GMW14872 - Cyclic Corrosion Laboratory Test

WORLDWIDE Test Procedure
ENGINEERING GMW14872
Materials
STANDARDS
Cyclic Corrosion Laboratory Test
GMW15272 for specific Method and applicable

1 Scope region).
Note: Nothing in this standard supercedes The basic exposures for cosmetic corrosion are
applicable laws and regulations. found below in exposures 0, A, B, and C.
Exposure D is used for functional assessment
Note: In the event of conflict between the English
(refer to Table A1). All corrosion mechanisms are
and domestic language, the English language shall
accelerated at different rates on test. Completing
take precedence.
the test may not ensure that a component passes
1.1 Purpose. This procedure describes an the functional requirement. A comprehensive
accelerated laboratory corrosion test method to failure mode analysis must be conducted to ensure
evaluate assemblies and components. The test all failure modes are considered and life
procedure provides a combination of cyclic expectancy is met.
conditions (salt solution, various temperatures,
Exposure 0: All Areas (0 Year/Initial Delivery (ID)).
humidity, and ambient environment) to accelerate
metallic corrosion. The procedure is effective for Exposure A: Underbody Components.
evaluating a variety of corrosion mechanisms, such Exposure B: Underhood Components.
as general, galvanic, crevice, etc. The test Exposure C: Exterior Components/Panels,
exposure/conditions can be individually tailored to Secondary Surfaces, and Interior Components.
achieve any desired level of corrosion exposure.
Exposure D: All Components (Functional).
Also, synergistic effects due to temperature,
Note: For Exposure 0 (0 Year/ID) evaluate parts at
mechanical and electrical cycling, along with other
two (2) cycles of the defined exposure linked to the
stresses, can be comprehended by this test. See
associated vehicle area and mounting location as
Deviations Section (pages 21 and 22 of this
defined in Table A1.
document), for typical modifications.
Note: Reference the Deviations section of this
1.2 Foreword. The test method is comprised of
document for optional modifications.
1% (approximate) complex salt mist applications
coupled with high temperature and high humidity
and high temperature dry off. One (1) test cycle is 2 References
equal to 24 h. Note: Only the latest approved standards are
A cycle is made up of the daily events or test applicable unless otherwise specified.
inputs illustrated in Figure A1. A cycle normally 2.1 External Standards/Specifications.
requires 1 day to complete. The test exposure is ASTM D610 ISO 12103-1
dictated by a targeted coupon mass loss. A target
range for the number of cycles necessary to meet ASTM D1193 SAE 2001-01-0640
the required mass loss is provided in Table A1 for ISO 6270-2 SAE J2329
Method 1/2 and Method 3. The coupon mass loss ISO 8407
values are used to verify that the correct amount of 2.2 GM Standards/Specifications.
corrosion has been produced by the test. In
addition to meeting mass loss requirements, the GMW14700 GMW15357
test must be conducted such that the number of GMW15272 GMW15358
cycles required to meet coupon mass loss GMW15282 GMW15359
requirements falls within the specified range. GMW15356 GMW16277
1.3 Applicability. This is a cyclic corrosion test 2.3 Additional References.
(refer to Figure A1) used for validation testing
SAE 1008-1010
(cosmetic and/or functional/general durability),
development testing, and quality control testing, for
all global environmental regions (refer to
© Copyright 2010 General Motors All Rights Reserved
March 2010 Originating Department: North American Engineering Standards Page 1 of 22
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Copyright General Motors Company

Provided by IHS under license with General Motors Company Sold to:Trelleborg Fluid Solutions, 559885
No reproduction or networking permitted without license from IHS Not for Resale,12/13/2010 06:39:57 MST
GM WORLDWIDE ENGINEERING STANDARDS GMW14872
3 Resources 3.2.2.2 Wet-Bottom. The apparatus shall consist

