Author: Helen Morley

The importance of Corrosion Testing in The Defence Sector

In our fourth sector article, we look at the military & defence sector, which covers a vast array of products from aircraft components (like airframes, avionics, and connectors), naval vessels, weapons systems, vehicles (tanks, trucks), and marine/defence/naval electronic equipment, as corrosion can significantly impact their functionality and lifespan in harsh environments, leading to rigorous testing to ensure proper corrosion protection measures are in place.

Corrosion can significantly impact military equipment in several ways:

1. Structural Integrity: Corrosion weakens the metal components of vehicles, ships and aircraft leading to potential structural failures. This can compromise safety and reliability, especially in combat situations
2. Operational Readiness: Corrosion can cause critical systems to malfunction, reducing the operational readiness of military equipment. This can delay missions and reduce the effectiveness of military operations
3. Maintenance Costs: The cost of repairing and replacing corroded parts can be substantial. Regular maintenance to address corrosion issues is necessary, but it also adds to the overall lifecycle cost of the equipment
4. Performance Degradation: Corrosion can affect the performance of military equipment by causing issues such as increased friction, reduced efficiency, and potential breakdowns
5. Aesthetic and Camouflage: Corrosion can degrade the appearance of military equipment, affecting the camouflage and making them more visible to adversaries

Salt is one of the most pervasive chemical compounds in the world. It is found in the oceans and seas, the atmosphere, ground surfaces, and lakes and rivers. It is impossible to avoid exposure to salt. The worst effects occur, in general, in coastal regions

Corrosion testing has long been used in this sector to meet the challenges of production and development of equipment and materials.

The most common standard for testing products which fall under the military/defence category is MIL-STD-810H The standard covers 28 different test methods, this article focuses on Test Method 509.7 Salt Fog, which is performed to determine the effectiveness of protective coatings and finishes on materials, to identify any potential problem areas, quality control deficiencies, design flaws, etc., in a relatively short time.

Typical problem areas include, but are not limited to:

Corrosion Effects.

1. Corrosion due to electrochemical reaction.
2. Accelerated stress corrosion.
3. Formation of acidic/alkaline solutions following salt ionization in water.

Electrical Effects.

1. Impairment of electrical materiel due to salt deposits.
2. Production of conductive coatings.
3. Corrosion of insulating materials and metals.

Physical Effects.

1. Clogging or binding of moving parts of mechanical components and assemblies.
2. Blistering of paint as a result of electrolysis.

To determine the effects of the above, test specimens are placed in an enclosed chamber and exposed to the following test profile:

Step 1. With the samples in the chamber, adjust the test chamber temperature to 35 °C and condition the test item for at least two hours before introducing the salt fog.

Step 2. Expose the samples to a 24 hour period of 5% salt spray at a rate of 0.5 to 3.0ml/80cm²/hour, in a chamber temperature of +35C , the pH of salt spray should be between 6.5 -7.2.

Step 3. Dry the test item at standard ambient temperatures and a relative humidity of less than 50 percent for 24 hours, generally accepted ambient conditions are laboratory environment 23C /50%RH

Step 4. Repeat steps 1 to 3 at least once.

The above can be modified as experience has shown that alternating 24-hour periods of salt fog exposure and drying conditions for a minimum of four 24-hour periods (two wet and two dry), provides more realistic exposure and a higher damage potential than does continuous exposure to a salt atmosphere

To perform the above test fully automatic in a single chamber with ambient climate control to 23C/50%RH , will require an Ascott Cyclic Corrosion chamber complete with external midi temperature and humidity climate control unit.

Other popular standards in this sector include:

• MIL-STD-202
• RTCA-DO-160
• MIL-STD-750
• MIL-STD-883
• Plus many others

With current advances in technologies across all aspects of the defence sector and supporting industries, the need for testing keeps on growing.  Many breakthroughs in product development will be adopted by civilian industries over time, a process made easier by the rigorous testing demanded by this sector

Overall, corrosion is a significant challenge for maintaining the effectiveness, safety, and longevity of military equipment. In a situation where all equipment must be in constant readiness for possible deployment in any conditions globally, corrosion can cause major problems – addressing corrosion through regular testing, maintenance, and the use of advanced materials and coatings is essential for ensuring that military equipment remains operational and reliable.

