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Since 2000, an Aluminum Cosmetic Corrosion task group within the SAE Automotive Corrosion and Protection (ACAP) Committee has existed. The task group has pursued the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. A cooperative program uniting OEM, supplier, and consultants has been created and has been supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Prior to this committee's formation, numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels. However, correlations between these laboratory test results and in-service performance have not been established. Thus, the primary objective of this task group's project was to identify an accelerated laboratory test method that correlates well with in-service performance.

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.