Klass.-Nr.

50 21 1 September 2004
Body and Add-on Parts
Corrosion Test
PV
1210
Konzernnorm
Descriptors: corrosion, body, add-on part


Page
Fachverantwortung/Responsibility Normung/Standards (EZTD, 1733)
K-QS-32/2 Frau Dr. Hasse Tel: -42106 Laudien Dr. Eisenberg Wiesner Tel: +49-5361-9-29064 Sobanski


Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the responsible procurement department.
VOLKSWAGEN AG
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Changes
The following changes have been made as compared to Test Specification PV 1210, 2001-05:
Referenced standards updated
Previous issues
1981-08; 2001-05
1 Scope
This Test Specification is used for corrosion testing in sample and standard-production tests
conducted on completely painted bodies, body panels, assemblies and components with differing
anti-corrosion coatings.
It serves to monitor and evaluate corrosion behavior or corrosion protection measures of these
parts when exposed to static load.
2 Designation
Corrosion resistance according to PV 1210
3 Test method
3.1 Principle
The test is an alternating cycle consisting of a combination of various climatic and/or corrosion
loads.
A test cycle consists of
4 h salt spray fog test according to DIN 50021-SS,
4 h aging in the DIN 5001423/50-2 standard climate (including cooling-off phase),
16 hours humid aging at elevated temperature, climate according to DIN 50017- KK
(40 3) C; 100% humidity.
After 5 cycles, a 2-day rest phase takes place in the DIN 5001423/50-2 standard climate.
Using this test method, corrosion behavior under static load resulting from salt, humidity and
temperature is evaluated.
Under these defined corrosion conditions, different anti-corrosion coatings can be comparatively
assessed.
A correlation with the corrosion mechanism in actual driving operation is not necessarily possible,
as the types of vehicle damage and corrosion curves are complex and are not completely covered
and reflected by the changing corrosion load.
A short interruption of the test for inspection purposes and/or the removal of test specimens is
permitted. Interrupting the test by changing the test program is not permitted.
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PV 1210: 2004-09

3.2 Test fixtures
Assemblies, components and test panels can also be tested in suitable single or alternate devices.
The devices must comply with the specifications in DIN 50014, DIN 50017 and DIN 50021.
3.3 Body test
Testing is performed according to Section 3.1. Examples are given in Section 3.6.
In order to carry out a specific evaluation of cavities, the body can be turned.
Before being initially brought into the salt spray test chamber, the body, mounted on the pivoting
frame, is preconditioned in the DIN 5001423/50-2 standard climate, and is then moved into the
test chamber kept at a constant temperature.
3.3.1 Salt spray phase
During the test sequence with rotation, before each salt spray cycle, the body is turned about its
lengthwise axis so that it is positioned as in the following sequence: 0, 45, 135, 225and 315.
3.3.2 Standard climate aging / humid aging at elevated temperature
During the cooling-off phase and during humid aging at elevated temperature, the body is
positioned horizontally.
3.3.3 Repeating the test cycles
After humid aging at elevated temperature is completed according to Section 3.1, the body is
immediately placed in the salt spray test chamber and turned 90in a clockwise direction to 45,
135, 225or 315, according to the respective test cycle.
3.3.4 Weekend aging
The rest phase entails aging in the DIN 5001423/50-2 standard climate, with the body in
a horizontal position and placed either in a suitable garage/hall or in the test chamber.
3.4 Component test
The required minimum for complete testing is 5 parts.
The components or their sections are tested in accordance with DIN EN ISO 7253 (see Section 4).
Cavities must be exposed to the salt spray fog by cutting/opening of parts. If necessary,
unprotected trim edges must be covered before testing.
3.5 Evaluation
After 15, 30, 60 and 90 cycles, the specimens are evaluated with regard to
Type of corrosion (coating and/or base metal corrosion),
Form of corrosion (surface or edge corrosion),
Time of appearance and development of corrosion,
as well as with regard to additional changes in the anti-corrosion coating such as loss of adhesion
or blistering.
Organic coatings can be evaluated according to DIN EN ISO 4628-1, Table 3.
Page 3
PV 1210: 2004-09