Corrosion testing in the paint and surface coatings industry

In the third of this series of articles we take a look at the importance of corrosion testing for manufacturers of paints and other surface coatings

Corrosion testing is crucial for paint and surface coatings manufacturers to ensure their products provide effective and long-lasting protection.

Any substrate that is exposed especially out of doors will be subject to corrosive wear over time. In addition to natural weathering, abrasion and impact can accelerate this process.  Using a reliable and effective coating can dramatically reduce and slow this damage.

This is true for everyday paints and finishes that we might use in our own homes, right through to highly specialised coatings for industrial applications in extreme conditions.  So, from the humble tin of paint to refresh your gate to the specialised coating developed for an ocean pipeline, the principles are the same – to provide protection from the elements and longevity of coating.

Below are just some of the reasons why corrosion testing is so important to the paint and surface coatings industry

Durability and Performance: Corrosion testing helps assess the durability and performance of paints and coatings under various environmental conditions. This ensures that the products can protect surfaces from rust and degradation over time.

Quality Control: Regular testing ensures that paint formulations meet industry standards and performance expectations, leading to consistent product quality

Regulatory Compliance: Paint manufacturers must comply with various international standards, such as ISO 9227 and ASTM standards, which specify methods for corrosion testing

Material Selection: Testing helps in selecting the best materials and formulations for specific applications, whether for architectural, automotive, or industrial use

Innovation and Development: Continuous testing drives innovation, allowing manufacturers to develop new, more effective corrosion-resistant coatings

ASTMB117 is one of the most widely used Salt Spray Tests – Ascott Chambers are used around the world to deliver reliable and repeatable Salt Spray Testing.

For full compliance with ASTM B117, we also supply CorroSalt – highest purity salt that meets the following requirements:

Total Impurities; < 0.3%

Halides (Bromide, Fluoride & Iodide) excluding Chloride; <0.1%

Copper; <0.3ppm

Anti-caking agents; None

All CorroSalt is supplied with Certificate of Analysis and Certificate of Conformity.

In addition to providing world leading corrosion chambers, we also have a huge range of test equipment available at our online shop www.ascottshop.com   This includes wet and dry film measuring devices, coating performance equipment, film applicators and much more.

Offering a one stop shop for paint test equipment, we are continually adding to our range, so if there is something that you are looking for that you don’t find on our website, please contact us and we will do our best to help.

Paint and coatings manufacturers around the world have relied on Ascott to deliver reliable, accurate and repeatable results for many years. We are proud to partner with the leading names in this industry.

Contact us to find out more about our range of corrosion testing equipment to meet all needs.

New F-GAS Regulation

CO2 Refrigeration from Ascott

There is a new EU Regulation 2024/573, in force from 01.01.2025 which details requirements for new equipment in the category of “self-contained refrigeration systems”, where the refrigerant contained must have a GWP (Global Warming Potential) limit of >150.

Ascott has been working closely with the R&D team from weisstechnik Germany, and are extremely proud to be the first Corrosion chamber manufacturer, to come to market with CO2 cooling technology inside our refrigeration units.

The CO2 cooling technology that we use has a GWP of 1, which is a huge reduction in GWP to the gas used previously-  R449A (GWP1397) which was contained within the units.

The new innovative technology is immediately available for all cooling units from Ascott:

·         ACC112 with ambient control

·         ACC29 sub-zero deep freezing to -20°C

·         ACC29 sub-zero deep freezing to -40°C

·         All Ascott Atmosfar chambers

The new Ascott cooling units offer improved performance and efficiency. The energy consumption is heavily reduced, and this also results in quieter operation of the units

❄️CO2 cooling ensures precision in a controlled laboratory environment, where repeatable and reliable testing is critical ❄️

What are the benefits of CO2 Refrigeration?

· Improved control:

Achieve reliable cooling down to -40°C, unlike traditional R449A systems our new units utilise superior technology to enhance control

·         -:

We no longer have a requirement for a cascade system to achieve  -40°C, nor do we need 2 refrigerants to achieve this, now we use a single stage with CO2 only inside

·         Reduced Maintenance

No mandatory leakage tests, streamlining your operations.

