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Methods of Compound Corrosion Test: Nissan Engineering Standard
Methods of Compound Corrosion Test: Nissan Engineering Standard
Methods of Compound Corrosion Test: Nissan Engineering Standard
1. SCOPE
This Standard specifies the method to measure compound corrosion that uses the combined processes of salt
spraying or salt solution immersion followed by drying and moistening. The process will simulate and accelerate
corrosion of metal materials used on automobiles. Therefore this test will measure corrosion of metals of functional
decorative parts together with the coating effect of inorganic or organic plating of vehicle models.
2. SAMPLES
2.3.1 Cleaning
Depending on the degree of dirt, samples shall be first immersed in an appropriate solvent such as ethyl alcohol
or acetone, and then the solvent shall be wiped off with a soft cloth. No corrosive solvents or substance that
coats the test sample materials, or substance that destroys protective coatings shall be used.
(1) Samples shall not touch any other parts other than the supporting frame.
(2) Samples shall not interfere with each other.
(3) Marks and holes for sample identification shall be made as close to the lower edge as possible.
To protect the holes on sample pieces for suspension, Item 2.3.3 above shall apply.
Furthermore, the tests including salt solution spraying (Methods I and IV) shall satisfy the following conditions:
(1) When testing the plate sample specified in Item 4.2 of NES M 0007, the plate shall be placed so that the main
face inclines 15° from the vertical line, and the plate shall be placed in the testing chamber so that it is not
orthogonal to the spray direction when the testing chamber is viewed from above. However, when using the
plate and products other than those specified above, the angle of the main surface with respect to vertical line
shall be as per consultation with the persons concerned.
(2) There shall be no interference with the free fall of the spray.
(3) Solutions collected on one sample shall not drip on other samples.
(4) As a rule, different materials shall not be tested in the same testing chamber at the same time. (However, it may
be conducted as a reference to make comparisons.)
The tests involving salt solution immersion (Method V) shall satisfy the following conditions:
(1) The samples main face shall be placed vertically.
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M0158 [2009-N]
2.3.5 Post-treatment of test samples
After completion of the test, the sample shall be taken out without damaging the exposed surface,
then washed quickly to remove any salt from the surface, and immediately dried at ambient
temperature without removing corrosion. In order to observe surface corrosion, rust shall be removed
by sand blasting or rust removing agent listed in the JIS Z 2371 attachment.
3. TESTING EQUIPMENT
As a rule, the testing equipment shall have the ability to generate and automatically repeat 3 different
processes, i.e. salt solution spraying or immersion, drying and moistening. Depending on the agreement
of parties involved, the test may be performed simultaneously using multiple pieces of testing equipment.
In addition to the above conditions, the testing equipment shall satisfy the following:
(1) Materials used for the equipment shall not corrode under the testing conditions.
(2) The compressed air of the equipment shall not be contaminated with oil and/or dust.
The test involving salt spraying shall satisfy the following conditions:
(1) The spraying nozzle of the test solution shall be set so that the spray does not directly hit the test
sample. Condensed liquid on the ceiling or cover of the testing chamber shall not drip onto the test
sample.
(2) Testing solution used on test samples shall not be returned to the tank and reused.
Examples of equipment are shown in Attachment Figures 1 and 2.
4. TESTING CONDITIONS
Table 1 Compound corrosion test conditions
Name of
Processes in one cycle Cycle conditions
test method
Note: Instant setting ··········· The time it takes for 1 cycle is fixed, and the time count is started even if the atmosphere has not reached
the stipulated condition.
Conditioned setting ··· The cycle does not proceed to the next step until the atmosphere reaches the required conditions.
Consequently, the time taken for 1 cycle is different depending on the apparatus etc.
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M0158 [2009-N]
Table 2 Applications of each testing method
Application Examples
Corrosion resistance in general (surface rust and penetrated rust): Vehicle body panel, road wheel,
CCT-I
under-floor piping, drive shaft, propeller shaft, fastening parts (bolts and nuts) etc.
