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Salt spray, salt mist and cyclic corrosion testing

Corrosion and Salt Spray Testing

Controlled corrosion exposure for materials, coatings and components used in marine, coastal, offshore, road-salt and humid environments.

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Resonate Testing supports teams that need comparative corrosion evidence, customer approval support, product release data or design-stage confidence. Testing is carried out against ASTM B117, ISO 9227, MIL-STD-810, RTCA DO-160 and DEF STAN 00-35 requirements and provides factual evidence under controlled conditions; it is not product certification.

What is corrosion and salt spray testing?

Salt Spray or Salt Fog Testing is an accelerated corrosion test method that primarily uses an atomised 5% saline solution to evaluate the corrosion resistance of metals, coatings and surface treatments.

During the test, samples are placed in a controlled chamber where they are continuously exposed to a fine mist of saline solution at a constant temperature. This testing accelerates the corrosion process, allowing the performance of materials and coatings to be assessed in a significantly shorter time that natural outdoor exposure.

  • Salt Spray / Salt Fog: Controlled exposure to a salt-laden atmosphere, commonly used for comparative coating and material assessment.
  • Neutral salt spray: Typically associated with 5% sodium chloride solution and pH control where required by the applicable method.
  • Cyclic salt mist: Exposure routes that may include repeated salt mist and conditioning stages when the specification requires it, subject to technical review.
  • Customer-specific methods: Requirements can be reviewed against OEM, defence, aerospace, marine or product-release specifications.
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Corrosion and Salt Spray Testing in the UK & Ireland

Resonate Testing supports teams that need comparative corrosion evidence, customer approval support, product release data or design-stage confidence. Testing is carried out against ASTM B117, ISO 9227, MIL-STD-810, RTCA DO-160 and DEF STAN 00-35 requirements and provides factual evidence under controlled conditions; it is not product certification.

Ready to plan your testing campaign? Send your requirement, specification, drawings or test profile for engineer review and receive guidance on chamber fit, instrumentation, and programme readiness.

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Not sure if you need Corrosion and Salt Spray Testing?

  • Comparing the performance of coatings, materials or surface treatments.
  • Supporting customer approval, product release or design freeze.
  • Assessing products exposed to marine, coastal, offshore, road-salt or humid conditions.
  • Responding to a customer specification that references corrosion or salt spray standards.
  • Investigating effects on fit, function, appearance, safety or acceptance criteria.

Environmental Testing

Corrosion & Salt Spray FAQs

Corrosion and Salt Spray Standards

Corrosion requirements vary by sector, product and customer specification. Resonate Testing can review the requested method, sample size, exposure duration, acceptance criteria and reporting needs before confirming suitability.

Reference Standards:

ASTM B117

ISO 9227

IEC 60068-2-11

MIL-STD-810 Method 50

Standard / Guidance Primary Focus Typical Relevance to Testing
ASTM B117 Salt spray (fog) corrosion testing Commonly specified for evaluating corrosion resistance of metals, coatings, finishes and surface treatments.
ISO 9227 Corrosion tests in artificial atmospheres - salt spray Widely used for NSS, AASS and CASS testing of metallic materials, coatings and surface treatments.
IEC 60068-2-11 Environmental salt mist testing Relevant to electrical/electronic components and equipment requiring assessment under salt-laden atmospheric conditions.
ASTM G85 Annex A1 Modified salt spray / acetic acid salt spray Used where a more specific or accelerated corrosive environment is re required beyond conventional neutral salt spray.
RTCA DO-160 Section 14 Salt fog testing for airborne equipment Relevant to aerospace/avionics equipment that may experience salt-laden atmospheric exposure.
MIL-STD-810 Method 509 Salt fog environmental testing Used for defence and ruggedised equipment to assess the effects of salt deposits and corrosive atmospheres.
DEF STAN 00-35 Method CN2 Climatic / environmental corrosion testing Relevant to UK defence equipment and material where salt-laden or corrosive environmental exposure is specified.
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What we send before we quote

The more complete the requirement, the faster the technical review. Share the documents and sample details that define the exposure and acceptance criteria.

  • Test standard, customer specification or OEM method.
  • Sample description, dimensions, mass, quantity and photographs.
  • Material, coating, surface finish or treatment details.
  • Required exposure duration, cycles or sequence.
  • Acceptance criteria, inspection points and reporting expectations.
  • Any hazards, cleaning requirements, handling constraints or post-test checks.

What you receive after testing

Outputs are agreed before work begins so the report aligns with the customer, quality or programme requirement.

  • Specimen identification and agreed test method.
  • Test conditions, exposure details and recorded checks.
  • Observations, photographs where agreed and any deviations.
  • Factual results against the defined method and acceptance criteria.
  • Supporting data pack or report format agreed at quotation.

Pass/fail statements should only be used where the acceptance criteria are defined before testing.

Not sure which corrosion route applies?

Many projects start with a customer requirement, an unclear standard reference or a sample that needs suitability review. An early engineering discussion can help confirm whether the requested exposure, chamber setup, sample preparation and reporting route are practical.

  • Coating, plating and material comparison.
  • Product release and customer approval support.
  • Marine, coastal, offshore, automotive and transport exposure concerns.
  • Environmental sequence planning with humidity, rain, vibration or functional checks.

Corrosion and Salt Spray Testing FAQs

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Send your corrosion testing requirement for engineer review

Share your standard, sample details, drawings, photographs, exposure duration and acceptance criteria. Resonate Testing can review the requirement and advise on the most practical route for salt spray, salt mist or corrosion exposure testing.

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