In the first of a series of articles covering some of the industry sectors for whom corrosion testing is a vital part of product development and ongoing quality control, we look at the importance of corrosion testing in the Automotive Industry.

This sector covers a wide range of companies, from major household names that are a familiar sight on the worlds roads, to the many “behind the scenes” manufacturers, providing vital components throughout the supply chain.

When it comes to environmental factors, the automotive industry must consider a huge array of adverse conditions, from extremes of temperatures and humidity levels to the effects of road salt and atmospheric/rainfall pollution.

Corrosion testing is crucial in the automotive industry for several reasons:

Safety: Corrosion can weaken critical components of a vehicle, such as the frame, brakes, and fuel lines, potentially leading to dangerous failures

Durability: By testing for corrosion, manufacturers can ensure that parts and materials will withstand harsh environmental conditions, extending the lifespan of the vehicle

Cost Efficiency: Identifying and addressing corrosion issues early can prevent costly repairs and replacements down the line

Performance: Corrosion can affect the performance of various vehicle systems. Ensuring components are resistant to corrosion helps maintain optimal performance

Compliance: Many regions have strict regulations regarding vehicle safety and environmental impact. Corrosion testing helps manufacturers meet these standards

Overall, corrosion testing helps maintain the reliability, safety, and longevity of automotive components, which is essential for both manufacturers and consumers.

Automotive corrosion testing has a long history.  From the earliest days, Salt Spray Testing was used, for example ASTMB117  which has been in use for over 80 years.   Over the decades, increasing globalisation opened up many export markets for automotive manufacturers, and it became more important than ever to ensure that vehicles were able to withstand corrosion in all conditions, not just those of the home market.

This was a major driver behind the development of Cyclic Corrosion Testing, with automotive companies, especially Japanese manufacturers, beginning to develop cyclic tests that were more accurately able to simulate real world conditions.

Cyclic Corrosion Testing combines salt spray testing with other environmental conditions such as controlled humidity, drying and wetting. These are repeated in sequences of varying length and duration, creating a “cycle”

Some tests also extend these climates by requiring additional parameters, such as sub-zero refrigeration, rapid temperature changes and liquid immersion.

There are now numerous cyclic corrosion test standards, of ever-increasing complexity. Here at Ascott, we have responded with solutions to meet these requirements and beyond.

Contact us to find out how we can help you to incorporate these protocols into your testing and develop safer, more reliable and cost-effective products.