CCT-IV External panel scab rust: External panel, external topcoat
CCT-V Internally accelerated penetration of rust: Internal panel, box structure parts
15 cm interval
4.2 Salt water spraying condition
Salt water spraying condition and control method are in
compliance with NES M 0140. The control method of
spraying volume that is especially important is excerpted.
As indicated in Figure 1, using any collecting container
within 15 cm interval inside a test chamber, the amount Sampling
of test solution accumulated in the collecting container is container
inspected after the continuous operation for 24 hours or 15 cm interval
more. The amount shall be within the range of specified
2
value (1.5±0.5 mℓ/8.0 cm /h). Do not perform any tests Figure 1 Salt water sampling positions
for the portions that cannot be contained in the range of inside a test chamber
the specified value. If the range that can be within the specified value is small, (1) adjust position and
angle of a nozzle, (2) adjust spraying pressure, and (3) adjust spraying rate by replacing a nozzle, etc.
4.3 Regarding rotation of the test piece during the test (Methods I and IV) containing salt water
spraying
The environmental variations (variations in salt spraying rate, temperature and humidity) within the
tolerance of the specified value for a test condition are due to the difference in installation position for
test piece. Therefore, as a measure for reducing such variations, the rotation of test piece is required.
However, regarding the rotation method and its frequency, they shall be determined through the
consultation between the concerned parties, after considering the required accuracy for the test.
<Case 1> For the test period of 2 weeks or more
Move the test piece any number of times (recommended to perform in the frequency of once per week or more) during
the test period, by an installed unit or by a unit of installed row. For example, if there are 4 installed units, number them
1 to 4 beforehand, and perform the moving of the installed units in the order of: 1→2→3→4→1→ on a weekly basis.
<Case 2> For the test period of 2 weeks or less
Since the number of rotations will be smaller, perform the test within the range of the median value 1.5±0.1 mℓ/8.0
2 2
cm /h (specified value: 1.5±0.5 mℓ/8.0 cm /h) for the spraying rate specified in 16. Spraying rate of the Attachment
Table 1.
<Case 3> For securing the accuracy by long-term test
For the purpose of improving the test accuracy, the following describes the examples of the procedure for complete
randomization of the rotation order:
(1) Number nonnegative integers 1 to n for each test piece number n.
(2) Generate random numbers of nonnegative integers 1 to n for the n installation positions for test pieces.
(3) Install test pieces to each position, according to the numbers that are identical with the installation position numbers
for test pieces.
(4) Perform the rotation of the test piece by repeating (2) and (3) described above any number of times (recommended
to perform in the frequency of once per week or more) during the test period.
0.16
Fluctuation coefficient for the decrease in plate thickness
0.14
0.12
(Standard deviation/mean)
0.1
0.08
0.06
0.04
0.02
0
0 2 4 6 8 10 12
(None) (On a weekly (Once every (On a daily
basis) 3 days) basis)
Number of rotations
2
Figure 1 Rotation effects of SP600 (Standard zinc marking volume at 120 g/m , no chromates)
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M0158 [2009-N]
4.4 Conditions for salt solution immersion
2+
The salt solution for immersion test shall be replaced with fresh solution when the Fe concentration
2+
reaches more than 15 ppm. The Fe concentration shall be determined by methods such as atomic
absorption or inductive coupled plasma spectrometry.
5. EVALUATION OF RESULTS
The test results shall be evaluated according to relevant material or product standards, or otherwise, the
agreement between the parties concerned shall apply.
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M0158 [2009-N]
The results obtained from this investigation to determine the ratios were for drying (66.3%), moistening
(3.3%) and salt spraying (7%), respectively. Because rust streaks appeared with slow acceleration rate
at low humidity, the humidity for the moistening step was chosen to be 95% RH. It was discovered that
the ratio of spray solution is only 0.7% for the whole cycle, and so the solution is sprayed once a day,
considering the accuracy for the spraying volume.
B) Reproducibility in the market (exposure in Okinawa) and acceleration method of CCT-IV method
Figure 4 shows the highly positive correlation between CCT-IV Method and outdoor exposure in
Okinawa using steel panel plated in different ways. Figure 5 compares the acceleration rate of each
test showing CCT-IV Method has an acceleration rate 3 times higher than the current CCT-II Method.
