Help with Corrosion (Humidity) Testing Procedure - Sintered Metal Steel Parts

Ron Rompen

Trusted Information Resource
#1
I have been assigned to find a humidty test standard for evaluating the corrosion resistance of the parts which we make and ship to various OEM's.

My initial thought was to use ASTM D1735 (100% humidity in a heated environment), however when I conducted my initial trials the parts failed miserably (not really a surprise, but......).

Our test provider suggested that the test protocol was too aggressive, and suggested that we use a non-condensing test, however they failed to suggest one, and I am not really familiar enough with test methodology to suggest (or even look for) one.

Can anyone with any experience in this field provide a guideline? All I need is the name or number of the standard - I will do the rest of the work :)

Thanks in advance.
 
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Marc

Hunkered Down for the Duration
Staff member
Admin
#2
Re: Help with Corrosion (Humidity) Testing Procedure

Can you be a bit more specific about the parts as well as the test requirements? I did a lot of environmental testing, but mostly on electronic assemblies.

HANG ON WHILST I THINK......
 
Last edited:

Marc

Hunkered Down for the Duration
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#3
Re: Help with Corrosion (Humidity) Testing Procedure

Ron - What is the material (I assume it's an alloy)?
 

Ron Rompen

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#4
Re: Help with Corrosion (Humidity) Testing Procedure

Morning Marc. The parts are sintered powdered metal (transmission components, so never exposed to regular corrosion processes after assembly) which are coated with a rust inhibitor immediately prior to packaging and shipment.

We have had several complaints for 'rust' this year which (IMHO) is directly attributable to the excessively hot and humid weather we experienced, however I have no hard data to support this theory. When I did send parts for testing (as noted before) they were found to have >90% corrosion on all surfaces after testing (72 hrs @ 100% RH @ 100°F). The test provider (a 3rd party) has recommended a non-condensing test, but hasn't provided any additional information.

Yes, I could go back to my customer and ask what -=THEY=- recommend, but I don't want to open that can of worms just yet; there is no test requirement on the prints currently, and I don't want to nudge them towards adding one.
 

Ron Rompen

Trusted Information Resource
#6
Re: Help with Corrosion (Humidity) Testing Procedure

Thank you Jean....I will go through that one (OMG its a huge document!) and see if I can tweak it for use with our parts.
 

Ron Rompen

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#7
Re: Help with Corrosion (Humidity) Testing Procedure

Just realized that I neglected to answer the question - the material is steel.
 

Marc

Hunkered Down for the Duration
Staff member
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#8
Re: Help with Corrosion (Humidity) Testing Procedure

Ron,

I used to write test plans (EDCTP's and QAPP's) years ago and used MIL-STD-810. Be sure to look at Part One (especially 14 and 15) to determine the conditions your parts will experience. Humidity is method 507, but again - Conditions of the test can be different especially considering transportation.

I remember doing some work for Lucas some years ago where they switched transportation methods (cast iron foundation brake cylinders) and rust inhibitor didn't work. They had to add individual wrapping (!) of a rust inhibitor paper for each part.

I know there are a couple of discussions here with regard to rust not having been seen before and being blamed on unusual high humidity but off hand didn't see them in a search today. I wish I still had contacts at Borg - I worked with them in Gallipolis, OH some years ago on sintered metal transmission parts (I think they sold that plant not long after I was there).

The test lab is right in that you would probably want non-condensing humidity - But again - Your transportation profile and storage profile may actually show the parts are subject to significant temperature changes which would induce condensation.

I guess the big thing is this is "new" and if nothing else has changed the weather may actually be the factor.

One thought - Are they receiving rusted parts or are they finding them at the line or somewhere else? I mention this because I have seen customers change their storage, etc. which induced problems. Sometimes a trip to the customer's plant can be of value.

I haven't looked lately so I'm not up to the "latest" technology, but in years past when a "new" problem came up I have used tracking packages which monitored temper, humidity and vibration from shipping to receipt and identified transportation heat and humidity problems (especially with rail transportation) in the south-west US and into Mexico.

Well, just a few thoughts.

Oh, and Jean - Thanks for the MIL-STD-810 reference. Getting old - I worked with "C" and "D"! I hadn't seen "G".
 

JeantheBigone

Quite Involved in Discussions
#9
Re: Help with Corrosion (Humidity) Testing Procedure

Here in the soggy south of the US we have had problems with P/M low alloy steel parts that had not been oil coated both upon receipt and when it had been on our floor for "too long." This wasn't the manufacturer; the parts were shot peened prior to us getting them, and it was the shot peener who was supposed to oil coat them. I don't have any systematic studies of it, but it did seem to correlate with high temperatures and the rainy part of the summer. We were able to rework by shot peening, but we had to do it on a kan-ban basis because cleaning them up and leaving them out on the floor was an invitation to let them get those ugly red spots again.
 
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