Salt mist spray testing
The salt mist spray test, also known as the salt fog test, is a standardized method used to evaluate the corrosion resistance of materials, products, and coatings.
The test is conducted in a controlled environment where materials are exposed to a salt mist (a fine spray of salt solution) to simulate corrosive conditions.
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Variations of salt mist spray tests
- Description: The most used and standardized test. It utilizes a neutral salt solution (pH 6.5-7.2) to simulate corrosive conditions.
- Application: Suitable for general corrosion testing of coatings, metals, and treated surfaces.
Standards:
ISO 9227, ASTM B117, IEC 60068-2-11, IEC 60068-2-52
- Description: A variation of the salt mist spray test where acetic acid is added to the salt solution, resulting in a lower pH (pH 3.1-3.3). This accelerates the corrosion process.
- Application: Commonly used to test coatings such as anodized or organic coatings on aluminum.
Standards:
ISO 9227
- Description: A more aggressive variation where copper (II)-chloride is added to the acetic acid solution. This causes rapid corrosion (pH 3.1-3.3).
- Application: Widely used in the automotive and aerospace industries to test highly corrosion-resistant materials.
Standards:
ISO 9227, ASTM G85
- Description: Combines salt mist exposure with dry and wet cycles to simulate more realistic environmental conditions.
- Application: Used for advanced corrosion testing in sectors such as marine, offshore, and automotive industries.
Standards:
ASTM G85, SAE J2334
- Description: A specific cyclic test combining salt mist with dry cycles and a more diluted salt solution. It is less corrosive than NSS but simulates more realistic exposure.
- Application: Suitable for products subjected to prolonged mild corrosion.
Standards:
ASTM G85 (Annex A5)
- Description: Uses real seawater or a synthesized version of seawater as the salt solution. This replicates marine conditions.
- Application: Applied to materials for offshore or shipbuilding applications.
Standards:
No standard international norm but often customized.
- Description: Materials are exposed to salt mist combined with vibrations, shocks, or other mechanical stresses.
- Application: Used for environments with heavy mechanical and corrosive stress, such as automotive or industrial machinery.
- Description: Test conditions are tailored to specific client requirements, such as:
- Variable salt concentrations.
- Combined high temperatures and salt mist.
- Extended testing durations.
- Application: Designed for niche products or extreme environments where standard testing does not suffice.
Standards
Evaluates the resistance of materials and components to corrosion caused by salt mist.
A method for assessing the corrosion resistance of a product or material under a salt mist environment.
This standard enables more advanced corrosion testing, including cyclic exposure and the use of additional chemicals. It is used in situations where simple salt mist tests, such as ASTM B117, are insufficiently realistic.
A military test method designed to evaluate the corrosion resistance of materials and equipment in environments influenced by salt mist and sea air.
A German standard specifically used within the automotive industry for conducting salt mist tests. This methodology, developed by the Verband der Automobilindustrie (VDA), is often applied to evaluate the corrosion resistance of metals, coatings, and other materials used in vehicles.
Corrosion tests in artificial atmospheres - Salt spray tests. This standard is globally recognized and applicable to a wide range of industries, including automotive, aerospace, construction, and maritime.
Assesses the corrosion resistance of materials, coatings, and products by exposing them to a controlled salt mist environment. It is an accelerated test designed to provide a quick indication of how well a material can withstand corrosion in real-world conditions.
Simulates the daily exposure of vehicles to natural weather conditions, such as rain, salty air, temperature fluctuations, and dryness. This test predicts the lifespan and corrosion resistance of materials and coatings under real-use conditions.
Testing more realistic scenarios
Sebert Group may combine the salt spray test with other environmental and mechanical tests, such as vibration or thermal cycling. This gives a more complete picture of how a product behaves under combined loads. It provides insight into the durability and suitability of your product for specific applications, allowing you to guarantee its quality and longevity.
Specifications of the salt mist spray test and test chambers
The machine used for salt mist spray testing is a specialized salt mist chamber (also referred to as a corrosion chamber or salt spray chamber). This equipment is designed to create and maintain a standardized salt mist in a controlled environment, allowing materials or products to be subjected to prolonged corrosive conditions.
Specifications of the salt mist spray test:
- Salt concentration: 5% salt solution, composed of 99.5% pure NaCl mixed with demineralized water.
- Temperature: Standard set at 35°C (±2°C), with a range of 5°C to 55°C.
- Test chamber dimensions:
- Small test chamber: 450 x 600 x 400 mm
- Large test chamber: 980 x 990 x 550 mm
5 reasons to perform a salt mist spray test
- The test simulates a corrosive environment often caused by salty air or water, such as in coastal areas or during exposure to winter conditions (e.g., road salt).
- It evaluates how well a material, coating, or product resists corrosion and oxidation.
- The salt mist spray test is commonly used to verify whether a material meets durability and reliability standards.
- This is essential for industries such as automotive, aerospace, maritime, and construction, where corrosion protection is critical.
- The test helps manufacturers and engineers choose the most suitable anti-corrosion treatments, such as galvanization, powder coating, or anodizing.
- It also provides insights into the performance of various coatings under similar conditions.
- The test replicates conditions that would normally take years to develop in a natural environment, accelerating the process of product development and validation.
- It is especially valuable for applications where products are exposed to harsh conditions, such as offshore installations or industrial environments.
- The Sebert Group combines salt mist spray testing with other environmental and mechanical tests, such as vibration or thermal cycling. This provides a more comprehensive understanding of how a product performs under combined stresses.
- Combined testing ensures products are exposed to realistic scenarios, such as vibrations in a corrosive environment (e.g., a vehicle operating in a high-salt environment).
- By conducting these tests, The Sebert Group offers valuable insights into the durability and suitability of your product for specific applications, ensuring quality and longevity.
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