Salt Spray Testing Services

Salt Fog Test

Purpose of Salt Spray Testing
Salt Spray Testing is often used for:- Quality control during production
- Benchmarking and comparison of coatings
- Evaluating coating integrity after physical damage (e.g., scratches)
- Research and development of new surface treatments
It is important to note that while Salt Spray Testing is extremely useful for comparing performance and identifying defects or weak spots, it does not directly predict the exact service life of a material in a real-world environment. Actual environmental exposure conditions may vary greatly, involving factors like UV light, temperature fluctuations, air pollutants, and mechanical wear, which are not always simulated in salt fog tests.
Purpose of Corrosion Testing & Standard Test Protocol
Purpose of Corrosion Testing
Samples to be tested are placed inside the salt spray chamber, usually at a 15° to 30° angle from vertical. The salt solution is atomized using pressurized, purified air, creating a dense fog of salty droplets that settle on the samples’ surfaces. Exposure durations can range from a few hours to over 1000 hours, depending on the requirements of the test or the specification being followed. In some cases, artificial defects, such as cross-hatch cuts or scratches, are deliberately introduced into the coating to test how well the material resists corrosion at vulnerable points. As corrosion progresses, dendritic patterns or “corrosion creepage” can form along the scratch lines. The length of these dendrites is often measured as a quantitative indication of the coating’s ability to prevent corrosion from spreading.Standard Test Protocol – ASTM B117
The most widely accepted procedure for conducting Salt Spray Testing is defined by the ASTM B117 standard. Developed by ASTM International, this standard outlines how to create and maintain a corrosive environment using pressurized air to atomize a 5% sodium chloride (NaCl) solution, producing a consistent and fine salt mist inside a closed chamber.Key Parameters of ASTM B117:Temperature Range: Typically maintained between 35°C and 50°C, with the standard condition being 35°C.Humidity Level: Approximately 95% Relative Humidity (RH) is maintained in the chamber.Salt Solution: A 5% NaCl solution with a pH between 6.5 and 7.2.Spray Rate: Typically 1 to 2 ml of salt solution per 80 cm² per hour.These tightly controlled conditions ensure repeatability and reliability across laboratories and testing facilities worldwide.Results Evaluation Criteria
Results are evaluated based on:— Appearance of rust, blistering, or coating delamination— Time taken for corrosion to appear— Corrosion coverage or penetration— Length of corrosion creep from damaged areasVisual inspection is commonly used, often in accordance with ISO 10289 or ASTM D610 for rating corrosion and rust grades. Some organizations also apply more advanced methods such as microscopic examination, weight loss measurements, or electrochemical analysis to supplement visual assessments.