of the chamber design as defined in ISO 6270-2.
3.1 Facilities. Laboratory (preferably with
During wet-bottom generated humidity cycles, the
controlled ambient conditions).
tester must ensure that visible water droplets are
3.2 Equipment. found on the samples to verify proper wetness.
3.2.1 Ambient Stage. The apparatus for the 3.2.2.3 Steam Generated Humidity. Steam
ambient stage shall have the ability to maintain the generated humidity may be used provided the
following environmental conditions: source of water used in generating the steam is
 Temperature: 25 ± 3 °C. free of corrosion inhibitors. During steam
 Humidity: 45 ± 10% Relative Humidity (RH). generated humidity cycles, the tester must ensure
that visible water droplets are found on the
 Duration: 8 h per cycle. samples to verify proper wetness.
3.2.2 Humid Stage. The apparatus for the humid 3.2.3 Dry Off Stage. The apparatus for the dry off
stage shall have the ability to ramp to (within 1 h) stage shall have the ability to ramp to (within 3 h)
and maintain (for 7 h) under the following and maintain (for 5 h) under the following
environmental conditions: environmental conditions:
 Temperature: 49 ± 2 °C.  Temperature: 60 ± 2 °C.
 Humidity: ~100% RH.  Humidity: ≤ 30% RH.
 Duration: 8 h per cycle.  Duration: 8 h per cycle.
The apparatus shall consist of a fog/environmental The apparatus shall also have sufficient air
chamber, suitable water supply conforming to circulation to prevent temperature stratification,
ASTM D1193 Type IV, provisions for heating the and also allow thorough drying of the test samples.
chamber and the necessary means of control.
3.2.4 Salt Mist Application. The solution shall be
3.2.2.1 Water Fog. The apparatus shall include sprayed as an atomized mist, and should be
provisions for a supply of suitably conditioned sufficient to rinse away any salt accumulation left
compressed air and one or more nozzles for fog from previous sprays. The test samples and
generation. The nozzle or nozzles used for the coupons shall be thoroughly wet/dripping. Suitable
generation of the fog shall be directed or baffled to application techniques include using a plastic
minimize any direct impingement on the test bottle, or a siphon spray powered by oil-free
samples. regulated air to spray the test samples and
At least two clean fog collectors shall be placed coupons.
within the exposure zone so that no drops of Note: The force/impingement from this salt
solution from the test specimens or any other application should not remove corrosion or
runoff source shall be collected. The collectors damage coatings/paints system of test samples.
shall be placed in the proximity of the test
specimens, one nearest to any nozzle and the 3.2.5 Corrosion Coupons and Mounting
other farthest from all nozzles. Collection rates for Hardware. Coupons serve to monitor the average
2
each 80 cm of horizontal collection area should be general bare steel corrosion produced by the test
in the range of 0.75 to 1.5 mL/h (on average) of environment. Coupons consist of
water will be collected in each collector over a 25.4 wide x 50.8 long x 3.18 mm thick pieces of
minimum duration of 16 h. Fog collection rates may bare SAE 1008-1010 carbon steel, cold-rolled steel
be adjusted within this range as necessary to meet per SAE J2329 CR1E, uncoated, no post-coating
mass loss target rates. treatment, which are stamped with an
alphanumeric identification number (reference
Suitable collecting devices include glass or plastic Figure A2).
funnels with the stems inserted through stoppers
into graduated cylinders. Funnels with a diameter The coupons shall be secured to an aluminum or
of 10 cm have an area of about 80 cm . Where
2 nonmetallic coupon rack with fasteners as shown
samples cannot be read immediately upon in Figure A3 and Figure A4. The bolt, nut and
completion of the humid stage, closed cell foam washers shall be made from a non-black plastic
balls can be used in combination with the material, preferably nylon. Figure A4 shows a
collections funnels (i.e., foam ball in mouth of completed coupon rack configuration. The number
of coupons recommended for different test
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funnel) to allow moisture to collect while minimizing

evaporation. durations are shown in Table A2.
3.3 Test Vehicle/Test Piece. The test sample
(design, surface, and preparation) should be
March 2010 Page 2 of 22

agreed to by the parties concerned (Design Sodium Chloride must be reagent grade or Morton
Engineer/Materials Engineer/Corrosion Engineer) Culinox 999 Food grade. Calcium Chloride must be
and should simulate actual production materials reagent grade. Sodium Bicarbonate must be
and conditions when possible. reagent grade (e.g., Arm & Hammer Baking Soda
The number of test samples selected should be or comparable product is acceptable). Water must
sufficient to ensure that the test results are meet ASTM D1193 Type IV requirements.
statistically significant at some predetermined Note: Either CaCl2 or NaHCO3 material must be
confidence level, unless otherwise specified. Any dissolved separately in water and added to the
unusual observations made during sample solution of the other materials. If all solid materials
preparation should be recorded and reported as are added dry, an insoluble precipitate may result.
part of the test results. Salt solution makeup calculator for the appropriate
Where appropriate, test samples and/or control amount of sodium chloride, calcium chloride,
panels of known performance should be tested sodium bicarbonate, and water examples are
concurrently. These controls can allow the shown in Appendix B, Figures B1 through B6.
normalization of test conditions during repeated Additional contaminants (dust, grit, poultice, and
running of the test (supplementing the required exhaust condensate) called out in the Deviation
mass loss controls) and may also allow Section are defined in Appendix C through
comparison of test results from different repeats of Appendix F.
the test.
4.1.2 Coupon Preparation. Corrosion coupons
Where actual/representative production samples should be cleaned with methanol or acetone
are available and the in-service orientation is solution and accurately weighed prior to use. The
known, test samples should be oriented to simulate weight, in grams, shall be recorded and retained
these conditions. for future reference. If coupons are not used
When using test panels and/or the in-service immediately, they should be stored such that they
orientation is not known, the sample shall, in are corrosion free at the start of test.
principle, be oriented such that it is facing upward It is critical that all forming or preservation
and at an angle of 20 ± 5 degrees from vertical. oils/lubes be removed prior to exposure to allow for
3.3.1. Preconditioning of Test Samples. The general/uniform corrosion of the coupon. This
gravelometer and/or a scribing tool can be used to process can be aided by using a commercial grade
provide damage to coating layers prior to testing in degreaser prior to methanol or acetone clean.
order to better represent potential in-service 4.1.3 Coupon Rack Preparation. Prior to start of
damage when appropriate. The use of either of test, prepare the coupon rack with sufficient
these preconditioning methods shall be agreed coupons to monitor the test. The number of
upon by the parties concerned and shall conform coupons recommended for different test durations
to the methods describe in the GMW14700 and/or are shown in Table A2.
the GMW15282.
The exact location of each coupon on the rack
3.4 Test Time. See cycle times in Table A1.
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shall be identified and recorded using the

Calendar time: 0 days pre-stamped numbers for reference as illustrated in
Figure A4.
Test hours: 0 hours
Allow a minimum 5 mm spacing between the
Coordination hours: 0 hours coupons and the rack surface. All coupons shall be
secured vertically with no more than 15 degree
3.5 Test Required Information. Not applicable.
deviation from vertical and must not contact each
3.6 Personnel/Skills. Not applicable. other.
The coupon rack shall be placed in the general
4 Procedure vicinity of the test samples being tested, such that
4.1 Preparation. the coupons receive the same environmental
4.1.1 Salt Solution Preparation. The complex salt exposure as the test samples.
solution in percent (%) by mass shall be as Note: Mass loss coupons are test monitoring
specified below: devices and are not intended to be exposed to
 Sodium Chloride (NaCl): 0.9%. additional stresses which may be added to the
base test (i.e., gravelometer, dust, grit, exhaust
 Calcium Chloride (CaCl2): 0.1%. condensate, thermal exposure, etc.) Additional
 Sodium Bicarbonate (NaHCO3): 0.075%.

