1. CORROSION TESTING –
EVALUATION OF LIFE SPAN
OF AUTOMOTIVE COMPONENTS
Magdalena Walczak, Dr.-Ing.
Department of Mechanical and Metallurgical Engineering
Email: mwalczak@ing.puc.cl
Tel. +56-2-354-4627
CONTENT
1. INTRODUCTION – CORROSION TESTING: WHAT’S THE DEAL?
2. THEORY – PREDICTION OF DEATH BY CORROSION
3. CASE STUDY – TESTING OF AUTOMOTIVE COMPONENTS
presented at
VII ENCUENTRO DE GESTIÓN DE ACTIVOS FÍSICOS
Santiago de Chile, 27th Nov 2009
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

2. (1/3) INTRODUCTION
Wroclaw University of Technology
Wroclaw, Poland
MPI Iron Reseach MPI Coal Reseach
Düsseldorf, Germany Mülheim an de Ruhr, Germany
ThyssenKrupp, DOC GmbH
Dortmund, Germany
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

3. (1/3) INTRODUCTION
FROM MAINTENANCE TO CORROSION
THE IRON PILAR OF DELHI
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

4. (1/3) INTRODUCTION
HISTORICAL STUDY OF CORROSION COST
Corrosion 62 2006 (Biezma)
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

5. (1/3) INTRODUCTION
CORROSION COST AND WHAT TO DO ABOUT IT STRATEGIES FOR
DEALING
DISTRIBUTION OF CORROSION COST WITH CORROSION
(USA, average for 1996–1999)
P.R. Roberge, 2007
CORRECTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
CORROSION CONTROL
CORROSION PROTECTION
www.dr-maiko.com fot. M.Walczak fot. A. Pino
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

6. (1/3) INTRODUCTION
CATEGORIES OF CORROSION PROTECTION AFTER GERMAN ASSOCIATION FOR CATHODIC PROTECTION
CORROSION PROTECTION
PRECAUTION IN THE ELECTROCHEMICAL
PREVENTION SURFACE PROTECTION CORROSIVE MEDIUM PROTECTION
SURFACE COATING CORROSION CATHODIC
MATERIAL SELECTION INHIBITORS PROTECTION
(COATING)
SUITABLE DESIGN ELIMINATION OF CATHODIC AND
STIMULANTS ANODIC PROTECTION
SUITABLE PACKAGE (VOLTAGE)
AND STORAGE ELIMINATION OF
STRAY CURRENTS
NON-METALLIC METALLIC
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

7. (1/3) INTRODUCTION
AUTOMOTIVE COATING FOR CORROSION PROTECTION
CLEAR COAT
UV-protection
Typical coating thickness 200 µm
BASE COAT
visual effects
FILLER COAT
protection aganist
www.honda.com stone-chippinng
ED-PAINT
corrosion protection and leveling
ZINC corrosion protection
TYPICAL AUTOMOTIVE CORROSION GUARANTEE
COSMETIC CORROSION: 5Y PERFORATION CORROSION: 10 Y
CONVERSION COATING
corrosion protection
adhesion
IF-STEEL
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

8. (1/3) INTRODUCTION
THE PROBLEM OF CORROSION TESTING
www.autobild.de
for. M.Walczak
LOCALIZED CORROSION, E.G. CREVICE
DESIRED TEST RESULT GENERAL CORROSION, E.G. ATMOSPHERIC
s min h d m y
DESIRED LIFESPAN*
*corrosion life of a component
CATASTROPHIC CORROSION, E.G. SCC
www.corrosionclinic.com
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

9. (2/3) THEORY
THE PHENOMENON OF CORROSION
MATERIAL
DAMAGE MODEL OF AN AUTOMOTIVE COATING
-
ENVIRONMENT + - + + +
-
+
-
+ - + +-
2 4 3 1
+ +
-
- - -
+ + + + +
- - -
-
+ + + + - +
- - -
+ + + + +
O2
PAINT OH -
Zn 2+ Cl -
OH -
OH - O2 Fe 2+
ZINC e- Zn
STEEL e-
INTACT DE-
WHITE RUST RED RUST
INTERFACE LAMINATION
ANODIC: Me → Me + ne-
CATHODIC: Ox + ne- → R
for each reaction:   αzFη   (1 − α )zFη 
j = ja − jc = A exp  −  − exp 
(Butler-Volmer eq.)   RT   RT 
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

