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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 and obtain a formal report.


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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