Vehicle Accelerated Corrosion Testing

At a glance

Millbrook conducts accelerated corrosion testing to evaluate cosmetic corrosion performance of whole vehicles and subsystems. Anti-corrosion processes associated with painting, sealing and assembly can be validated in a timely and cost-effective manner.

Vehicle on special surfaces at Millbrook for accelerated corrosion test
Vehicle in salt trough for corrosion inspection at Millbrook

Corrosion performance can be a pivotal factor in determining vehicle life, and forms the foundation of a corrosion warranty offered by manufacturers. Millbrook tests the corrosion resistance of the chassis, body and individual components for manufacturers and suppliers to identify issues early and to reduce warranty costs.

Vehicle on special surfaces at Millbrook for accelerated corrosion test

Whole-Vehicle Corrosion Testing

Millbrook’s dedicated accelerated corrosion testing method has been established for many years and includes “real-life” testing, followed by a corrosion inspection. This involves accelerated corrosion testing for whole vehicles and focuses on corrosion elements. One corrosion year can be compressed into two weeks of testing, before a corrosion inspection.

Corrosion and General Durability Testing

Accelerated corrosion tests can be conducted in conjunction with general vehicle durability testing on the test track.  A Millbrook accelerated general durability test covers moderate to high-severity vehicle usage. This test is inclusive of whole-vehicle corrosion inputs and allows two tests to be conducted on one vehicle in parallel.

Customizable Targets and Tests

Millbrook’s whole-vehicle accelerated corrosion tests can be set up to represent between one and fifteen years of real-world use. They can be tailored to suit relevant vehicle sales regions, which vary from low to severe global corrosion environments. Cosmetic corrosion targets can be tailored to individual customer requirements and to suit a particular target market. 

Corrosion Inspection

Corrosion inspection includes the assessment of paint systems, undercutting resistance and paint adhesion. Vehicles are inspected at the end of each corrosion “year”. Photographic evidence is taken and test reports are issued for all components and areas which do not meet specified targets. Upon completion, full test reports are issued to customers detailing cosmetic, functional and serviceability concerns.

Whole vehicle corrosion tests can be followed up with component-level teardowns. These include the removal of all mechanical and trim components including a visual corrosion inspection of each component. Component teardowns are highly recommended after whole vehicle corrosion tests to highlight any concerns.

Body-in-white teardowns include the complete separation of all body panels to expose the internal surfaces of all body panels. This approach can be used to expose hidden corrosion and body panel sealant issues.