goatngs Technology. Proceasings of the fourth Annual ESD Advanced Goatings Canferanaa, The Engineering Society, Ann Arbor, Ml, 1984, pp, 29+ ro} Roudebush, LA., Townsend, HE, and MeCune, D.C., “Updete on the Development of an Improved ‘Cosmatic Cerrasion Test by he Automotive and Stool Industries,” Automotive Corrosion and Prevention Conlerenca Proceecings, P-268, Society of Automotive Engineers ‘Warrendale, PA. 1988, pp. 53-63. Townsend, H.E., “Accelerated Corrosion Testing: A Cooperate Etfor by the Automotive and Stee! industries, * Procaesings of the Symposium on_Canosion-esisiant Automotive Shest ‘Stools, ASM Materials Congress, ASM international, Metals Park, OM, 1988, pp. 55.87, Townsend, H.E, “Sialus of a Cooperative Effon by the Automotive and Steel industries o Develop a ‘Standard Accelerated Corrosion Test” Automalive Corrosion and Prevention Contarence Prrceedings, P.228, Society of Automotive Engineers, Warendale, PA, 1989, pp. 133-145. Townsend. HE, Granata, R.D., MeCuns, D.C., Schumacher, W.A., and Nevile, RJ. "Progress by the ‘Automotive and Sige! Indusirs Towerd an Improved Laboratory Cosmetic Corrosion Tesi,” Automotive Corrosion and Prevention Conference Proceedings. P-260. Society of Automotive Engineers, Warrendale, PA, 1991, pp. 73-57,634 $3 Test Equipment—Test equipment used shall be documented and include the folowing Iforvaton SAE 42334 leeued JUNE {{mutine cabinets are used to conduct the tes, tho folowing information must be recorded for each cabinet Cabinet Manuiacturer’Mode} Humiaiy ‘Temperature Humidiication Process De-humidiication Process Heating Process Cooling Procoss Alr Circulation Process Seo Capacity Calforaton Process Frequency of Calibration amp Time Between Stages BRU rzeneaogp SOLUTION INFORMATION: = Froauency of Salt Solution Changes (recommend weekly or sooner if contamination is a suspected concern) Method of Selt Application © pH Measurement Method Wa foonrder isin use, cycle proties should be submmitied with test sample date. i a racorder Ie net in uso, trier cocumentation should be provided indicating typical staacy-ste conditions and tne rams thong between steady-state condtions, PREPARED BY THE SAE AUTOMOTIVE CORROSION AND PREVENTION COMMITTEE‘SAE 42334 Issued JUNSB Stephens, M.L., “SAE ACAP Division 3 Project: Evaluation of Corresion Test Methods,” Automotive ‘Gorrasion_and Prevention Conference Proceedinas, P-228, Society of Automotive Engineers, Warrendale, PA, 1989, pp. 167-164. Lutze, FW. and Shatler, RJ. “Accelerated Atmospheric Corrosion Testing of AIS! Panels," Automoitve ‘Corrosion and Prevention Conference Proceedings, P-250, Society of Automotive Engineers, Warrendale, PA, 1991, pp. 116-127, Petechel, M., “Statistical Evaluation of Accelerated Corrosion Tests and Correlation with Two-Year On: Vehicle Tess." Automotive Corrasion and Prevention Conference Proceedings, P-260, Society of Aulomotive Engineers, Warrendale, PA, 1991, pp. 178-208. Davidson, B.D. and Schumacher, W.A., "An Evelvation and Analysis of Commoniy Used Accelerated Cosmetic Corosion Tests Using Direct Comparison with Actual Field Exposure,” Automotive Corrosion and Prevention Conference Proceedings. P25). Socisty of ‘Automotive Engineers, Warrendale, PA, 1991, pp. 205-218. ‘Ostermiler, M.A, and Townsend, HE. “On-Vehicte Cosmetic Gorrosion Testing of Coated and Cokt- Rolled Stee! Sheet.” Autometive Corrosion and Prevention Conference Proceedince, P- £288. Society of Automotive Engineers, Warrendale, PA, 1993, pp. 65-83, Granata, R.D. and Moussav-Madani, M. “Characterization of Corrosion Products and Corrosion Mechanisms on Automotive Coated Sieels Subjected to Fleld and Laboratory Excosure “Tests,” Leign University Report to the ASP Corrosion Task Force, January 10, 1996. ASTM E 601-92, “Standard Practice for Conducting an Intr'aboratory Study to Determine the Precision fof a Tost Methos,” Annual Sook of Standards, American Society for Testing and Materials, West Conshohocken, PA ASTM E 177-908, “Standard Practco jor Use of the Terms Precision and Bias in ASTM Test Metnod,” ‘Annual Book of Standards, American Society for Testing and Materials, Wes ‘Conshohocken, PA, Townsend, HE and McCune .C., “Round-Robin Evaluation of a New Standard Laboratory Test for ‘Cosmetic Corrosion” Automotive Cartosion and Prevention Conference Proceedings. ‘S8-1285, Society of Automotive Engineers, Warrendale, PA, 1997, pp. 53-68, Devoloped by the SAE Automative Corrosion end Prevention Committee