·       Quiet and Efficient

Our CO2 cooling systems run quietly and consume less energy.

·        Sustainable and Future Proof

Advanced Green technology with a minimal Global Warming Potential (GWP), our CO2 solutions comply with the latest environmental regulations, whilst also remaining in compliance with international test standards.

For further information please contact Ascott by email: info@ascott-analytical.com or call us on +44 (0) 1827 3184040 to speak to one of our specialists in Corrosion.

The importance of corrosion testing in the aerospace industry

We are proud to supply corrosion testing equipment to a huge number of companies in the aerospace sector, covering everything from commercial air traffic to defence and space exploration.

Corrosion testing is vital in the aerospace industry for several reasons:

1. Harsh Environmental Conditions: Aerospace components are exposed to extreme conditions, including high altitudes, varying temperatures, humidity, and exposure to saltwater during take-off and landing.
2. Safety and Reliability: Corrosion can compromise the structural integrity of aircraft, leading to potential failures.
3. Cost Efficiency: Detecting corrosion early can prevent costly repairs and replacements.
4. Regulatory Compliance: The aerospace industry is heavily regulated, and corrosion testing is often required to meet stringent safety and performance standards.
5. Innovation and Material Development: Corrosion testing drives the development of new materials and coatings that are more resistant to corrosion, enhancing the overall performance and durability of aerospace components

By incorporating rigorous corrosion testing protocols, the aerospace industry can ensure that its materials and components are robust, safe, and reliable, ultimately leading to more efficient and longer-lasting aircraft.

One of the most commonly used test standards within the aerospace industry is  ASTM G85 Annexe 4  as this simulates exfoliation corrosion.  Exfoliation corrosion is a specific type of intergranular corrosion that primarily affects metals, especially aluminium alloys.  This must be closely monitored in aircraft structures, where maintaining the integrity of materials is critical for safety.

The range of samples that are tested by the aerospace industry can range from the smallest rivets to entire sections of aircraft.  Larger components such as aircraft seating and engine parts that are too large for standard chambers can be accommodated in our CorroFlex chambers, these are available in a wide range of sizes and are the perfect solution for larger samples where a walk in room would have redundant space.

As the industry is increasingly looking at alternative fuels and composite materials to minimise the environmental impact of air transport, this means even greater investment in research and testing.

The rise in popularity and use of unmanned aircraft and drones presents another growing area of the market, with future plans for widespread delivery services via drones in many countries the most obvious example.  The possibilities for drone use in search and rescue operations are currently being explored and we expect to see some major innovations in this field over the coming years.

Ascot Chambers are used by aerospace manufacturers around the world to ensure reliable, repeatable testing.

Contact us for further information and quotations.

In the first of a series of articles covering some of the industry sectors for whom corrosion testing is a vital part of product development and ongoing quality control, we look at the importance of corrosion testing in the Automotive Industry.

This sector covers a wide range of companies, from major household names that are a familiar sight on the worlds roads, to the many “behind the scenes” manufacturers, providing vital components throughout the supply chain.

When it comes to environmental factors, the automotive industry must consider a huge array of adverse conditions, from extremes of temperatures and humidity levels to the effects of road salt and atmospheric/rainfall pollution.

Corrosion testing is crucial in the automotive industry for several reasons:

Safety: Corrosion can weaken critical components of a vehicle, such as the frame, brakes, and fuel lines, potentially leading to dangerous failures

Durability: By testing for corrosion, manufacturers can ensure that parts and materials will withstand harsh environmental conditions, extending the lifespan of the vehicle

Cost Efficiency: Identifying and addressing corrosion issues early can prevent costly repairs and replacements down the line

Performance: Corrosion can affect the performance of various vehicle systems. Ensuring components are resistant to corrosion helps maintain optimal performance

Compliance: Many regions have strict regulations regarding vehicle safety and environmental impact. Corrosion testing helps manufacturers meet these standards

Overall, corrosion testing helps maintain the reliability, safety, and longevity of automotive components, which is essential for both manufacturers and consumers.

