One of our customer, A Automotive, a well - established automotive component manufacturer, was facing a significant challenge. Their product line included a variety of critical components such as brake calipers, wheel hubs, and electrical connectors. However, in regions with harsh winter road conditions and coastal areas, these components were experiencing premature corrosion, leading to frequent warranty claims and a damaged brand reputation.
The corrosion issue was not only affecting the aesthetic appearance of the components but also their functionality. For example, corroded brake calipers could lead to reduced braking efficiency, posing a serious safety risk. The electrical connectors, when corroded, would cause intermittent electrical failures, which were frustrating for customers and costly for the company to repair.
To address this pressing problem, A Automotive decided to invest in a state - of - the - art Salt Spray Fog Corrosion Chamber. After extensive research and evaluation, they selected a chamber from us, known for its high - quality and reliable testing solutions.
The Salt Spray Fog Corrosion Chamber from us offered several advanced features. It had precise control over the salt spray concentration, allowing ABC Automotive to simulate different real - world scenarios. They could adjust the sodium chloride (NaCl) solution concentration from 5% to 20%, replicating the salt levels in coastal areas as well as those in regions with heavy road salt usage. The chamber also had excellent temperature and humidity control. The temperature could be regulated from room temperature up to 50°C, and the humidity could be maintained at a consistent 95% relative humidity, creating an environment that accelerated the corrosion process and closely mimicked real - world conditions.
Once the chamber was installed, A Automotive immediately began testing their components. For the brake calipers, they placed samples inside the chamber and subjected them to a continuous salt spray for 800 hours at a 15% salt concentration and a temperature of 40°C. After the test, the uncoated brake calipers showed severe pitting and corrosion on the surface. The corrosion had penetrated deep into the metal, weakening its structure.
Based on these results, A Automotive's R & D team started working on improving the coating process for the brake calipers. They experimented with different types of anti - corrosion coatings and application methods. After several rounds of testing in the salt spray chamber, they developed a new multi - layer coating system. When the brake calipers with the new coating were tested in the chamber for the same 800 - hour period, the corrosion was significantly reduced. The surface showed only minor signs of discoloration, and the structural integrity of the calipers remained intact.
The electrical connectors also underwent rigorous testing. A Automotive subjected them to a cyclic test in the chamber, alternating between salt spray and dry air periods to simulate real - world usage. The original connectors showed a rapid increase in electrical resistance after just 200 cycles, indicating corrosion at the contact points. The R & D team then redesigned the connectors, using more corrosion - resistant materials and improving the sealing. The new connectors were retested in the chamber, and after 500 cycles, their electrical resistance remained stable, demonstrating their improved corrosion resistance.
The implementation of the Salt Spray Fog Corrosion Chamber brought about remarkable results for A Automotive. In the first year after the new coating and design improvements, the number of warranty claims related to corrosion dropped by 70%. This not only saved the company approximately $800,000 in direct repair and replacement costs but also enhanced its brand image in the market. Customers were more satisfied with the durability of the components, leading to an increase in customer loyalty and a 15% growth in market share in the affected regions.
The success of A Automotive's use of the Salt Spray Fog Corrosion Chamber serves as a prime example of how investing in advanced testing equipment can lead to significant improvements in product quality, cost - savings, and market competitiveness in the automotive industry.
除了文章中提到的部件,还有哪些部件需要进行盐雾腐蚀试验?
用数据和图表说明盐雾腐蚀试验箱的测试结果.
如何提高盐雾腐蚀试验的准确性和可靠性?