coupons may be required to monitor special test Note: Although not preferred, corrosion by-product
conditions (refer to Deviations section). removal by chemical cleaning per ISO 8407 may
4.2 Conditions. be used.
4.2.1 Environmental Conditions. 4.3.4.2 Compare the actual mass loss to the
targeted value. Refer to Table A1 for targeted
4.2.2 Test Conditions. Deviations from the
mass loss values, in grams, for various test
requirements of this standard shall have been
exposures as a function of the coupon's original
agreed upon. Such requirements shall be specified
thickness. Testing should be conducted as
on component drawings, test certificates, reports,
necessary to achieve necessary coupon mass
etc.
loss. The number of cycles required to achieve
4.3 Instructions. required mass loss must meet that defined in
4.3.1 Test Execution. See Figure A1 (Flow Table A1.
Diagram) for the steps that comprise the test Note: Coupon mass loss targets corresponding to
method. Repeat the cycle daily, as necessary, until incremental test exposures are not included in
the test exposure requirements are met. At the Table A1. The processes defined in section 4.3.4
option of the test requestor, the test can be Test Monitoring and section 5.3.1 Coupons may be
continued throughout weekends to decrease the used to check test progress and assure that the
overall test time provided that the number of cycles test is being run correctly. Corrosion mass loss
and mass loss requirements are met. should increase consistently between documented
4.3.2 Salt Application. For each salt mist exposure values. If the actual mass loss does not
application, use the spray apparatus to mist the fall within the targeted range for the specified
samples and coupons until all areas are thoroughly exposure(s) as listed in Table A1, then the test
wet/dripping. The quantity of spray applied should should be repeated. Also, the reasons why the test
be sufficient to visibly rinse away salt accumulation did not fall within the target range should be
left from previous sprays. The first salt mist investigated and corrected before resuming the
application occurs at the beginning of the ambient test.
stage. Each subsequent salt mist application, when 4.3.5 Test Acceleration. Temperature and
specified, should occur approximately 1.5 h after humidity ramp times between the ambient stage
the previous application in order to allow adequate and humid stage, and between the humid stage
time for test samples to dry. A minimum of 1 h and dry stage, can have a significant effect on test
spacing between the end of a previous salt acceleration. (This is because corrosion rates are
application and the subsequent salt application is highest during these transition periods.) Typically,
required. the time from the ambient stage to the humid stage
4.3.3 Test Options. The test may be modified to should be approximately 1 h and the transition time
target specific component applications. Refer to between humid stage and dry stage should be
Deviations Section at the end of this document. approximately 3 h. These ramp times can be
4.3.4 Test Monitoring. Corrosion coupons shall be adjusted to increase or decrease test acceleration
removed and analyzed after a predetermined in order to meet targeted mass loss. Any significant
number of cycles (typically 5) throughout the test to deviations from the ramp time described should be
monitor the corrosion (less frequent for longer documented with the test results and requires prior
exposures that is > 40 cycles). To analyze approval by the parties concerned. Ramp time is to
coupons, remove one coupon from each end of the be included as part of the specified exposure
rack, clean to prepare for weighing, and an period.
average mass loss determination. Although 4.3.6 Extended Downtime. For any periods of
corrosion rate may vary somewhat during the extended downtime (i.e., greater than 4 to 5 days),
duration of the test, an assumption of linearity may it is recommended that test parts and associated
be useful in predicting the number of cycles to coupons receive a fresh water rinse prior to the
meet future mass loss targets. downtime period and are stored in ambient
4.3.4.1 Before weighing, clean the coupons using a conditions to help minimize corrosive effects during
mild sand/bead blast 80 ± 10 psi process to this time. If downtime exceeds or is expected to
remove all corrosion by-products from the coupon exceed 17 consecutive days, this condition should
surface. Wipe the coupons free of grit and weigh to be reviewed with test requestor. Additional special
determine the coupon mass loss using the formula: measures may be required to control the corrosion
behavior of the test samples during this period.
Mass Loss = (Initial Mass) - (End-of-Exposure
Storage in a desiccator, freezer, etc., may be
Mass).
appropriate. Extended downtime periods and any
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associated special measures should be included in as the targeted and actual coupon mass loss
the test documentation. associated with the documented data collection
4.4 Cosmetic Corrosion Inspection. The test points.
sample(s) shall be inspected for corrosion by 5.3.3 Test Equipment Documentation. The
means of GMW15356, GMW15357, GMW15358, information in 5.3.3.1 through 5.3.3.14 shall be
GMW15359, and photographed (as necessary) at recorded and available upon request for each
the end of predetermined cycles. Samples may be cabinet/exposure location used to conduct test
rated in terms of percent corroded area per conditions as appropriate.
ASTM D610 or some other comparable standard if 5.3.3.1 Cabinet Manufacturer/Model.
agreed upon by test requestor and tester. If test
5.3.3.2 Humidity Profile.
samples containing plastic materials are being
tested, any discoloration or degradation and/or 5.3.3.3 Temperature Profile.
adhesive bond failure (delamination) shall be noted 5.3.3.4 Humidification Process.
and recorded. 5.3.3.5 Collection Rate.
If scribing is required, on test samples, follow the 5.3.3.6 Dehumidification Process.
method described in GMW15282. This method
5.3.3.7 Heating Process.
includes measurement of corrosion creepback
from a scribe line. This method should be used 5.3.3.8 Cooling Process.
when reporting test results unless stated otherwise 5.3.3.9 Air Circulation Process.
on drawings or agreed upon by test requestor and 5.3.3.10 Capacity.
tester.
5.3.3.11 Size.
4.5 End-of-Test Functional Inspection. At the
end of test the samples shall be rinsed with fresh 5.3.3.12 Calibration Process.
tap water and allowed to dry before evaluating. 5.3.3.13 Frequency of Calibration.
End-of-test functional analysis may involve 5.3.3.14 Ramp Time Between Stages.
sectioning, microscopic analysis and/or removal of Cycle profiles (including typical steady state
corrosion product to determine degree and extent conditions and the ramp times between steady
of base metal attack. state conditions) should be maintained and
available upon request.
5 Data Note: A form for Test Equipment documentation
5.1 Calculations. can be found in Appendix H. If information does
 Salt solution (reference Appendix B). not change from test to test, documentation of a
representative test will be acceptable. All the
 Coupon mass loss (reference 4.3.4.1).
specified information will be required if test results
5.2 Interpretation of Results. Acceptance criteria are in question.
shall be specified within Engineering
5.3.4. Test Solution. The information in 5.3.4.1
documentation which may include: Material
through 5.3.4.5 shall be recorded and available
Specifications, Vehicle, Subsystem, Component
upon request.
Technical Specifications, Statement of
Requirements, Part Drawings, etc. 5.3.4.1 Frequency of Salt Solution Changes.
5.3 Test Documentation. 5.3.4.2 Method of Salt Application.
5.3.1 Coupons. Coupon mass loss values are to 5.3.4.3 pH of Solution.
be recorded periodically throughout test and 5.3.4.4 Salinity or Conductivity of Solution.
included as part of the overall test documentation 5.3.4.5 Solution Constituents.
in order to provide evidence of test control and
Note: The form for Test Solution documentation
adherence to specified test targets. This data may
can be found in Appendix J. All specified
be plotted using charts like the examples found in
information will be required if test results are in
Figure G1 and Figure G2.
question.
5.3.2 Test Reports. Test reports should include a
description of the specific test cycle executed,
description of test options or special instructions,
6 Safety
test deviations and/or extended test downtime This standard may involve hazardous materials,
periods (including any special measures taken). operations, and equipment. This standard does not
Test reports should also include (at minimum) propose to address all the safety problems
targeted and actual number of cycles run, as well associated with its use. It is the responsibility of the

