A global automotive parts supplier, specialising in brake components and chassis hardware, needed a reliable method to evaluate corrosion resistance. Their products were exposed to extreme conditions, including road salt, humidity, and temperature fluctuations. Ensuring long-term durability was essential for both safety and compliance with industry standards.
Challenge
The company faced significant limitations with their existing corrosion testing setup. Traditional salt fog chambers, which relied on continuous exposure to a saline mist, failed to replicate the fluctuating environmental conditions that automotive components experience in real-world applications. As a result, the data collected from these tests did not always correlate with actual performance in service.
Without cyclic corrosion testing, the company struggled to assess material degradation accurately. Extended validation timelines further complicated product development, delaying market entry and increasing costs. Additionally, the company had to comply with strict international standards, including ASTM B117, ISO 9227, and SAE J2334, all of which required rigorous corrosion resistance testing. A more advanced solution was needed to enhance testing accuracy, reduce validation time, and improve overall product reliability.
Solution
To address these challenges, the company integrated the Q-Fog SSP/CCT Corrosion Testing Chamber into their quality assurance and research facilities. The Q-Fog SSP/CCT was chosen for its ability to simulate real-world environmental exposure through programmable cycles of salt spray, humidity, drying, and condensation. Unlike static salt fog tests, this system enabled engineers to recreate the dynamic conditions that vehicles encounter over their lifespan, leading to more reliable and actionable test data.
Customised test protocols were developed to assess how various coatings and materials responded to different environments. Engineers designed test sequences that simulated the effects of coastal exposure, winter road conditions with de-icing salts, and high-humidity tropical climates. These tests provided a comprehensive evaluation of how different protective coatings performed under varying stress conditions.
The chamber’s automated operation significantly improved efficiency by minimising manual intervention. Test sequences were programmed and run with minimal supervision, allowing the company to allocate resources more effectively. The ability to adjust environmental conditions dynamically within a single test cycle further enhanced testing accuracy and reduced overall testing time.
Results and Impact
By shifting to cyclic corrosion testing with the Q-Fog SSP/CCT, the company achieved a 40% reduction in product validation time, enabling faster approvals and quicker market entry. Engineers gained critical insights into material behaviour, leading to the development of enhanced corrosion-resistant coatings and more durable components.
The company successfully met international corrosion resistance standards, including ASTM, ISO, and SAE requirements, strengthening its position in global markets. Additionally, early-stage corrosion detection helped identify potential weaknesses in materials before large-scale production, preventing costly product failures and reducing warranty claims.
With improved testing accuracy, engineers were able to refine their designs to enhance product lifespan and performance. The ability to simulate real-world conditions led to more reliable data, ultimately improving vehicle safety and longevity. The transition from static salt spray tests to cyclic corrosion testing resulted in better correlation between laboratory results and real-world performance, giving the company a competitive advantage in the automotive sector.
Conclusion
The adoption of the Q-Fog SSP/CCT Corrosion Testing Chamber transformed the company’s approach to quality assurance and product validation. By simulating real-world environmental conditions with greater accuracy, the company significantly improved testing efficiency, reduced validation time, and enhanced product performance. This advanced testing methodology not only ensured regulatory compliance but also helped the company develop more durable, corrosion-resistant automotive components capable of withstanding the harshest conditions.
Contact us today to learn how the Q-Fog SSP/CCT can help you optimise your testing process and deliver more resilient products to the market.