(Reference)
Cycle condition for CCT-II method is described as follows:
Salt spraying (35°C, 2h) → Drying (60°C, 2h) → Moistening (50°C,
95% RH, 4h)
Figure 4 Correlation between CCT-IV Figure 5 Comparison of acceleration rate
Method and exposure in Okinawa for each test method
Okinawa
Corrosion resistance
CCT-V CCT-III
in salt solution
0.89 0.20 0.60
(Reference)
(note) W2: Durasteel - 1 Cycle condition for CCT-III method is described as follows:
SZ: Durasteel - 2
ZM: Steel sheet and strip
Salt immersion (40°C, 7.5 min) → Moistening (40°C, 95% RH, 15
coated with zincrich min) → Drying (60°C, 7.5 min)
primer for automobiles
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M0158 [2009-N]
Attachment Figure 1 Compound corrosion test apparatus (CCT-I, II, IV)
Vent
Nebulizer
Mixing fan
Temperature
recorder Dry air supply
Cycle
controller
Control panel
Spray
collection vessel
Testing chamber
Sample piece
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M0158 [2009-N]
Attachment Figure 2 Compound corrosion test equipment (for salt solution immersion test) (CCT-V)
(19)
(17)
(15)
(8)
(16)
(14)
(18)
(10) (9)
(13) (12)
(11)
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M0158 [2009-N]
ANNEX
Revision objectives
The evaluation frequency of compound corrosion test in which corrosion of vehicle is reproduced and promoted on
the bench is getting higher. Because this test method was not standardized in the past, there were differences, etc
in test procedures and discrepancies in the test results between parts suppliers and material suppliers.
In addition, conditions which are impossible due to the capability of the tester were specified in conventional test
method.
Accordingly, the test method which has broad utility and is appropriate to the actual condition has been newly
established this time.
Points
(1) Clarification of test conditions
- The transition time to the ambient temperature in each chamber and the teaching method for the tester have
been specified.
- As a rule, the tester obtained from Materials Engineering Department at NTC shall be used as test conditions.
Temperature and humidity charts in the chamber and standard plate thickness reduction at that time are
scheduled to be presented as calibration sample for each tester in the future.
(2) Elimination of Method CCT-II
Though it was developed to evaluate outer body panel coating, it has been eliminated because scab rust on
outer body panel is currently evaluated using Method CCT-IV.
(3) Elimination of Method CCT-III
In the past, it was used for evaluation of parts which are exposed under wet conditions (bottom of the door,
hemmed inner surface, etc.). Recently, Method CCT-I or IV has better reproducibility. Also, it has been
eliminated because time in which the conditions are achieved is very short during 1 cycle of 30 min.
The following descriptions of procedures related to the test accuracy have been changed and corrected to meet the
actual condition.
2. Descriptions of "4.2 Salt water spraying condition" and "4.3 Regarding rotation of the test piece during the test
(Methods I and IV) containing salt water spraying": Descriptions of the amount of salt water to be sprayed have been
corrected.
As corrosion test results vary greatly depending on the test conditions such as the amount of salt water to be sprayed,
the corrosion tester has been strictly maintained. However, it has been found that the amount of salt water to be sprayed
may not be able to be met in a partial area of the tester due to age deterioration, etc. This time, a stricter control method
of the amount of salt water to be sprayed in the test chamber has been adopted to reduce variations of test results, and
descriptions regarding the rotation of the test piece during the test which is required to be highly accurate have been
added.
3. Addition of explanation in figure (Addition of reference descriptions regarding conditions of Methods CCT-II and III)
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M0158 [2009-N]
[Revised contents of fiscal 1996]
Because overseas operations reported that humidity was less than 20% under dry conditions during the test using a local
tester, a study has been made as to whether or not adoption should be made. As a result, the humidity conditions have
been revised because humidity of 35% or less has no effects on corrosion under dry conditions. Similarly, it has been
confirmed that there are testers in which humidity is less than 20% also in Japan.
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