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Salt Spray Weathering

Salt spray testing under ASTM B117 conditions subjects the test samples to conditions that are actually more corrosive than usual “real world” exposure. This is because the test uses sodium chloride in de-ionized water and usually lacks the moderating effects of other dissolved salts such as those containing calcium and magnesium, which tend to be somewhat protective.

Salt spray testing is the most popular form of testing for protective coatings. These tests have been used for more than 90 years as accelerated tests in order to determine the degree of protection afforded by both inorganic and organic coatings on a metallic substrate. The most widely used salt spray (fog) tests are described below.

The neutral salt spray (fog) test (ASTM B 117): is perhaps the most commonly used salt spray test in existence for testing inorganic and organic coatings, in particular where such tests are used for material or product specifications. The duration of the test can range from 8 to over 3000 hours, depending on the product. A 5% sodium chloride solution containing not more than 200 parts per million (ppm) total solids and with a pH range of 6.5 to 7.2 is used. The temperature of the salt spray chamber is controlled to maintain 35 + 1.1 or – 1.7Þ C (95 + 2 or -3Þ F) within the exposure zone of the closed chamber.

The acetic acid salt spray (fog) test (ASTM G 85, Annex A1): is also used for testing inorganic and organic coatings, but is particularly applicable to the study or testing of decorative chromium plating and cadmium plating on steel or zinc die castings, as well as for the evaluation of product quality. This test can be as short as 16 hours, although it normally ranges from 144 to 250 hours or more. Similar to the neutral salt spray test, a 5% sodium chloride solution is used, but the solution is adjusted to a pH range of 3.1 to 3.3 by the addition of acetic acid. The temperature of the salt spray chamber is controlled to the same temperature range as for neutral salt spray.

The copper accelerated acetic acid salt spray (fog), or CASS test (ASTM B 368): is primarily used for the rapid testing of chromium plating on steel and zinc die castings. It is also useful in the testing of anodized, chromated, or phosphated aluminum. The duration of this test ranges from 6 to 720 hours. A 5% sodium chloride solution is used, with one gram of copper (II) chloride dihydrate added to each 3.8 liters of salt solution. The solution is then adjusted to a pH range of 3.1 to 3.3 by adding acetic acid. The temperature of the salt spray chamber is controlled to the same temperature range as for neutral salt spray and for acetic acid salt spray.

Corrosion Group

Corrosion team is comprised of certified and experienced personnel from a variety of technical disciplines including: corrosion engineering, cathodic protection, paint inspection, chemistry, metallurgy, and materials science.  We also have a vast array of laboratory and field testing equipment. All of MATCO's testing equipment is calibrated on a routine basis in accordance with both national and international standards, and is ready to be put to use at a moment's notice.

Our team of NACE Certified Corrosion/Materials Selection/ Design/Coating/Cathodic Protection Specialists (*) includes:

Dr. M. Zee(*)                                             Mr. Geoff Rhodes (*)

Dr. George Bayer                                      Dr. Huiping Xu

Mr. Ed Larkin                                            Dr. Kasraie, PE

Dr. B. Bavarian                                         Marty Latona

An illustrated formal report documents the results of the investigation. If necessary, MATCO personnel can usually be on site almost immediately when requested during emergency situations.

We Value Our Customers... Throughout the years, we have noticed that much of our business comes from repeat customers. Our expertise and well-equipped lab can account for much of this, but we believe there is something more to it. We attribute it to the fact that we promote an open and friendly environment that is never too busy to meet your needs. At MATCO, we value your business whether you are a large corporation or a small enterprise. We will provide you with the attention you need and deserve. We invite you to visit us and get to know our staff, and share in the learning experience.

Why Choose MATCO? As one of the premier testing and failure analysis firms featuring state of the art equipment, MATCO is able to provide a unique and diverse blend of services. Thousands of investigations have been performed at MATCO arranging from jet engines and boiler tubes, to computer components and implants. Projects are not only conducted on your schedule from initiation to completion with competent and experienced personnel, and conducted in a discrete manner that ensures confidentiality as well.

MATCO's Typical Projects

Although MATCO's work is vital to its clients, it is rarely seen by the public. Here are some examples of recent jobs in which MATCO provided the timely, competent, customer-oriented engineering analysis that made the difference.

Failure Analysis: Metallurgical support for a major commercial airline fleet (US Airways) that includes failure analysis investigations, corrosion investigations, and quality control testing. Bridge and construction failure investigations are routinely performed at MATCO.

Corrosion Engineering: Cathodic protection system design and installation for a submerged ocean tunnel for the off-loading facility of the largest liquefied natural gas (LNG) process facility in the United States. Our certified team of corrosion investigators can perform testing to evaluate the integrity of pressure vessels. These include refineries, underground and above ground oil, gas and chemical process facilities   Our team has performed such analyses nation and worldwide, and will travel to your project site at a moment's notice for emergency evaluations.

Paint/Coating Analysis: On-site and laboratory investigation of paint delamination failures (flaking and peeling) on galvanized structural members of several major stadiums in the United States.

On-site Inspection: Our certified team of inspectors can perform non-destructive testing on project sites to evaluate the integrity of large structures.  Our team has performed such analyses nation and worldwide, and will travel to your project site at a moment's notice for emergency evaluations.  Such large structure evaluations have included off-shore oil platforms, wind power generation towers, concrete domes and stadiums, large underground cooling systems, and large elevated water towers. Our projects have taken us from Aloha Stadium in Hawaii to Alyeska Ski Resort in Alaska; from bridges in the Bahamas to titanium structures in Tokyo, Japan and damage evaluation of hurricane in Florida. This project included roofing, siding, paint and internal water damage for a large structure.

Environmental Testing: Comparative testing of the resistance of pharmaceutical labels to environmental stresses (MFG, Humidity, and QUV testing) for a major drug company to determine what labels held up the best.

Fire Investigation: Same-day analysis of the effects of a truck fire on the superstructure of a major highway bridge to determine whether or not the highway could remain open.

Explosion Investigations: Failure analysis of a gas main explosion that caused causalities.

Power Plants: Failure analysis and remaining life determination of boiler components in the power industry.

Implant Materials: Electrochemical corrosion evaluation and failure analysis of implant materials such as hips, knees, stents, etc. to improve products and performance.

Galvanized Steel: How its microstructure and galvanized layer chemistry affect its appearance and corrosion resistance. Prevention and evaluation of storage rust, cracking of galvanized layer, failure of painted galvanized steel. Cabinet salt spray testing, EIS testing of painted galvanized steel and metallurgical characterization tests are routinly performed for galvanized and painted galvanized steel panels.

Poles, Towers, Lattice & Anchor Rod: Inspection and evaluation of galvanized, Cor-Ten (weathering steel) and painted carbon steel structures. Failure analysis, fatigue investigations, protective coating evaluation, life expectancy determination, corrosion evaluation, underground, ground level and above ground were included in this investigations

R&D: Research & Development of new materials, coatings and sensors for the electric utility, pipeline, construction and chemical industry.