Automotive corrosion testing has a long history.  From the earliest days, Salt Spray Testing was used, for example ASTMB117  which has been in use for over 80 years.   Over the decades, increasing globalisation opened up many export markets for automotive manufacturers, and it became more important than ever to ensure that vehicles were able to withstand corrosion in all conditions, not just those of the home market.

This was a major driver behind the development of Cyclic Corrosion Testing, with automotive companies, especially Japanese manufacturers, beginning to develop cyclic tests that were more accurately able to simulate real world conditions.

Cyclic Corrosion Testing combines salt spray testing with other environmental conditions such as controlled humidity, drying and wetting. These are repeated in sequences of varying length and duration, creating a “cycle”

Some tests also extend these climates by requiring additional parameters, such as sub-zero refrigeration, rapid temperature changes and liquid immersion.

There are now numerous cyclic corrosion test standards, of ever-increasing complexity. Here at Ascott, we have responded with solutions to meet these requirements and beyond.

Contact us to find out how we can help you to incorporate these protocols into your testing and develop safer, more reliable and cost-effective products.

Considerations when purchasing a Corrosion Test Chamber

When purchasing a corrosion test chamber, various factors need to be considered to ensure it meets your specific testing requirements. Here are some key considerations:

1. Type of Corrosion Testing

• Salt Spray (Fog) Testing: Simulates harsh marine environments, commonly used for metallic coatings and paints.
• Cyclic Corrosion Testing (CCT): Alternates between salt spray, drying, and humidity conditions to more accurately replicate real-world conditions.
• Humidity Testing: Simulates high-humidity environments, useful for coatings and polymers.
• SO2 Testing (Kesternich): Used for testing corrosion caused by sulfur dioxide.

Ensure the chamber supports the specific tests required for your materials or standards (e.g., ASTM B117, ISO 9227).

2. Size and Capacity

• Chamber Volume: Ensure the chamber is large enough to accommodate your test samples without overcrowding.
• Internal Racks and Shelving: Verify whether the chamber comes with flexible or adjustable shelving to fit various sizes of test pieces.

3. Material and Build Quality

• Corrosion Resistance: The interior of the chamber should be made of corrosion-resistant materials, typically high-quality plastics or coated metals, to prevent degradation.
• Construction: The chamber should be durable, well-sealed, and able to maintain a consistent test environment.

4. Temperature and Humidity Control

• Temperature Range: Check the chamber’s ability to control temperatures, especially if cyclic testing or temperature-specific tests are needed.
• Humidity Control: Look for chambers with precise humidity control, particularly if you’re conducting combined temperature-humidity testing.
• Uniformity: Ensure the chamber provides uniform temperature and humidity levels across all samples to avoid skewed results.

5. Standards Compliance

Ensure the chamber can meet the required test standards for your industry (e.g., ASTM, ISO, IEC, or JIS standards). Compliance with specific standards is critical for reproducibility and meeting regulatory requirements.

Consider not only the test standards that you currently need to perform, but also bear in mind any that you may wish to perform in the future, and if any additional accessories will be needed for this.  Many of our accessories can be added later, whilst some are factory fit only, or require a factory fitted interface to allow the addition of an accessory at a later date

6. Automation and Control Systems

• User Interface: Look for an intuitive, easy-to-use control system for setting up test parameters.
• Programmable Cycles: If you’re performing complex cyclic corrosion tests, the ability to program and automate cycles is essential.
• Data Logging and Connectivity: Some chambers come with integrated data logging, enabling easier monitoring and reporting.

7. Maintenance and Calibration

• Ease of Cleaning: The chamber should be easy to clean and maintain. Salt deposits and other corrosive materials can build up, affecting performance.
• Calibration: Check if the chamber is easy to calibrate and if calibration services or tools are provided by the manufacturer.
• Consumables We supply compliant salt for salt spray testing, CR4 test panels and spares and consumables kits.  These can be purchased online to make life even easier.

8. Safety Features

• Leak Detection: Some chambers come with leak detectors to prevent any external corrosion damage or chemical hazards.
• Over-Temperature Protection: Ensure the chamber has safety mechanisms like over-temperature shutoff to prevent equipment failure or safety risks.

