ASTM B117 Salt Spray Test Complete Guide – Procedure & Applications
The salt spray test (ASTM B117) is one of the most widely required corrosion tests in manufacturing and coating qualification. It works by continuously exposing a sample to a fine 5% NaCl salt fog at 35°C inside a sealed chamber — simulating years of marine or industrial corrosion exposure in days or weeks. The test is used across automotive, aerospace, hardware, and coatings industries to compare coating systems, qualify surface treatments, and meet customer or regulatory corrosion performance requirements. Infinita Lab provides ASTM B117 testing with durations from 24 hours to 1000+ hours, with full test reports and visual inspection results.
TRUSTED BY
- Overview
- Scope, Applications, and Benefits
- Test Process
- Specifications
- Instrumentation
- Results and Deliverables
ASTM B117 Salt Spray Testing Overview
ASTM B117 is a widely used standard practice for evaluating the corrosion resistance of materials and surface coatings by exposing them to a controlled salt spray (fog) environment. The test simulates aggressive corrosive conditions such as marine or coastal atmospheres to assess material durability.
The method involves continuous exposure of specimens to a fine mist of salt solution under controlled temperature and pH conditions. It is primarily used for comparative analysis of coatings and materials rather than predicting exact real-world performance, making it an essential tool in quality control and material development.
Scope, Applications, and Benefits
Scope
Salt spray testing evaluates:
- Corrosion resistance of metals and coatings
- Protective coating performance
- Surface degradation and rust formation
- Comparative durability under saline conditions
- Material behavior in accelerated corrosive environments
Applications
- Automotive components and coatings
- Aerospace and marine materials
- Paints, plating, and surface treatments
- Fasteners, hardware, and metal parts
- Industrial and construction materials
Benefits
- Accelerated corrosion simulation
- Enables comparative material evaluation
- Supports coating and material development
- Identifies defects in protective finishes
- Improves product durability and reliability
ASTM B117 Salt Spray Test Process
Sample Preparation
Specimens are cleaned and mounted in the salt spray chamber.
1Salt Solution Preparation
A 5% NaCl solution is prepared using distilled water with pH maintained between 6.5–7.2.
2Exposure
Samples are exposed to continuous salt fog at ~35°C in a controlled chamber.
3Data Analysis
Samples are exposed to continuous salt fog at ~35°C in a controlled chamber.
4ASTM B117 Salt Spray Technical Specifications
| Parameter | Details |
|---|---|
| Test Principle | Continuous salt spray (fog) corrosion exposure |
| Solution | 5% NaCl in deionized water |
| pH Range | 6.5 – 7.2 (neutral salt spray) |
| Temperature | ~35°C ±2°C |
| Spray Rate | ~1.0–2.0 ml/80 cm²/hour |
| Test Duration | 24 hours to 1000+ hours (application dependent) |
| Measured Outputs | Corrosion rate, rust formation, coating degradation |
Instrumentation Used for Testing
- Salt spray chamber (fog cabinet)
- Atomizing nozzles and air supply system
- Solution reservoir (NaCl solution)
- Temperature and humidity control system
- Specimen racks and holders
- Data recording and monitoring system
Results and Deliverables
- Corrosion resistance performance data
- Time-to-corrosion or rust formation
- Coating degradation and failure analysis
- Comparative evaluation across samples
- Visual inspection and test report
Frequently Asked Questions
Salt spray tests are used to determine whether or not to what extent materials, coatings, and surface treatments used withstand corrosion in a reasonably realistic marine environment swollen with salt. It shows how far a given material would rust in a condition with seawater around – marine or coastal applications.
A 5% sodium chloride (NaCl) solution is usually used, replicating the condition to which a coated surface is corroded in salt-laden water. The solution is then converted into a whirling mist inside the walls of a test facility to enhance the corrosion process.
The test procedure may last 24 hours to a few weeks, depending on the provided test material and particular standards. The test includes all the certain real-world cycles of exposure to the salt, with the drying-up periods designed to 'wet up' and 'dry up' the salt alternately.
After the test is completed, the specimens are carefully checked for different forms of corrosion, such as rust, pitting, or even surface destruction. The corrosion results are then evaluated against the known standards regarding the performance of the material in question.
Industries such as automotive, aerospace, marine, construction, and coatings manufacturing use ASTM B117 testing to evaluate corrosion resistance and ensure durability of materials in harsh environments.
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