Climatic Testing: Temperature, Humidity, and Thermal Cycling
Representative Infinita Engineering Visual explaining the four-step workflow for Climatic Testing Services.Climatic Testing
Climatic testing is an essential part of the product development process, helping manufacturers ensure their items meet the necessary standards and regulations. For businesses looking for reliable and accurate climatic testing services, there are a variety of solutions available.
There is an expansive scope of climatic testing capabilities. Altitude testing, fungus testing, humidity testing, immersion testing, ingress protection (IP) testing, salt-fog testing, solar radiation testing, temperature testing, thermal shock testing, and wind & rain testing are just a few to name. Customised test plans can also be accommodated, creating a test plan or adapting an existing one to suit the requirements. During testing, customers are kept updated with the progress, and engineering assistance is provided if necessary. Upon completion of the testing, a formal test report is provided promptly.
You will need top-of-the-line equipment, including walk-in environmental chambers, reach-in environmental chambers, thermal shock chambers, altitude chambers, salt fog chambers, a wind-driven rain machine, a drip pan, and all necessary IP coding equipment. Remaining up-to-date with the latest technologies is required for accurate climatic testing.
Climatic testing exposes materials, products, or packaging to controlled temperature and humidity conditions in an environmental chamber, simulating the extreme climates a product may encounter across manufacturing, storage, and distribution. Standards like ASTM D4332, IEC 60068, MIL-STD-810, and ISO 16750 provide the common language for simulating years of environmental exposure in a matter of days or weeks.
Common Test Standards
- ASTM D4332: conditioning containers, packages, or packaging components for testing — covers six standard temperature/humidity range scenarios, from deep freeze to desert-like heat
- IEC 60068: international baseline standard for electronic and electrical product environmental testing
- MIL-STD-810: defence and aerospace environmental test methods, including Method 507.6 for humidity and Method 521 for icing
- JESD22/IPC-9701: semiconductor and PCB reliability standards, often requiring highly accelerated stress testing (HAST)
Also Read – Common Uses of Temperature Humidity Bias (THB) Testing in Electronics
Test Procedure (ASTM D4332)
- Select the temperature and humidity conditions representative of the product’s expected distribution or storage environment (e.g., tropical, desert, deep freeze)
- Place the test unit in an environmental chamber capable of maintaining the selected condition uniformly
- Expose the unit to the controlled condition for a minimum of 72 hours, or as specified by the governing test plan
- Monitor and log chamber temperature and humidity throughout to confirm the target condition was maintained
- Remove and inspect the unit for changes in physical properties — warping, cracking, corrosion, mold growth, or dimensional creep
What Climatic Testing Reveals
Extreme heat can cause plastic packaging to “creep” — a slow deflection under sustained load that can destabilise a palletised load during transport. Cold exposure can embrittle plastics and adhesives, while high humidity promotes corrosion and mold growth in both packaging and product. Climatic conditioning is frequently performed before mechanical distribution testing (such as ASTM D4169 or ISTA protocols) specifically to ensure the subsequent mechanical test reflects a realistically aged, rather than pristine, condition.
Industry Specifications Referencing Climatic Testing
- ASTM D4332: conditioning standard for packaging and containers
- IEC 60068-2-38: combined temperature/humidity cyclic test (Test Z/AD)
- MIL-STD-810, Method 507.6: humidity test method
- ISO 16750: environmental conditions for automotive electrical/electronic equipment
Conclusion
Climatic testing’s value comes from sequencing — conditioning a sample to a realistic worst-case climate before running mechanical or distribution tests reveals failure modes that testing a fresh, unconditioned sample would completely miss.
What is temperature testing? Temperature testing exposes a sample to controlled high or low temperatures for a specified period. The sample may be tested while operating or in a non-operating condition. The purpose is to determine whether the product can maintain its structural, electrical, mechanical, or functional performance within the required temperature range.
What is humidity testing? Humidity testing exposes samples to controlled levels of moisture and temperature inside an environmental chamber. It is used to evaluate moisture absorption, corrosion, swelling, insulation breakdown, coating failure, adhesive degradation, and changes in dimensional stability. Conditions may be constant or varied during the test.
What is thermal cycling? Thermal cycling repeatedly exposes a sample to alternating high and low temperatures. The repeated expansion and contraction can create stress between materials with different thermal expansion rates. This method is commonly used to identify fatigue, delamination, cracking, solder-joint damage, seal failure, and connection problems.
What is the difference between thermal cycling and thermal shock? Thermal cycling usually involves controlled transitions between temperature extremes over a defined ramp rate. Thermal shock involves much faster temperature changes, often by transferring the sample between separate hot and cold chambers. Thermal shock generally creates more severe and immediate thermal stress.
What is a climatic test chamber? A climatic test chamber is an enclosed system that controls temperature, humidity, or both. Chambers may range from small benchtop units to large walk-in rooms. Sensors and control systems maintain the required conditions and record environmental data throughout the test.
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