5.2 Verification Method Listing

5.
2 Verification Method Listing

ID: DVM-0089-MA
Ver: 4
Copy: 0
COMPONENT CORROSION TEST - SIMULATED ARIZONA PROVING GROUND
Owner:
CLC-MATL
Verification Method Status:
RELEASED
Method Type:
Subjective Evaluation
Prototype Type:
COMPONENT/ASSEMBLY
CETP No. :
Facility Type:
Test Procedures:
FLTM BI 123-03
Associated Requirement(s):
ID
MA-0045
Version
9
Copy Title
0
RESISTANCE TO CORROSION - INTERIOR
Associated DVO(s):
18966
DVM Comments:
This test method is a laboratory test which is used to predict part performance in
CETP 00.00-R-311.
procedure simulates the corrosive conditions of the APG Vehicle Accelerated
Corrosion Test (CETP 00.00R-311) conducted on vehicles at the Ford Arizona Proving Grounds (APG) and
produces coating failure
modes that are the same as those observed on the interior and exterior areas of
vehicles tested at APG.
Corrosion testing of 0.81 mm thick cold-rolled steel, with only one side painted,
produces metal perforations
within 45 to 55 cycles, i.e., approximately 70 days.
Operating Conditions:
Application
This test procedure is used to evaluate the corrosion performance of coatings applied to components. It is
designed to simulate the corrosive conditions of the Arizona Proving Ground (APG) Vehicle Accelerated
Corrosion Test (CETP 00.00-R-311).
Apparatus Required
Automatic Method:
Humidity Cabinet
Thermotron Industries
291Hollen Park Drive
Holland, MI USA 49423
(616) 392-1491
Automated Cyclic Corrosion Test Chamber, model ACT-30-CHM-1, or equivalent, with forced air
circulation, temperature control of +/- 2 degrees C to 65 degrees C and relative humidity control of +/- 2% up to 90%.
Manual Method:
Humidity Cabinet
Thermotron Industries
291Hollen Park Drive
Holland, MI USA 49423
(616) 392-1491
Model No. SE-600, or equivalent with forced air circulation, temperature control of +/- 2 degrees C to 65 degrees C andrelative
humidity control of +/- 2% up to 90%.
Materials Required
Tank
Polyethylene or plastic-lined tank, with cover, of sufficient size and capacity to permit the test samples
to be sprayed with the salt solution. For 100 x 300 mm test panels a 42 L Nalgene polyethylene tank
(VWR Catalog No. 60463 - 040) is adequate.
Uncontrolled Copy
FORD/ STEERING WHEEL ASSEMBLY
Version 9 As Of 18-DEC-06
System Design Specification (SDS)
RELEASED
The information contained in this System Design Specification (SDS) is Confidential to Ford Motor Company
Page
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5.2 Verification Method Listing