Signs of rust creep on painted sheets can be examined using a non-destructive thermographic
method for quantitative evaluation of the development and spread of defects.
The test is concluded when corrosion grade Ri5 according to DIN EN ISO 4628-3 or corrosion
perforations occur.
The following must be stated in the test report:
Parts examined : e.g., painted sheets
Corrosion protection measures: e.g., paint finish (coating thickness: 96 m, measured
in the sheet center)
Test: Start/end
Evaluation:
Start of base metal corrosion: e.g., after 15 cycles: surface corrosion Ri 2
Blistering: e.g., after 18 cycles: blistering grade 2 (S4)
Adhesion loss: e.g., D = 3 mm
End of test. e.g., after 30 cycles
Notes / remarks
3.6 Examples for week cycle
3.6.1 Example 1
In manufacturing operations from 5:30 a.m. to 10:30 p.m., for one salt spray test chamber and
four chambers for humid aging at elevated temperature (Table 1), change-over times
max. 2 15 minutes per test cycle, throughput eight passenger car bodies.
Table 1
Bodies Salt spray fog test Cooling-off phase Humid aging at
elevated temperature
Weekend aging
A/B 6:00 a.m.-
10:00 a.m., Mo-Fr
10:15 a.m.-
2:15 p.m., Mo-Fr
2:30 p.m.-
5:45 a.m., Mo-Sa
6:00 a.m.-
5:45 a.m., Sa-Mo
C/D 10:00 a.m.-
2:00 p.m., Mo-Fr
2:15 p.m.-
6:15 p.m., Mo-Fr
6:30 p.m.-
9:45 a.m., Mo-Sa
10:00 a.m.-
9:45 a.m., Sa-Mo
E/F 2:00 p.m.-
6:00 p.m., Mo-Fr
6:15 p.m.-
10:15 p.m., Mo-Fr
10:30 p.m.-
1:45 p.m., Mo-Sa
2:00 p.m.-
1:45 p.m., Sa-Mo
G/H 6:00 p.m.-
10:00 p.m., Mo-Fr
10:15 p.m.-
2:15 a.m., Mo-Fr
2:30 a.m.-
5:45 p.m., Mo-Sa
6:00 p.m.-
5:45 p.m., Sa-Mo

Page 4
PV 1210: 2004-09

3.6.2 Example 2
In normal shift, for one salt spray test chamber and two chambers for humid aging at elevated
temperature, throughput: four passenger-car bodies (Table 2)
Table 2
Bodies Salt spray fog test Cooling-off phase Humid aging at
elevated temperature
Weekend aging
A/B 8:00 a.m.-
12:00 p.m., Mo-Fr
12:15 p.m.-
4:15 p.m., Mo-Fr
4:30 p.m.-
7:45 a.m., Mo-Sa
8:00 a.m.-
7:45 a.m., Sa-Mo
C/D 12:30 p.m.-
4:30 p.m., Mo-Fr
4:30 p.m.-
8:30 p.m., Mo-Fr
8:30 p.m.-
11:45 a.m., Mo-Sa
12:00 p.m.-
11:45 a.m., Sa-Mo

4 Note on testing
4.1 Salt spray fog test
The coated bodies, body panels, components and assemblies must be scribed through to the
metallic base material.
5 Referenced standards
*)

DIN 50014 Climates and Their Technical Application, Standard Climates
DIN 50017 Atmospheres and their Technical Application; Condensation Water Test
Atmospheres
DIN 50021 Spray Tests with Different Sodium Chloride Solutions
DIN EN ISO 4628-1 Paints and Varnishes Evaluation of Degradation of Coatings
Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance; Part 1: General Introduction and Designation
System
DIN EN ISO 4628-3 Paints and Varnishes Evaluation of Degradation of Coatings
Designation of Quantity and Size of Defects, and of Intensity of Uniform
Changes in Appearance; Part 3: Assessment of Degree of Rusting
DIN EN ISO 7253 Paints and Varnishes Determination of Resistance to Neutral Salt
Spray (Fog)

*)
In this section, terminological inconsistencies may occur as the original titles are used.