The standard “VW PV 1210 Body and attachment parts/suspension parts - Corrosion testing” developed by the Volkswagen automobile company describes a corrosion test method for sample and production tests performed on fully painted bodies, body panels, assemblies and components with different anti-corrosion coatings. This method is used to examine and evaluate the corrosion properties or corrosion protection measures of these parts when subjected to static load.
In principle, this test is a cyclically alternating combination of different climatic or corrosive loads. A test cycle includes:
It is strictly forbidden to change the test program. After every 5 cycles, a 50554-day rest phase takes place in an environment of 23 degrees Celsius and 50 percent relative humidity (standard atmosphere) according to the VW 2 standard. A test consisting of 15 cycles lasts a total of 3 weeks.
This test method is used to evaluate corrosion properties under static load from salt, moisture and temperature.
Corrosion leakage in a scribe line can be examined to assess the adhesion of coatings. The scribe should penetrate the metallic substrate and be loaded in a vertical position (according to ISO 17872). The scribe line should be assessed for loss of adhesion and corrosion according to ISO 4628-8.
Under these defined corrosion conditions, different anticorrosive coatings can be comparatively evaluated. A correlation with the corrosion mechanism in real driving operation is not necessarily possible, because the types of damage and corrosion curves occurring in the vehicle are complex and are not fully covered and reflected by the static corrosion load.
It is permissible to interrupt the test for a short time to examine and remove samples. In certain cases, 5-day rest periods may be skipped after every 2 cycles. In this case, a test consisting of 15 cycles will take 15 days. However, such a shortening of the test period is permissible only if it can be demonstrated that the test result will not be affected. This must be recorded.
Assemblies, components and test sheets can also be tested in suitable constant or alternating atmosphere chambers. These chambers must comply with the specifications of ISO 6270-2, ISO 9227 and VW 50554 standards.
A minimum of 5 pieces are required for full component testing. Gaps must be made accessible to salt spray by separation, opening or changing the installed position. Unprotected trim edges must be sealed prior to testing.
After 5, 15, 30, 60 and 90 cycles, samples are evaluated for:
Organic coatings can be assessed according to the table entitled “Rating scheme for determining the quantity of defects” in the standard “ISO 4628-1 Paints and varnishes - Assessment of deterioration of coatings - Determination of the quantity and size of defects and the intensity of uniform changes in appearance - Part 1: General identification and description system”.
The scribe line is evaluated for corrosion and loss of adhesion according to “ISO 4628-8 Part 8: Evaluation of the degree of delamination and corrosion around a scribe or other artificial defect” and for filiform corrosion according to “ISO 4628-10 Part 10: Evaluation of the degree of filiform corrosion”.
Signs of corrosion leakage in painted panels can be examined using a non-destructive thermographic method for quantitative assessment of the development and propagation of defects.
The test is completed when the degree of corrosion Ri 4628 or corrosion holes are formed according to the standard “ISO 3-3 Paints and varnishes - Assessment of the quantity and size of defects and the intensity of uniform changes in appearance - Part 5: Assessment of the degree of rusting”.
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