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user of this standard to establish appropriate safety global region specified in Method 3 cosmetic and
and health practices and determine the functional.
applicability of regulatory limitations prior to use. Test to GMW14872, UH, Mid PS, 4 sp, Method 3,
Exposures B and D.
7 Notes Example 4: For a door hinge mounted outside the
7.1 Glossary. Not applicable. weatherstrip in a global region specified in
7.2 Acronyms, Abbreviations, and Symbols. Method 1/2 functional.
EXT Exterior Test to GMW14872, Secondary Surface (SS)
Outside the Weather Strip (O/WS), Method 1/2,
g Grams
Deviation Option 1, Duration 70 cycles.
h Hours
In addition, the criteria for making pass/fail
ID Initial Delivery (0 year) determinations must be specified (i.e., Vehicle
INT Interior Technical Specification Paragraph Number, etc.)
I/WS Inside the weather strip
ND Not Defined 9 Release and Revisions
O/WS Outside the weather strip This standard was originated in November 2005. It
was first approved by the Global Laboratory
PS Protected from splash
Corrosion Testing Harmonization Team in August
RH Relative Humidity 2006. It was first published in November 2006.
s Seconds
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Issue Publication Description

sp Salt sprays Date (Organization)
SS Secondary Surface
1 NOV 2006 Initial publication.
UB Underbody
UH Underhood 2 MAR 2010 Added Exposure 0:
0 year/ID to 1.2 and
Table A1. Added Notes 1
8 Coding System to 3 to Figure A1. Updated
This standard shall be referenced in other 3.3 and added 3.3.1
documents, drawings, etc., as follows: Preconditioning of Test
Test to GMW14872 Samples. Moved 4.5 Test
Monitoring to 4.3.4.
Test to GMW14872, vehicle area including
Moved 4.4 Test
mounting location, method, cosmetic and/or
Acceleration to 4.3.5.
functional test exposure, (0, A, B, C or D) or where
Added 4.3.6 Extended
the drawing or material specification calls for a
Downtime. Updated
specific deviation. This deviation should specify an
Underhood section of
associated mass loss.
Table A1. Replaced
Example 1: For an underbody (UB) component Method SH/SM with
pertaining to a global region specified as Class 3 Method 1/2 and
cosmetic (including 0 year/ID, i.e., 2 cycles) and Method SL with Method 3
functional. in Table A1. Added
Test to GMW14872, (UB), All, 4 sp, Method 3, additional source under
Exposures 0, A, and D. Figure A4. Updated
Example 2: For a low, mid, or high Deviations to include
underhood (UH) component pertaining to a global coupon exposure and
region specified as Class 1 or Class 2 cosmetic mass loss.
and functional with splash protection not defined. (Corrosion GSSLT -
Test to GMW14872, UH, All, 4 sp, Method 1/2, Global Subsystem
Exposures B and D. Leadership Team)
Example 3: For a mid mounted and protected from
splash underhood component pertaining to a

Appendix A
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Note 1: The typical ramp time from the ambient stage to the humid stage is 1 h and is part of the 8 h humid stage.
Note 2: The typical ramp time from the humid stage to the dry stage is 3 h and is part of the 8 h dry stage.
Note 3: For extended downtime refer to 4.3.6.
Figure A1: GMW14872 Flow Diagram

