Corrosion Test Results for Heavy duty Anti-Corrosion Coatings: Salt Fog Exposure, Cyclic Weathering, and Adhesion Tests

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Corrosion Tests

Salt Fog Exposure, Cyclic Weathering, and Adhesion Tests

Our coated steel panels have successfully gone through 13,000 hours of Salt Fog Exposure (ASTM B 117) tests, and our coated aluminum panels have gone through over 10,000 hours. 5,000 hour is the maximum testing hours according to ASTM standards. We've stopped the tests since we saw no hope of destroying the coatings and the results were impressive enough and we could save some funding by stopping the tests.

Tensile adhesion (pull-off strength) was measured in accordance with ASTM D 4541 following 1,100 Hours of Cyclic Weathering and 8,372 hours of salt fog exposure test. Adhesion by Tape test (ASTM D 3359) was performed after 8,372 hours of salt fog exposure.

All our tests and result data used below are provided by KTA of Pttsburgh Pennsylvania, a wellknown American Association for Laboratory Accreditation (A2LA) approved Independent testing lab with over 60 years of experiences.

View The Full KTA Lab Report
The testing panels are Q-Panel Standard substrates.

Steel panels are type S (CRS SAE1008/1010;0.032" thick,ground finish)

Aluminum panels are type A (Alloy 3003H14;0.025" thick; bare mill finish)

Results

Blistering and rusting are rated on a scale of 0 to 10. A "10" indicates no blistering or rusting or less than 0.01% of rust observed. After meticulously scratched off the black corrosion product, the undercutting appearing to be even narrower than the reported results displaying on this page.

Below are salt fog test (ASTM B 117) results over 5,000 hours.

ID	Hours	Metal	Blistering	Rusting	Undercutting	Continuation Status
P1	13,740	Steel	10*	10-	2-7	Stopped
P2	13,740	Steel	10	10-	1-9	Stopped
P3	12,740	Steel	10	10-	1-5	Stopped
P4	12,740	Steel	10	10-	3-6	Stopped
P5	8,372	Steel	10	10-	2 (Avg.)	Scratched and Contined+
P5	12,740	Steel	10	10-	1-4	Stopped
P6	8,372	Steel	10	10-	3 (Avg.)	Scratched and Contined+
P6	12,740	Steel	10	10-	1-4	Stoped
P7**	8,372	Steel	10	10-	3 (Avg.)	Stopped
P8**	8,372	Steel	10*	10-	3 (Avg.)	Stopped***
P9	10,740	Al	10	10-	0	Stopped

* One No.2 size blister.
- Some discoloration and staining present.
+Those panels were put back into salt fog chamber for continue testing after scratched off the surface corrosion product
** Photograph of these panels are showing below
*** Adhesion test results available on this page

Below are photographs for salt fog test (ASTM B 117) results over 8,372 hours.

P7 after 8,372 hours Salt Fog Exposure (coated CRS panel) P8 Adhesion Test after 8,372 hours Salt Fog Exposure.

Pull-Off Test: (the three circles)
Tape Adhesion Test (the three cross marks)

Adhesion by Tape Test (ASTM D 3359) results after 8,372 hours of salt fog test, rated on a scale of 0 to 5 with 5 being the best:

ID	Replicate1	Replicate2	Replicate3	Avg. Adhesion
P8	5A	5A	5A	5A

Adhesion test for pull-off strength (ASTM D 4541) results after 8,372 hours of salt fog test (Good Painting Practices (by SSPC) says 200 psi or better is considered good adhesion.):

ID	Pull Stub	Pull-Off Strength (psi)	Location of Break	Average Pull-Off Strength (psi)
P8	A	386.8	30% adhesion to substrate, 20% cohesive failure of corrosion present on substrate, 70% cohesion within gray layer	557.5
	B	569.9	5% adhesion to substrate, 70% cohesion within gray layer, 25% cohesion within white layer
	C	733.7	10% Glue Failure, 5% adhesion to substrate, 50% cohesion within white layer, 45% cohesion within gray layer

Adhesion test for pull-off strength (ASTM D 4541) results after 1,100 hours of cyclic weathering test:

ID

Pull Stub

Pull-Off Strength (psi)

Location of Break

Average Pull-Off Strength (psi)

1

A

611

100% cohesive failure within primer

652

B

734

80% cohesive failure within primer, 20% glue failure

C

611

100% cohesive failure within primer

2

A

673

80% cohesive failure within primer, 20% glue failure

812

B

1009

100% cohesive failure within primer

C

754

30% cohesive failure within primer, 70% glue failure

3

A

815

70% cohesive failure within primer, 30% glue failure

849

B

877

90% cohesive failure within primer, 10% glue failure

C

856

100% cohesive failure within primer

Cyclic Weathering and More Salt Spray Exposure data:

Test Name Hours
Metal
Blistering Rusting Undercutting

Salt Spray Exposure 5,000
Steel

10

10

<1 mm

Salt Spray Exposure 3,000
Aluminum

10

10

<1-1mm

Salt Spray Exposure 4,500
Aluminum

10

10

0 mm

Cyclic Weathering 5,000
Steel

10

10

4 mm

Cyclic Weathering 3,000
Aluminum

10

10

0-1 mm

Cyclic Weathering 6,500
Aluminum

10

10

0-<1 mm

Photographs

Below are pictures of sample panels taken after the tests. Click images to see enlarged views.

Salt Fog Exposure & Cyclic Weathering

Salt Fog Exposure on coated cold roll steel (CRS) panel after 5,000 hours exposure. The incision line area was scraped before picture taking.

Salt Fog Exposure on coated cold roll steel (CRS) panel after 1,000 hours exposure. Scraped afterward. The incision line area was scraped before picture taking.

Salt Fog Exposure on coated cold roll steel (CRS) panel after 2,000 hours exposure. The incision line area was scraped before picture taking.

Salt Fog Exposure on coated cold roll steel (CRS) panel after 2,000 hours exposure, before being scraped .

Salt Fog Exposure on coated aluminum panel after 3,000 hours exposure. The brown sparkles are rust splashed from steel panels.

Cyclic Weathering on coated aluminum panel after 3,000 hours exposure. The brown sparkles are rust splashed from steel panels.

Salt Fog Exposure on coated aluminum panel after 4,500 hours exposure. The brown sparkles are rust splashed from steel panels.

Cyclic Weathering on coated aluminum panel after 6,500 hours exposure. The brown sparkles are rust splashed from steel panels.

Adhesion Tests

1) ASTM D 4541: 652 psi average after 1,100 hrs of cyclic weathering test

2) ASTM D 4541: 812 psi average after 1,100 hrs of cyclic weathering test

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