16-Oct-2025
Presto Instruments
Corrosion Testing is a valuable technique to analyze the reliability and lifespan of materials used in industries from aerospace to automotive and construction to manufacturing sectors. From several alternatives available, one of the most commonly used equipment for corrosion testing is the Salt Spray Chamber (also known as a salt fog chamber).
Salt spray chambers are used to mimic natural corrosive environments in a controlled and accelerated system. It determines corrosion performance, enhances product quality and meets international specifications. It would be worth it for businesses interested in enhancing the durability and quality of their products to understand how a salt spray chamber operates, the advantages, and overall features.
The Salt Spray Chamber simulates corrosive environments to test the performance of coating materials or surface finishes. It is done by exposing to saline conditions under accelerated exposure for a specific duration. The automotive, aerospace and marine sectors depend on them to evaluate the quality of components, coatings and finishes in line with standard practices such as ASTM B117.
A salt spray chamber works on the principle of accelerating the corrosion process and operates as a simulated environment to mimic the real world. It generates a fine, consistent condensation of a salt solution (usually sodium chloride) in a controlled exposure environment and places test specimens into it for a predictable amount of time.
Sample preparation and cleaning, preparation of 5% NaCl solution, chamber burning and a horizontal plan view of the samples at 15-30° are the typical steps to be followed to conduct the test. Here is a full description of this process:
The samples are carefully cleaned of dirt, oil, or contamination to remove any impurities prior to commencing the salt spray test. This will serve the purpose of allowing the samples to be positioned on racks or holders at an angle and to ensure that every specimen is exposed to similar conditions when the salt mist is sprayed.
A standardized salt solution is made by dissolving pure sodium chloride (NaCl) in deionized water at a concentration of typically 5%. The solution should have a pH in the specified range of 6.5 to 7.2, depending on acceptance testing standards, typically in compliance with ASTM B117 or other applicable international standards.
The Samples that are made are located inside the salt spray chamber. The salt solution is prepared inside the chamber. The various system components, such as the atomizer and the heating controls, are adjusted and assembled. The chamber is preheated to the required temperature for the test cycle, and generally, this is around 35°C.
As soon as the chamber is made, the necessary temperature and moisture conditions are needed. The atomizer will spray a fine salt mist on a continuous basis. This promotes a corrosive environment, which will accelerate the natural rust process. The test will be conducted for a certain amount of time; this may take place over a few hours or a few days.
Parameters such as temperature, pH of the salt solution, air pressure and spray quality are constantly monitored. This minimizes variations within the chamber. Monitoring from time to time ensures that it is in line with standards and prevents deviation capable of influencing the validity of the results.
At the end of the specified test duration, the chamber is turned off, and the samples are moved carefully. The samples are moved gently to remove any salt deposits, then evaluated. Any corrosion, rust spots, blistering or coating failures will be documented and compared with the acceptance criteria in order to assess performance.
Salt Spray chambers are built using corrosion-resistant, usually non-metallic materials and sealed chambers to mimic an extreme salt-laden environment. Here are the key features of salt spray chambers described below:
Salt Spray Chambers simulate a hostile and corrosive environment based on cascading a fine mist of salt solution. This functional feature enables manufacturers to develop natural corrosion and evaluate materials, coatings, and surface finishes. This is a vital feature for estimating product lifespan and enhancing product quality expectations for all industries.
In corrosion tests, it is important to have a stable temperature – commonly around 35 °C. Salt spray chambers have accurate heaters and controllers that keep the conditions the same for the entire duration of the test. The consistent temperature leads to precise, repeatable results and conforms to international standards, ASTM B117 (in the U.S.) or ISO 9227 (in the rest of the world).
The sophisticated atomizers and nozzles in the chamber produce a fine mist that is evenly distributed across all surfaces of the sample. Because the fog is uniform, there is no danger of uneven corrosion and the results will be uniform and trustworthy. Even exposure is crucial for comparisons of multiple samples or when testing the performance of protective coatings under identical test conditions.
Today’s salt spray chambers incorporate an intuitive (control panel)/touch screen that enables the user to quickly input parameters such as temperature, fog collection rate, and test time. The technology of these interfaces makes operation simpler for the user, reduces potential for human error, and allows the operator to spend less time focused on complex machinery adjustments, learning and ultimately enhancing operator productivity in laboratories and industry.
Salt spray chambers are designed with safety devices to promote user and equipment protection, including over-temperature protection, automatic shut-off, and low-water level alarms. Such safety features ensure safe and reliable operation, as well as a proper test result, all while reducing downtime associated with maintenance, forming processes that are safe, lean, and compliant with industry safety standards.
Here are the relevant Salt Spray Chamber Standards described under various environmental conditions.
For high-quality salt spray chambers, Presto Instruments is the top choice because it provides accurate and reliable corrosion tests that simulate harsh environments for materials and products.
Presto Instruments has years of experience, a client base all over the world and a quick customer support team that is committed to their customers, making their chambers a trusted option in all industries.
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