Brush
Camel hair brush, flat style (VWR Catalog No. 17215-067, or equivalent).
Towels
Paper or cloth.
Sodium Chloride
Reagent grade.
Hydrochloric Acid
Reagent grade.
Sodium Hydroxide
Reagent grade.
Distilled or Deionized Water
10-ppm max dissolved solids per ASTM D 1888.
Kaolin
Powder, N.F. grade.
Stop-off Lacquer
Microshield Stop-off Lacquer, or equivalent.
Source: Pyramid Plastic
Tolber Division
P.O. Box 704
Hope, Arkansas 71802-0704
Telephone: (501) 777-3251 or 5759
Procedure
Automatic Cabinet Test Procedure:
After sample preparation place the samples in the temperature/humidity cabinet and run per the test
requirements outlined in the following procedure.
Automatic Cabinet Procedure
Interval Initial test conditions Final test conditions Time
1. 23 degrees C and 50% RH Initial salt spraying of samples 1 minute to wet parts
2. 23 degrees C and 50% RH 23 degrees C and 50% RH, no spraying 3 minutes, loop to interval
1, three times total
3. 23 degrees C and 50% RH 23 degrees C and 50% RH, final salt spray 1 minute
4. 23 degrees C and 50% RH 23 degrees C and 50% RH 2 minutes
5. 23 degrees C and 50% RH 23 degrees C and 50% RH 1 hour and 15 minute
drying phase
7. 50 degrees C and 85% RH 50 degrees C and 85% RH 22 hours
Repeat this 24-hour cycle for the number of total cycles required by the specification.
Alternate Procedure
Manual Cabinet Test Procedure:
Prepare a 5% salt solution for manual spray as follows:
Dissolve 53 g of sodium chloride per liter of distilled or deionized water. Sufficient test solution should
be prepared to allow samples to be completely immersed.
Adjust the solution pH to 6.0 - 8.0 by the addition of hydrochloric acid or sodium hydroxide.
Replace salt solution and clean out tank when appreciable rust accumulates in the bath and deposits on
the samples, or when the pH is outside of the 6.0 - 8.0 range (do not readjust the pH).
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After sample preparation run the samples per the test requirements outlined in the following procedure.
Manual Cabinet Procedure
Interval Initial test conditions Final test conditions Time
1. Manual Sample Dip (Salt Solution) @ 23 degrees C, 15 minutes to wet parts.
2. Drain & Dry @ 23 degrees C* Drain & Dry @ 23 degrees C* 1.2 - 1.3 hours.
3. Place in Cabinet @50 degrees C & 85 -90% RH.
. Remove from Cabinet @ 50 degrees C & 85-90% RH, 22.4 - 22.6 hours.
Repeat this 24-hour cycle for the number of total cycles required by the specification.
*Note: Wipe the bottom edge of the samples with a towel to remove excess salt, which accumulates
during the drain-and-dry period. Use care not to remove the kaolin from the remainder of the
panel. Repeat intervals 1 through 3 every 24 hours, Monday through Friday. During
weekends and holidays leave the specimens in the humidity cabinet (which continues to
operate).
Note: One test cycle is completed after performing intervals 1 through 3.
Evaluation
1. Visually examine for blisters, rust and other evidence of deterioration of the coating system at the
intervals indicated in the Laboratory Test Request by the requesting Engineering Activity.
If the percentage red rust is required, the test samples shall be rated in accordance with the rating scale
in ASTM D610.
Note: To facilitate inspection, the kaolin coating may be removed by gently wiping the sample surface
with a soft towel under running tap water.
Note: During prolonged holiday periods (over 4 days), the testing should be interrupted and the specimens
removed from the humidity cabinet.
Chemicals, materials, parts, and equipment referenced in this document must be used and handled properly.
Each party is responsible for determining proper use and handling in its facilities.
Sample Preparation:
All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 degrees C and 50 +/- 5%
relative humidity for not less than 24 h prior to testing and tested under the same conditions unless
otherwise specified.
In order to simulate dust contamination, load a camel hair brush with a small amount of dry kaolin powder and
lightly brush it on the painted surfaces to obtain a uniform, thin, dry coating. (Remove kaolin from any masked
areas) The application of kaolin shall occur only once (prior to testing).
(Optional) In instances of extended testing or for paint-coating systems that do not resist corrosive attack at the
edges, it may be necessary to mask the edges and holes of the sample parts and the holes, edges and backs of
panels with an air-dry stop-off lacquer. The requesting Engineering Activity shall denote such masking on the
Laboratory Test Request. Allow drying for twenty-four hours.
Design-Specific Information:
The components should be positioned as close to vehicle orientation as possible.
Production representative surrogate test plaques may be used if part geometry does not allow a flat sample plaque to be cut from the part.
Prior approval must be obtained from the appropriate materials engineering department before using surrogate test plaques.
Steering wheel testing must be conducted on samples taken from parts.
Conditioning and Test Conditions
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All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 0C
and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions
unless otherwise specified.
Data Generated (Units):
* AATCC rating number
Accuracy:
Maximum Uncertainty:
* ASTM D610 Corrosion Rating
Accuracy: +/- 0.5%
* Visual Evaluation
Accuracy: +/- 0.5
* Visual observation
Accuracy:
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5.2 Verification Method Listing

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5.

2 Verification Method Listing

COMPONENT CORROSION TEST - SIMULATED ARIZONA PROVING GROUND

Verification Method Status:

RESISTANCE TO CORROSION - INTERIOR