Salt Spray Testing

Ensure corrosion resistance and regulatory compliance, while avoiding risk to your team and the environment. Element’s salt spray testing services help you get to market faster without compromising quality. By simulating high-saline environments, we provide accurate and reliable results that reflect real-world conditions, helping you maintain product integrity and performance.

What is salt spray testing at Element?

A salt spray test (also called salt fog testing) is a corrosion testing method that uses high-saline environments to measure the corrosion resistance of products, paints, and coatings over extended periods. This accelerated process applies a 5% NaCl (sodium chloride) solution to coated or painted equipment. At Element, we can adjust our salt spray testing for specific requirements to simulate different climates or working conditions. Samples are checked regularly to monitor corrosion levels, noting milestones such as white and red rust development or coating degradation. Our labs provide detailed test reports with before-and-after photographs, calibration data, time/date records, and Element's certifications.

Two Element testing experts in laboratory safety equipment ready for testing

What can Element offer you for salt fog testing?

Environments we can simulate

Elements' alternative salt spray testing can simulate a variety of corrosive environments to ensure the integrity of a product. Some of our capabilities include:

Neutral salt spray (NSS)

Acetic acid salt spray (ASS)

Copper-accelerated acetic acid salt spray (CASS)

Calcium chloride (CaCl₂)

Synthetic seawater testing

Hydrogen-induced cracking (HIC)

Custom cyclic corrosion testing

Components and materials we test

Element specializes in testing a wide range of materials, from automotive and aerospace coatings to industrial metals and electronics. Whether you're evaluating large assemblies or small fasteners, we ensure precise and relevant results tailored to your industry needs.

Methods and solutions offered

We provide customized testing conditions, including temperature, humidity, and salt concentration variations, meeting diverse standards like ASTM B117 and ISO 17025. You will also receive comprehensive test reports, including pictures and descriptions at each stage of testing, enhanced with detailed element analysis if required, facilitating informed decision-making.

Cutting-edge equipment we use

We use advanced chambers to replicate real-world environments, exposing samples to salt-laden mist, temperature, and humidity variations. For large or unusually shaped components, our largest chamber is 8’H x 8’W x 10’L, and can reach temperatures of up to 55°C.

Labs offering this service

With accredited labs around the world, we deliver timely results, ensuring that your projects stay on track regardless of geographical location.

Standards we test to and materials we test

These are our most prevalent requests. Don't see what you're looking for? Contact us!

American National Standards Institute

ANSI/SCTE 143SCTE

American Society for Testing and Materials

ASTM B117, ASTM B368, ASTM D1654, ASTM D1745, ASTM D2247, ASTM G85

General Motors

GM 4298, GM 9540

International Electrotechnical Commission

IEC 60068, IEC 60945, IEC 68-2-11

International Standards Organization

ISO 9227, ISO 12944, ISO 20340

Military Standards

DEF STAN 07-55, DEF STAN 00-35, MIL-STD-202, MIL-STD-810, MIL-A-8625, MIL-F-5541, MIL-DTL-5541, MIL-STD-1312, MIL-STD-883, RTCA DO-160

National Electrical Manufacturers Association

NEMA 250

Netherlands Normalisatie-Instituut

NEN 10068

Society of Automotive Engineers

SAE J1810, SAE J1211, SAE J2334

Telecordia

GR-487-CORE

Underwriters Laboratory

UL 2703, UL 50

Expert GMW 3172 Testing

Element offers tailored GMW 3172 testing to ensure your electronics perform in corrosive environments. We can support programs with virtually any condition listed in the standard, including environmental conditioning and functional tests. our experts can help you design a GMW 3172 test program that conforms to test requirements while meeting your product’s unique needs.

Your Challenges, Our Solutions

Meeting Tough Industry Standards

Element delivers precise salt spray testing aligned with ASTM B117 and ISO 17025 requirements, ensuring your products achieve full compliance and meet the toughest industry regulations without delays.

Preventing Corrosion Before It Happens

Our accelerated testing methods quickly identify corrosion risks, allowing you to refine your materials and designs to ensure long-term durability and performance in harsh environments.

Handling Large and Complex Components

Equipped with chambers up to 8’H x 8’W x 10’L, Element can accurately test oversized assemblies, intricate designs, and high-value components with unmatched precision and care.

Testing Across Diverse Materials

From metals to polymers, our expertise spans multiple materials, ensuring reliable corrosion insights no matter the composition of your components.

Why Choose Element

Element testing engineer in anechoic chamber for electromagnetic compatibility and wireless device testing

Global Accredited Labs

ISO 17025 and NADCAP accredited facilities worldwide.

Accurate and Reliable Testing

Minimal variability in test conditions for precise results.

Industry-Specific Expertise

Experience in automotive, military, marine, and aerospace testing.

Comprehensive Reporting

Detailed test reports with photographs, calibration data, and certification records.

100+
Years

of testing excellence

55°C
Chamber Capacity

for accurate high-temperature corrosion testing

ISO 17025
& NADCAP accredited labs

5
Regions supported

for local coverage with global reach

Element engineer monitoring SAR equipment during technology testing

But don't just take our word for it

See what others have to say about partnering with Element

The customer service is great. Expediting is available for rush jobs. Turnaround time always meets the lead time we are quoted.
Jack K,
Fastener Dimensions, Inc.
Excellent Service and Turn Around Time.
Justin,
Gilco Spring of Florida
Element was very fast to answer any questions I had, they made sure I understood all of the processing information and kept in close contact with me the entire time. I would highly recommend anyone using this facility!
Tabitha Keener,
Production Paint Finishers, Inc.
Outstanding customer service and support from the entire Element Materials team for our customer-requested salt spray process validation testing. Specifically, we are impressed with the rapid turnaround time for our requests and the clarity and accuracy of the test analysis reports. Your team's responsiveness and attention to detail truly set you apart from other laboratory testing services we've worked with in the past. We consider Element Materials "best in class" and look forward to continuing our business partnership. Thank you.
Bill Gross,
Manager Quality Assurance, Jackson Tumble Finish

Frequently asked questions

What is the difference between salt spray and salt fog testing?

From a testing standpoint, salt fog testing and salt spray testing are the exact same test, with names often used interchangeably. These tests are often referred to by these different names because the levels of salt being applied vary accordingly to the specific environmental conditions needed to be replicated.

What are the outcomes of ASTM B117 testing?

The test provides visual inspection results on corrosion resistance, coating adhesion (combined with ASTM D3359), and corrosion development from scratches (combined with ASTM D1654). Note: correlating results to real-world conditions is challenging.

When is it not recommended to use ASTM B117?

It is not recommended for products with decorative chromium plating, zinc die castings, or cadmium plating on steel. For these, consider ASTM B368 or Practice G85 instead.

What are the testing conditions for ASTM B117?

The test is performed in chambers with a temperature of 35°C (+/- 2°C), neutral pH (6.5–7.2), and a salt concentration of 5% sodium chloride. Exposures are typically 96, 240, or 600 hours.