Note 1
Table A1: GMW14872 Mass Loss Targets (3.18 mm thick coupons) – Cosmetic and Functional
Test Exposure
Mounting Number of
Vehicle Note 2 Cosmetic Mass Loss (Penetration Functional Mass Loss
Location of Salt Sprays Method Note 3 Note 4 Note 4, Note 5
Area ) Requirements and Number Requirements
Component (sp)
of Test Cycles and Number of Test Cycles
Exposure D
Exposure A
9.47 ± 0.38 g (430 ± 17 µm)
Method 1/2 0.84 ± 0.14 g (38 ± 6 µm)
68 ± 7 cycles
Underbody 6 ± 1 cycles
All 4 per cycle
(UB)
Exposure A Exposure D
Method 3 0.42 ± 0.07 g (19 ± 3 µm) 4.74 ± 0.19 g (215 ± 9 µm)
3 ± 1 cycles 34 ± 4 cycles
Exposure B Exposure D
Method 1/2 1.32 ± 0.13 g (60 ± 6 µm) 7.11 ± 0.28 g (323 ± 13 µm)
All – Splash
Protection 9 ± 1 cycles 51 ± 6 cycles
Not Defined 4 per cycle
Note 6
(ND) Method 3 0.66 ± 0.07 g (30 ± 3 µm) 3.55 ± 0.14 g (161 ± 6 µm)
Mid – Method 1/2 0.88 ± 0.09 g (40 ± 4 µm) 4.74 ± 0.19 g 9215 ± 8 µm)
Underhood Protected 11 ± 2 cycles 59 ± 6 cycles
from Splash 1 per cycle
(UH) Exposure B Exposure D
Note 6
(PS) Method 3 0.44 ± 0.04 g (20 ± 2 µm) 2.38 ± 0.10 g (108 ± 4 µm)
High – Method 1/2 0.44 ± 0.4 g (20 ± 2 µm) 2.38 ± 0.10 g (108 ± 4 µm)
Protected 6 ± 1 cycles 30 ± 3 cycles
from Splash 1 per cycle
Note 6 Exposure B Exposure D
(PS) Method 3 0.22 ± 0.02 g (10 ± 1 µm) 1.19 ± 0.05 g (54 ± 2 µm)
Exposure C Exposure D
Exterior
All 4 per cycle Method 1/2/3 3.94 ± 0.28 g (179 ± 13 µm) 7.23 ± 0.29 g (328 ± 13 µm)
(EXT)
Outside the Exposure C Exposure D
Weather 1.98 ± 0.14 g (90 ± 6 µm) 3.61 ± 0.14 g (164 ± 7 µm)
1 per cycle Method 1/2/3
Secondary Strip 25 ± 3 cycles 45 ± 5 cycles
Surface (O/WS)
(SS) Inside the Exposure C Exposure D
1 per 5
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Weather Note 7 Method 1/2/3 0.40 ± 0.3 g (18 ± 1 µm) 0.73 ± 0.03 g (33 ± 1 µm)
Strip (I/WS) cycles
Exposure C Exposure D
1 per 5
Low Note 7 Method 1/2/3 1.30 ± 0.09 g (59 ± 4 µm) 2.38 ± 0.10 g (108 ± 4 µm)
cycles
Interior 24 ± 3 cycles 43 ± 4 cycles
(INT) Exposure C Exposure D
1 per 5
Mid, High Note 7 Method 1/2/3 0.40 ± 0.03 g (18 ± 1 µm) 0.73 ± 0.03 g (33 ± 1 m)
cycles
Note 1: For Exposure 0 (0 Year/ID) evaluate parts at 2 cycles of the defined exposure linked to the associated vehicle area and mounting location.
Note 2: Refer to GMW15272 for applicable linkage of global region to test Method 1/2 or Method 3.
Note 3: Penetration factor based on material and dimension is 45.4.
Note 4: In addition to mass loss requirements, the test must be conducted such that the number of cycles falls within the specified range.
Note 5: Exposure D is used for functional assessment. All corrosion mechanisms are accelerated at different rates on test. Completing the test may
not ensure that a component passes the functional requirement. A comprehensive failure mode analysis must be conducted to ensure all
failure modes are considered and life expectancy is met.
Note 6: In order to be classified as Protected from Splash, the associated vehicle application(s) must effectively employ all Splash Shielding Best
Practices and the component must be classified as "Dry" based on the Vehicle Splash Shield Performance Evaluation (GMW16277)
Procedure.
Note 7: Number of salt sprays for 1 per 5 cycles should be sprayed at the start-of-test and every 5 cycles thereafter.

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Figure A2: Coupon Schematic
Nylon bolts and washers suitable are as

follows:
Bolt: ¼"-20 x ½ in hex head cap screw, solid
nylon
¼"-20 x 3/7 in hex head cap screw, solid
nylon
Washer: ½ x .257 x .197 in thick flat washers
Nut: ¼"-20 nut, solid nylon
Figure A3: Coupon Hardware Illustration

Figure A4: Coupon Bracket Assembly Illustration
Suitable coupons and/or coupon rack assemblies along with salt solution, dust, grit, poultice, and exhaust
condensate can be purchased from the following:
ACT Test Panels

273 Industrial Drive
P.O. Box 735
Hillsdale, Michigan 49242
(517) 439-1485
Auto Technology Company

20026 Progress Drive
Strongsville, Ohio 44149
800-433-8336
National Exposure Testing

3545 Silica Road
Suite E
Sylvania, Ohio 43560
(419) 841-1065
Table A2: Recommended Number of Coupons and Removal Frequency

Number of Required Cycles Number of Coupons Removal Frequency
≤ 10 cycles 6 5 Cycles
11 to 20 cycles 10 5 Cycles
Note 1
Note 1: Additional coupons may be required if earlier evaluations must be conducted.
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Appendix B
Figure B1: GMW14872 Salt Solution Calculator for Anhydrous (X=0) Calcium Chloride Based on a
Five Gallon Batch Solution
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Figure B2: GMW14872 Salt Solution Calculator for One Hydrate (X=1) Calcium Chloride Based on a
Figure B3: GMW14872 Salt Solution Calculator for Dihydrate (X=2) Calcium Chloride Based on a
Note: An electronic copy can be obtained upon request. Please contact GMNA Corrosion Engineering.