9. Cost and Energy Efficiency

• Initial Purchase Cost: Compare prices but ensure that lower-cost models still meet your test requirements.
• Operating Costs: Consider the power consumption, water usage, and maintenance requirements, which contribute to long-term operating costs.
• Energy Efficiency: Energy-efficient models will reduce operating costs, particularly if the chamber will be used frequently.

10. Customer Support and Warranty

• Manufacturer Reputation: Choose a supplier with a solid reputation for reliable and well-built chambers.
• After-Sales Support: Ensure the availability of spare parts, calibration services, and technical support.
• Warranty: Review the warranty terms and conditions, especially concerning the key components like control systems, heating elements, and seals.

11. Additional Features

• Salt Fog Collection: Some chambers are equipped with features to collect and measure the amount of salt fog during testing.
• Sample Viewing Windows: If observation during testing is required, a clear viewing window with proper lighting is beneficial.

12. External Utilities

Your corrosion chamber will require power supply as well as connections to pressurised de-ionised water, compressed air, drainage and exhaust venting. If these are not available, we can advise on suitable accessories to enable chamber operation.

By considering these factors, you can ensure that the corrosion test chamber you choose meets your needs, performs reliably, and offers a good return on investment.

For further help and advice, please contact us

Celebrating 35 Years of Excellence

2024 is the 35th Anniversary year of Ascott, and whilst we will be marking this special occasion throughout the year, last week saw the main event of our Anniversary celebrations.

Colleagues and their families were joined by suppliers, distributors and other valued contacts for a “Peaky Blinders” themed race and casino night.

We would like to thank everyone who was able to join us on this special night, making it a fun and memorable event for all.

Protect your Investment!

Corrosion chambers benefit from regular servicing by a trained engineer. This maximises reliability, minimises downtime and ensures that your chamber performs as expected.

Your chamber is an important asset.  As a comparison, if you bought a brand new car, you would always ensure that you followed the manufacturers recommendations for approved servicing and spare parts to ensure optimum performance and  to maintain value.

It is therefore very important to ensure that your chamber servicing and calibration is undertaken by an Ascott approved engineer.  Ascott have fully trained and experienced engineers to provide maintenance and calibration of corrosion chambers world-wide.

With an in-depth knowledge of the Ascott range, and able to issue Ascott Certificates of Calibration, our engineers will help you to protect your investment for many years to come.

Our engineers will always use genuine and approved spare parts and consumables and will be able to provide installation, commissioning, training and callout services well as regular scheduled service and calibration.

Don’t settle for anything less – always check that your service is Ascott approved!

Mass Loss Coupons for GMW14872 & GM9540P are now available from Ascott!

We have added to our extensive offering of accessories and consumables with our new ACC135 panels. These complement our CR4 Test Panels for ISO 9227 & VDA 233-102 and our highest purity Corro-Salt for Salt Spray Testing.

Heavy Oil Mass Loss Coupons that are fully compliant with the requirements of  GMW14872 & GM9540P.

Originally developed by General Motors these standards have gained popularity for corrosion tests within the automotive industry and have also become the preferred corrosion test of the US Navy.

These panels are supplied in a Pack of 20, protectively wrapped to eliminate environmental contamination. With  a 1/4″ / 6.35mm centre hole to allow for secure bracketing.

• Material Type: Cold Rolled Steel (ASTM 1008/1010 )
• Size: 1″ x 2″ / 25.4 x 50.8mm
• Thickness: 0.125″ / 3.175mm
• Numeric ID

Part code ACC135 – contact us for a quote or buy direct from our online store 

At Ascott, we are always looking to develop our products, improving performance and user experience. Going forwards, all Ascott Chambers (with the exception of 120L and Kesternich models) will now feature a viewing window/panel.

The viewing window allows for easy visual inspection without the need to remove the side panel and can be quickly and easily opened by using the key provided if access is required.

Benefits of new design:

• Clear view of Air Saturator and PLCs
• Early visual identification of possible issues
• Allows users to relay information/images to service engineers
• Panel opens easily with key provided
• Secure locking door prevents ingress of dust or other foreign substances

1 key is supplied as standard with each chamber, additional/replacement keys are available to order for end users and service engineers.  (Part Code FASC912)