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Wire Harness Connector Salt Spray Test According To The Standard

The necessity of salt spray test for wiring harness connectors. Whether it is for wiring harness accessories, such as connectors, terminals, clips, or wiring harness assemblies, the DV test cannot bypass the salt spray test. When a car or truck is walking, the location of the wiring harness connectors can come into contact with water splashing on the tires, especially after snow in northern winters, where salt is used to speed up the melting of snow on the road. These connectors usually require a salt spray test to verify their corrosion resistance.

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The standard of wiring harness salt spray test verification is to check the reliability of the contact resistance, not to check the appearance. These connectors are often used with seals to improve salt spray resistance.
Wire harness connector salt spray test according to the standard.

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IEC 60068-2-11:1981 “Environmental testing of electrical and electronic products – Part 2: Test method test Ka: Salt spray test method”

GB/T 2423.17-2008 “Environmental testing of electrical and electronic products – Part 2: Test method test Ka: Salt spray test method”

IEC 60068-2-52:2017 “Environmental Testing Part 2: Test Methods Test Kb: Salt Spray, Alternating (Sodium Chloride) Solution”

GB/T 2423.18-2012 “Environmental Test Part 2: Test Method Test Kb: Salt Spray, Alternating (Sodium Chloride) Solution”

Which connectors need to be salt spray tested? Salt spray environments are mainly used in military, special vehicles and marine applications. Generally, the salt spray test is carried out in a salt spray test chamber with a 5% salt solution, and its exposure time is 48-96 hours.

Salt spray is highly corrosive to many materials and has been shown to cause the failure of many connector plating systems, including precious and non-precious metal coatings. If tested with salt spray, connectors that were originally suitable for the application environment will fail during the test. The purpose of a salt spray test is to evaluate the performance of a product, not to damage it. Salt spray test for connectors suitable for marine environments. The attributes of the salt spray test are mostly appearance inspection, weight inspection and resistance measurement.

Which products do not need to do salt spray test?

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For protected areas of vehicles (eg cabins), salt spray testing in such environments is not required. In these applications, for the application of precious metal coatings, common failure mechanisms are porosity corrosion and corrosion creep, which are evaluated by MFG (mixed gas flow of HCl, SO2, H2S, etc.) testing. For the contact interface of non-precious metal coatings, the main failure mechanism is fretting corrosion, which is evaluated by vibration and high frequency temperature and humidity cycling tests.

Salt spray test for tinned products of connector terminals.

Many companies use salt spray to inspect incoming tin-plated products of connector terminals and monitor their appearance.

The connectors tested may not be exposed to salt or marine environments at all when used, and these products are likely to be installed in a protected environment where the use of salt spray testing does not show conformance to the actual application.

There is an oxide film on the surface of the tin-plated product itself, and its main failure mechanism is fretting corrosion after fitting. In this case, the salt spray test has nothing to do with its failure mechanism. Even if the oxide layer on the surface turns black after the salt spray test, in actual use, the mating terminal can still easily push off the oxide film and contact the pure tin inside to form a metallic connection.

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The salt spray test has no acceleration factor, and 48 hours of salt spray does not represent how many years the product will last under certain conditions.

Environmental reliability testing equipment.

Environmental reliability testing equipment is widely used in constant temperature, constant humidity, changing temperature, changing temperature and humidity, salt spray test from raw materials, component level, circuit board/module level, to complete machine electronics, electrical appliances, electric power and other products. Mixed gas test, ozone aging test, UV accelerated aging test, xenon lamp aging test, sulfur dioxide corrosion test, high-altitude low pressure test, IPX1~8 waterproof level test, dust/sand test, drop test, combustion test, half sine wave / Trapezoidal wave acceleration shock test, sine/random vibration test, crash simulation test, drop test, tensile strength test, fatigue test, earthquake test, high accelerated life aging and stress screening and other mechanical and mechanical environmental tests, climate environmental tests and comprehensive Environmental test project.

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Post time: Sep-30-2022