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Figure B4: GMW14872 Salt Solution Calculator for Anhydrous (X=0) Calcium Chloride Based on a
Ten Liter Batch Solution
Figure B5: GMW14872 Salt Solution Calculator for One Hydrate (X=1) Calcium Chloride Based on a
Figure B6: GMW14872 Salt Solution Calculator for Dihydrate (X=2) Calcium Chloride Based on a
Note: An electronic copy can be obtained upon request. Please contact GMNA Corrosion Engineering.

Appendix C
Dust Type
Arizona Dust conforming to ISO 12103-1, A2 Fine, procured from Powder Technology Incorporated of
Burnsville, Minnesota. Dust may also be purchased from ACT Test Panels, Auto Technology Company, and
National Exposure Testing.
Spray Apparatus
A simple garden duster is suitable for dust application (refer to Figure C1 for example).
Dust Application
Dust should be applied such that a semi-transparent layer is applied to the entire part or focal area of the part.
Keep the applicator agitated to ensure proper dust application (agitate/shake duster between applications).
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Figure C1: Garden Duster Example
Note: For bulk supply use suppliers defined above. Smaller quantities may be purchased from ACT Test
Panels, Auto Technology Company, and National Exposure Testing (refer to Appendix A for contact
information).

Appendix D
Grit Specification
Grit Trough Solution Mix (typical recipe to be mixed with 18.9 L of water (5 gal) – total solution amount can
be increased or decreased by multiplying or dividing as necessary).
Solid Contaminants:
Fire Clay – 900 g
Cinders – 900 g
Sand – 900 g
Ottawa Lakes Screening – 1080 g
1% Complex Salt Mix:

NaCl (sodium chloride) – 170.37 g
CaCl2  2H20 (calcium chloride dihydrate)
Note 1
– 25.07 g (18.93 g – anhydrous)
Note 1: It is permissible to use hydrated salts.
NaHCO3 (sodium bicarbonate) – 14.2 g (baking soda is also suitable and can be purchased at a grocery
store).
Mixing Instructions:
Add 18.9 L (5 gal) of the 1% complex salt solution to the premix bag of solid ingredients (or if you do not have
pre-mixed bags, weigh out the materials, put them in a container able to hold at least 22.7 L (6 gal) and then
add the water). Thoroughly mix liquid and solids together with moderate agitation. If spraying the solution,
immediately after agitation or during agitation, siphon solution from the top half of the mix for use in spraying
on test samples. An alternative method would be to build an automatic spray system incorporating a pumping
device that either prescreened the coarse solids or drew liquid from the top half of the solution. In the case of a
test where a part is to be submerged in the solution and then cycled/stroked, make sure that the part stays in
rds
the top 2/3 of the solution to avoid ingestion or damage due to large particles that fall out of solution and
reside in the bottom of the mix.
Note: Be sure to pour/douse the grit solution on all areas of the part that would potentially experience splash in
the field. Depending on number of samples, level of contamination, and exposure of test, it may be appropriate
to collect and reuse grit solution. A fresh batch of grit solution should be made at minimum once a month for
the duration of the test.
Note 1
Table D1: Grit Trough Constituent Supplier Information
Constituent Supplier Address Phone/Contact
Cinders Snow’s Nursery 5485 W. Dunbar Road, (734) 242-5126
Monroe, MI 48161
Fire clay – 20 Mesh Harbison Walker 28777 Goddard Road, (734) 955-6025
DMFC sacked Romulus, MI 48174
Sand – unwashed play Local Hardware Milford Proving Ground – (248) 431-9789
sand or 2NS Corrosion Engineering
Ottawa Lakes Screening Stoneco Michigan 15203 S. Telegraph (734) 241-8966
Road, Monroe, MI 48161
Note 1: For bulk supply use suppliers defined. Smaller quantities may be purchased from ACT Test Panels, Auto Technology Company,
and National Exposure Testing (refer to Appendix A for contact information).
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Appendix E
Poultice Specification
Solid Contaminants: Fire Clay – 22.5% by weight

Sand – 72.5% by weight
Calcium Chloride – 5% of the combined Fire Clay and Sand weight
Mixing Instructions:
Combine fire clay and sand. Add 5% Calcium Chloride to the combined weight of the fire clay and sand. Next,
distilled or deionized water per ASTM D1193 Type IV is added to the solid ingredients in small amounts until
desired poultice consistency. Poultice is to be packed (approximately 6.35 mm (¼ in) thick) on test specimens.
Example: (100 g batch)

Mix 22.5 g of fire clay and 72.5 g of sand. Add 5 g of Calcium Chloride to the fire clay and sand mixture.
Thoroughly mix solid constituents together. Add small amounts of water at a time while thoroughly mixing liquid
and solid constituents until it creates a thick and moist poultice consistency. Apply poultice to test specimen
packing the poultice to approximately 6.35 mm (¼ in) thick.
Note: For bulk supply use suppliers defined in Table D1. Smaller quantities may be purchased from ACT Test
Panels, Auto Technology Company, and National Exposure Testing (refer to Appendix A for contact
information).
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Appendix F
Table F1: Exhaust Condensate Specification (Reference SAE 2001-01-0640)
Amount per 113.56 L

