Corrosion testing at the Test Center of thyssenkrupp Automotive Systems

In addition to the forces and moments acting on a product, environmental stresses are the main factors influencing the service life of products. Corrosion plays a dual role here, because on the one hand it has a direct influence on the service life and on the other hand it has a value-reducing effect on the appearance.

Automotive Systems' Test Center has once again significantly strengthened its capabilities in the field of corrosion analysis by training additional employees to become specialists and investing in further equipment. This means that both pure corrosion tests can be carried out in special test chambers according to various test standards and the known fatigue strength tests can be superimposed with the influences of corrosion.

Corrosive media: constant stress for vehicle components

Corrosion has always been a significant challenge for the durability and reliability of vehicle components. In particular, chassis components such as springs, dampers and stabilizers are exposed to corrosive environmental influences in addition to the sometimes highly dynamicmechanical stresses. The corrosive media that affect these components range from salt-laden snow and slush, which contain road salt, to the salty air near the coast.

The importance of corrosion tests for the development of new vehicles

Corrosion tests are therefore an indispensable part of the development process for vehicle components in the passenger car, rail, bicycle or commercial vehicle sector. They ensure that both coated and uncoated parts fulfill their function over the entire lifespan of the vehicle. At the Test Center of thyssenkrupp Automotive Systems, corrosion tests are conducted systematically and in compliance with the applicable standards (e.g. DIN EN ISO 9227) to ensure that vehicle components function reliably even under extreme conditions.

In our Test Center, which is in operation 24/7, experienced test engineers ensure that the corrosion tests are carried out correctly at all times. Constant communication with our customers is also crucial. Every new vehicle part on the market and every customer requirement is individual. We therefore have to pay close attention to the details, but that always applies in our testing area.

Dr. Michael Oeter, deputy head of the Test Center at thyssenkrupp Automotive Systems

Corrosion chambers for larger or multiple vehicle components

The thyssenkrupp Automotive Systems Test Center has a modern corrosion laboratory with large corrosion chambers (up to 2,000 liters). These can also be used to test larger components and systems or several parts at the same time under realistic conditions. “Recently, a complete bicycle was tested in the corrosion chamber.”

Corrosion tests in the laboratory involve exposing components to various corrosive media. These tests simulate real-life environmental conditions to which vehicle parts are exposed during use.

Michael Oeter explains: “Our test team takes care of development-related tests and pursues various testing approaches. Both the influence of corrosive media on unloaded or pre-damaged surfaces and the influence of surface damage caused by corrosion on the operational stability of the components are examined.” Both options are offered to manufacturers and their suppliers at the Test Center.

Realistic corrosion tests under operating loads

In addition to standardized corrosion tests, the Test Center also performs customized tests according to customer-specific requirements. These include the combination of mechanical loads and corrosive influences to create realistic conditions. Michael Oeter: “Individual corrosion tests are particularly important for understanding and optimizing the behavior of components under actual operating conditions.” All test setups for mechanical loading can be provided with appropriate enclosures for the test parts in the Test Center, in order to atomize or spray corrosive media according to customer specifications.

The exact reproduction of real spray patterns (wetting) on vehicle areas can be crucial for a meaningful test result. In the area of the chassis, for example, there are areas that are more and less exposed to salt-containing condensation water. The corrosion process is influenced by the degree of wetting and local drying processes.

This is why realistic spray patterns are so important for the test results. We rely on close coordination with our customers and their experience, but the expertise of our employees also makes a major contribution.

Dr. Michael Oeter, deputy head of the Test Center at thyssenkrupp Automotive Systems

Flexible and accredited test procedures

The quality of the test methods plays an equally crucial role in ensuring that real-world conditions are accurately reflected. The Test Center at thyssenkrupp Automotive Systems is accredited according to DIN EN ISO/IEC 17025:2018. The flexible accreditation certifies not only the ability to carry out standard tests of the highest quality, but also to develop and apply individual test concepts according to strict specifications. This flexibility is particularly important to meet the specific requirements of different customers and to ensure that the tests reflect real-world conditions as closely as possible.

Our test engineers have many years of experience in conducting and evaluating corrosion tests. Their expertise is crucial to correctly interpreting the often complex corrosion patterns so that appropriate measures can be taken to improve the components.

This is how OEMs benefit from the thyssenkrupp Automotive Systems Test Center.

What we offer our customers:

  • Expertise ranging from materials testing and component testing to system testing

  • Fast processing of inquiries and preparation of offers

  • One project – one test engineer as a permanent point of contact (with a deputy)

  • Wherever possible, 24/7 operation of the test stands

  • The customer is informed so that he feels as if he were on site