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The Auto/Steel Partnership Corrosion Project Team has completed a perforation corrosion test program consisting of on-vehicle field exposures and various accelerated tests. Steel sheet products with eight combinations of metallic and organic coatings were tested, utilizing a simple crevice coupon design. On-vehicle exposures were conducted in St. John's and Detroit for up to seven years to establish a real-world performance standard. Identical test specimens were exposed to the various accelerated tests, and the results were compared to the real-world standard. This report documents the results of these tests, and compares the accelerated test results (including SAE J2334, GM9540P, Ford APGE, CCT-I, ASTM B117, South Florida Modified Volvo, and Kure Beach (25-meter) exposures) to the on-vehicle tests. The results are compared in terms of five criteria: extent of corrosion, rank order of material performance, degree of correlation, acceleration factor, and control of test environment.

A series of painted materials were exposed at nine atmospheric corrosion test sites around the world as part of the AISI/SAE cosmetic corrosion program. The object of the exposure program was to assess the impact of accelerated atmospheric weathering on the cosmetic corrosion performance of the AISI materials and to determine if the accelerated atmospheric environment ranked the performance of materials in the same order as on-vehicle field testing. Accelerated atmospheric weathering was added to the AISI/SAE test program to round out the testing program and provide another “environment” in which to assess cosmetic corrosion. Accelerated weathering is believed to represent the closest test methodology to simulate actual field testing, the environment in which the materials must perform.