Number Ingredients Level (Weight Percent)
(30 gal)
1 Activated Carbon 0.5% 5715.2 g
2 Ammonia (as Ammonium Hydroxide, 29.7%) 0.25% 959.0 g
3 Sulfate (as Ammonium Sulfate) 0.125% 195.2 g
4 Acetate (as Ammonium Acetate) 0.04% 59.3 g
5 Sulfite (as Ammonium Sulfite) 0.025% 47.5 g
6 Formaldehyde (37%) 0.025% 76.7 g

Note 1
7 Nitrate (as Ammonium Nitrate) 0.012% 17.6 g
8 Formic Acid (88%) 0.01% 13.2 g
9 Chloride (as Ammonium Chloride) 0.005% 8.5 g
10 Water Balance
Note: Total for nitrite and nitrate.
Procedure:
Dissolve each of ingredients number 2 through number 9 in distilled water and add while stirring one by one to
the prepared container. Add rest of water and number 1 (activated carbon). Mix thoroughly. Keep in tightly
closed container.
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Appendix G
Figure G1: GMW14872 Underbody (UB) Mass Loss Target Chart for Method 1/2
Figure G2: GMW14872 Underbody (UB) Mass Loss Target Chart for Method 3
Note: An electronic copy for both corrosion severities (i.e., Method 1/2 and Method 3) and all of the vehicle
component areas (i.e., underbody, underhood, exterior, secondary surface, and interior) can be obtained upon
request. Please contact GMNA Corrosion Engineering.
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Appendix H - Test Equipment Documentation Form (Page 1 of 2)
Project Number(s):
Start-of-Test (Date): End-of-Test (Date):
Description of any test interruptions (fill in table below):

Date Description of Test Interruption
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General Operation (Manual (5 days)/Automatic (5 or 7 days)):

Information
Average Temperature (Lab or Operating Environment) (Range) (°C):
Average Humidity (Lab or Operating Environment) (Range) (% RH):
Are coupons placed In the location as test samples within the chamber (Yes/No)?
Are samples and coupons rotated within the chamber during the exposure (Yes/No)?
If yes, frequency:
Chart or data (temperature and humidity) documenting at least 1 weekend (include
date(s))
Cabinet Identification (Name/Number):

Cabinet Manufacturer: Cabinet Model:
Cabinet Serial Number: Air Movement (high/moderate/low and units):
Cabinet Size: Cabinet Capacity:
Last Calibration (Date): Next Calibration (Due Date):
Average Temperature (Range) (°C):
Heating Process:
Ambient Cooling Process:
Stage
Average Humidity (Range) (% RH):
Typical Time (minutes) to Dry Between Sprays for Standard Test Sample (Paint Panel):
Duration Of Individual Salt Applications (s):
Time Between Individual Salt Applications (minutes):
Ramp Time For Humidity To Return To Specified Ambient Humidity Following Salt Spray (minutes):
Chart or data (temperature and humidity) documenting at least 1 cycle of this stage (include
date(s))

Appendix H - Test Equipment Documentation Form (Page 2 of 2)

Ramp Time (Ambient to Humidity Stage):

Heating Process:
Humidification Process:
Humidity date(s))
Stage Collection Rate (fill in table):
Collection Rate
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Sample Actual 2
(mL/h/80 cm Moisture Visible on
Cycle Number of Date of Collection
per 8 h Samples (Yes/No)
Period Cycles
exposure)

Cabinet Size: Cabinet Capacity:
Dry off Ramp Time (Humidity to Dry off Stage):
Stage
Heating Process:
Dehumidification Process:
date(s))

Appendix J - Test Solution Documentation Form
Water Type (refer to ASTM D1193):

Volume of Batch (L or gal):
Sodium Chloride (NaCl) (g):
Sodium Bicarbonate (NaHCO3) (g):
Calcium Chloride (CaCI2  X H2O) (g): X=
Test Solution Monitoring (fill in table for each test solution batch):
Initial Total
Date of Initial Date of Final Final Conductivity
Conductivity Number of
Initial Use pH Last Use pH (µS @ 25 °C)
(µS @ 25 °C) Test Cycles
Test
Solution
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Spray Pressure (units): Spray Flow (units):