10. (2/3) THEORY
THE PHENOMENON OF CORROSION
MATERIAL
DAMAGE MODEL OF AN AUTOMOTIVE COATING
-
ENVIRONMENT + - + + +
-
+
-
+ - + +-
2 4 3 1
+ +
-
- - -
+ + + + +
- - -
-
+ + + + - +
- - -
+ + + + +
O2
PAINT OH -
Zn 2+ Cl -
OH -
solvent, gas, another material OH - O2 Fe 2+
ZINC e- Zn
pH, temperature, aggressive ions
STEEL e-
flow conditions, second phase
INTACT DE-
mechanical stress WHITE RUST RED RUST
INTERFACE LAMINATION
microorganisms
spatial variation of above ANODIC: Me → Me + ne-
CATHODIC: Ox + ne- → R
temporal variation of above
for each reaction:   αzFη   (1 − α )zFη 
j = ja − jc = A exp  −  − exp 
(Butler-Volmer eq.)   RT   RT 
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

11. (2/3) THEORY
THE DOUBLE APPROACH TO TESTING
LOCALIZED CORROSION, E.G. CREVICE
DESIRED TEST RESULT GENERAL CORROSION, E.G. ATMOSPHERIC
s min h d m y
DESIRED LIFESPAN*
*corrosion life of a component
CATASTROPHIC CORROSION, E.G. SCC
THE CASE OF AUTOMOTIVE COMPONENTS
TYPES OF CORROSION TESTS IN R&D AND QUALITY CONTROL
ELECTROCHEMICAL TECHNOLOGICAL ACCELERATED LONG-TIME
Kelvin probe stone-chipping salt spray field tests
polarization diagrams adhesion alternate clima
impedance spectroscopy scratch resistance
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

12. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
POLARIZATION CURVES OPEN CIRCUIT POTENTIAL
MEASUREMENT OF CORROSION CURRENT* TEMPORAL STABILITY OF CORROSION CURRENT*
*CORROSION CURRENT: icorr = ianodic = −icathodic
ANODIC: Me → Me + ne-
CATHODIC: Ox + ne- → R
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

13. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
SCANNING KELVIN PROBE
THE PRINCIPLE Uext
Iac
Vibration
along z-axis
Ref
∆Ψsample
Re f
passive surface
passivated defect
ELECTROLYTE
active corrosion
METAL in the defect
CORRELATION BETWEEN ∆Ψ AND THE CORROSION POTENTIAL
ECorr = ∆ Ψsample + const. = f ( x, y, t )
Re f
Courtesy Prof. G.Grudnmeier
Courtesy Prof. G.Grudnmeier
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

14. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
THE PRINCIPLE OF ACCELERATED CORROSION TESTING
MATERIAL
-
ENVIRONMENT
+ + - + ++
- -
+- + - + + - +
- -
ESTIMATION OF THE
-
+ + + + +
ACCELERATION FACTOR
- - -
-
+ + - + + +
- - -
+ + + + +
STRESSORS
solvent, gas, another material
pH, temperature, aggressive ions
flow conditions, second phase
mechanical stress
microorganisms
spatial variation of above
temporal variation of above Uhlig´s Corrosion Handbook
Courtesy Prof. G.Grudnmeier
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

15. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
EXAMPLE ACCELERATED TESTS (CYCLIC TESTING)
EXAMPLE TEST 1 EXAMPLE TEST 2 EXAMPLE TEST 3
24 Hours 24 Stunden 4 Stunden
Salt spray test Salt spray test Salt spray test
DIN 50021-SS DIN 50021-SS DIN 50021-SS
4 Cycles 4 Cycles 4 Stunden
Alternate condensed water Alternate condensed water Indoor climate
DIN EN ISO 6270-2 AHT DIN EN ISO 6270-2 CH DIN 50014
48 Hours 48 Hours 16 Hours
Indoor climate Indoor climate Alternate condenced water
DIN 50014 DIN 50014 DIN EN ISO 6270-2 AHT
1 CYCLE = 1 DAY,
1 CYCLE = 1 WEEK 1 CYCLE = 1 WEEK PRODECURE: 5 CYCLES AT ONCE AND
THEN 2 DAYS RESTING PHASE
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

16. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
CABINETS FOR ACCELERATED CORROSION TEST
LIEBISCH TEST CHAMBER
DOC, Dortmunder OberflächenCentrum GmbH
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

17. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
CABINETS FOR ACCELERATED CORROSION TEST
EXAMPLE SERIES OF 3 COATINGS IN A SALT SPRAY CYCLIC TEST, GLASS FLANGE ( 1 WEEK = 1 CYCLE)
COATING 3
DOC, Dortmunder OberflächenCentrum GmbH
COATING 2
COATING 1
WEEK 1 WEEK 2 WEEK 3 WEEK 4 WEEK 5
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

18. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
CABINETS FOR ACCELERATED CORROSION TEST
WALK-IN CORROSION CHAMBER WITH FOR COMPONENTS AND MODULES
DOC, Dortmunder OberflächenCentrum GmbH
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

19. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
OUTDOOR WEATHERING ACCORDING TO VDA 621-414
EXPOSURE WITH 5% INCLINATION TO THE HORIZONTAL LINE, ONCE A WEEK SPRAYING WITH 3% NACL SOLUTION
WEATHERING WITH AND WITHOUG SALT WITHOUT LIGHT PROTECTION WEATHERING WITH AND WITHOUT SALT WITH LIGHT AND RAIN PROTECTION
DOC, Dortmunder OberflächenCentrum GmbH DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

20. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
THE MANY REQUIREMENTS FOR COATED STEEL
ANTI-GRAFITTI
DECORATIVE LOOK
ANTI-BACTERIAL
ADHESION
CORROSION
PROTECTION PROCESS-
ABILITY
EASY TO CLEAN
SURFACE TEXTURE
ENVIRONMENTAL FRIENDLINESS
SCRATCH RESISTANCE
SOUND ABSORPTION
BRILLIANCE OF THE TO COAT
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

21. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF PAINT ADHESION AND DELAMINATION
CROSS CUT TESTS
AUTOMATIC SCORING AND CROSS CUT EQUIPMENT MANUAL SCORING
DOC, Dortmunder OberflächenCentrum GmbH DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

22. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF PAINT ADHESION AND DELAMINATION
CROSS CUT TESTS
TEST SAMPLE 1 TEST SAMPLE 2 TEST SAMPLE 3
25 Squares with score distance depending 100 Squares with score 64 Aquares with cut distance of 3
on the coatings thickness distance of 1 mm mm and additional diagonal scores
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

23. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF PAINT ADHESION AND DELAMINATION
CONICAL MANDREL TEST SINGLE IMPACT TEST
CROSSOD.312, ESTS
M CUT T ACCORDING TO DIN EN ISO 6860 MOD. 490, ACCORDING TO DIN 55996-2
Mandrel ø 3,2 mm – 38,1 mm Radius of curvature 1 mm
DOC, Dortmunder OberflächenCentrum GmbH DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

24. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF PAINT ADHESION AND DELAMINATION
STONE-CHIPPING TEST AFTER
DIN 55996-1
PROCEDURE A
bombardment 2 x 500 g / 1 bar / 10 s
PROCEDURE B
bombardment 2 x 500 g / 2 bar / 10 s
PROCEDURE C
• bombardment 1 x 500 g / 2 bar / 10 s
• corrosion exposure
• bombardment 1 x 500 g / 2 bar / 10 s
SHOT ABRASIVE
chilled cast granules of 4 – 5 mm
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

25. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF PAINT ADHESION AND DELAMINATION
STONE-CHIPPING TEST AFTER
COATING 1 COTAING 2
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

26. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
TEST OF WET STORAGE
THERMOSTATICALLY CONTROLLED VESSEL
STORAGE IN 5% NACL-SOLUTION:
40 °C / 40 H (ACCORDING TO BMW)
55 °C / 240 H (ACCORDING TO HONDA)
STORAGE IN LAGERUNG IN DS-WATER:
63 °C / 72 H (ACCORDING TO OPEL)
40 °C / 500 H (ACCORDING TO TOYOTA)
32 °C / 240 H (ACCORDING TO FORD)
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

27. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
ELECTROCHEMICAL ACCELERATED LONG-TIME TECHNOLOGICAL
THE DIFFERENT SAMPLE GEOMETRIES
DOC, Dortmunder OberflächenCentrum GmbH
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

28. (3/3) CASE STUDY
CORROSION TESTING OF AUTOMOTIVE COMPONENTS
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos

29. CORROSION TESTING – EVALUATION OF LIFE SPAN
OF AUTOMOTIVE COMPONENTS
Magdalena Walczak, Dr.-Ing.
Department of Mechanical and Metallurgical Engineering
Email: mwalczak@ing.puc.cl
Tel. +56-2-354-4627
SUMMARY CLEAR COAT
UV-protection
1. COMPLEXITY OF CORROSION HINDERS THE FORMULATION OF DETERMINISTIC MODELS
Typical coating thickness 200 µm
BASE COAT
visual effects
2. DOUBLE APPROACH IN ESTIMATION OF LIFESPAN: EXTRAPOLATION + ACCELERATION
FILLER COAT
protection aganist
3. MATERIALS FOR AUTOMOTIVE COMPONENTS ARE ACCEPTED PRELIMINARY BUT
stone-chippinng
VALIDATION IN A LONG TERM TEST IS TYPICALLY REQUIRED IN ADDITION
ED-PAINTprotection and leveling
corrosion
4. DEVELOPMENT OF NEW MATERIALS/COATINGS WITH MULTIPLE REQUIREMENTS
ZINC corrosion protection
5. REFERENCE SAMPLES ARE INDISPENSABLE
CONVERSION COATING
corrosion protection
IF-STEEL
PUC, Escuela de Ingeniería UC - Ingeniería Mecánica y Metalúrgica 27 Nov 2009
Magdalena Walczak, Dr.-Ing. VII Encuentro de Gestión de Activos Físicos