Deviations Door Hinges, Hood Hinges, Fuel Filler Door

Hardware, Decklid Hinges (assume no
The following procedure deviations are based on
weatherseal protection), Door Detent (assume no
field knowledge combined with Engineering
weather seal protection), and Windshield Wiper
judgment to enhance the test’s ability to predict
System.
field performance. Prior to making additional
modifications or to assist in determining the
appropriateness of one of the following options, Test duration to evaluate functional corrosion is
please contact GMNA Corrosion Engineering. 70 cycles with a minimum mass loss of 9.4 g
Deviations are generally made during the ambient (applicable for test conditions that require 4 salt
stage to include additional test inputs such as dust sprays per cycle), 5.4 g (applicable for test
applications, grit sprays, poultice applications, conditions that require 1 salt spray per cycle), or
dynamic cycling, electrical cycling, thermal inputs, 4.0 g (applicable for test conditions that require
gravelometer, exhaust condensate spray, and acid 1 salt spray per 5 cycles).
rain spray.
The test inputs associated with deviations apply Option 2: Air Conditioning Compressor
only to the test parts. Mass loss coupons are test Addition.
monitoring devices and should not be exposed to Modifications to Ambient Stage:
additional inputs that deviate from the base test
cycle (refer to Table A1). One (1) salt spray every 5 cycles starting with the
st
1 cycle – compressor running.
If corrosion rate monitoring is required to cover
both the base test cycle and the deviation One (1) grit spray every 5 cycles starting with the
th
conditions, an additional set of coupons will be 5 cycle – compressor static (refer to Appendix D
required and should see the same test conditions for grit solution).
as the samples. Compressor run time of 1.5 h (cycling 12 s on and
3 s off).
Option 1: Dust Application and Fresh Water
Rinse Addition. Note: Coupons only receive the salt sprays
Modification to Ambient Stage: defined in Option 2. The grit application should
only be applied to the test parts.
Number of salt sprays per cycle as defined in
Table A1.
One (1) dust application every 5 cycles starting Test duration to evaluate functional corrosion is
st
with the 1 cycle (dust should be applied 70 cycles with a minimum mass loss of 4.0 g.
immediately following the last daily salt spray
application to test parts only) (refer to Appendix C Option 3: Key Cylinder Addition.
for dust specification). Modification to Ambient Stage:
One (1) fresh water rinse applied to test parts only One (1) hose salt spray per cycle (approximately
and allowed to dry prior to the salt application on 10 s application, ¾ to 1 in hose, 22.7 L (6 gal) per
days when dust is applied. minute supply).
One (1) dust application (both sides of test sample
st
A list of component examples for dust and fresh in fixture) every 5 cycles starting with the 1 cycle
water rinse addition is provided below: (dust should be applied immediately following the
 Side Door Latches. salt spray application) (refer to Appendix C for dust
specification).
 Hood Latches (assume no weatherseal
protection). One (1) fresh water rinse applied and allowed to
dry prior to the salt application on days when dust
 Door Cavity Hardware. is applied.
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Note: Coupons only receive the salt sprays Note: Coupons only receive the salt spray defined
defined in Table A1. The dust application and fresh in Option 3. The dust application and fresh water
water rinse should only be applied to the test parts. rinse should only be applied to the test parts.
Test duration to evaluate functional corrosion is
A list of component examples for dust addition is 70 cycles with a minimum mass loss of 5.4 g.
provided as follows:

Option 4: Thermal Soak Addition. 4.0 g (applicable for test conditions that require
Modification to Ambient Stage: 1 salt spray per 5 cycles).
Oven Soak (number of hours) followed by
25 ± 3 °C, 45 ± 10% RH (number of hours). Option 5: Exhaust Condensate Addition.
Modification to Ambient Stage:
Note: When thermal soak is 4 h in duration and Three (3) salt spray per cycle spaced 1.5 h apart
st nd
4 sprays per cycle are required, perform 1 and 2 (for test parts and 4 salt sprays for coupons).
salt spray prior to oven soak with remaining 2 salt One (1) exhaust condensate spray 1.5 h after last
sprays spaced 1 h apart. When thermal soak is 2 h salt spray (for test parts only; refer to Table F1
in duration and 4 sprays per cycles are required, Exhaust Condensate).
st
perform 1 salt spray prior to oven soak with
remaining 3 salt sprays spaced 1 h apart. When
thermal soak is used in conjunction with a test that A component example for exhaust condensate
specifies 1 salt spray per cycle or 1 salt spray per addition is provided below:
5 cycles, then that salt spray shall occur prior to  Rear Bumper and Exhaust Tip.
oven soak.
Note: Coupons should receive the salt sprays
A list of component examples for thermal soak defined in Table A1. The exhaust condensate
addition is provided below: should only be applied to the test parts.
 Transmission Oil Cooler Line: 121 ± 2 °C (2 h).
 Muffler and Tailpipe: 204 to 260 °C (4 h). Test duration to evaluate functional corrosion is
 Exhaust Manifold, Flex Coupling: 482 ± 2 °C 70 cycles with a minimum mass loss of 9.4 g.
(4 h).
Additional options can be customized to specific
Note: Coupons only receive the salt spray defined components or subsystems to increase the ability
in Table A1. The thermal soak should only be to conduct validation or development testing.
applied to the test parts. General guidelines defined in Table A1 may be
used as a building block for customizing a test.
Prior to making additional modifications or to assist
Test duration to evaluate functional corrosion is in determining the appropriateness of one of the
70 cycles with a minimum mass loss of 9.4 g options, please contact GMNA Corrosion
(applicable for test conditions that require 4 salt Engineering.
sprays per cycle), 5.4 g (applicable for test
conditions that require 1 salt spray per cycle), or
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WORLDWIDE Test Procedure

Cyclic Corrosion Laboratory Test

GMW15272 for specific Method and applicable

March 2010 Originating Department: North American Engineering Standards Page 1 of 22

Copyright General Motors Company

3 Resources 3.2.2.2 Wet-Bottom. The apparatus shall consist

funnel) to allow moisture to collect while minimizing

March 2010 Page 2 of 22

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shall be identified and recorded using the

© Copyright 2010 General Motors All Rights Reserved

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Issue Publication Description

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March 2010 Page 7 of 22

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Figure A2: Coupon Schematic

Nylon bolts and washers suitable are as

Figure A3: Coupon Hardware Illustration

© Copyright 2010 General Motors All Rights Reserved

March 2010 Page 9 of 22

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Figure A4: Coupon Bracket Assembly Illustration

ACT Test Panels

Auto Technology Company

National Exposure Testing

Table A2: Recommended Number of Coupons and Removal Frequency

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March 2010 Page 10 of 22

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© Copyright 2010 General Motors All Rights Reserved

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1% Complex Salt Mix:

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March 2010 Page 14 of 22

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Solid Contaminants: Fire Clay – 22.5% by weight

Example: (100 g batch)

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March 2010 Page 15 of 22

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Table F1: Exhaust Condensate Specification (Reference SAE 2001-01-0640)