FLTM BI 103-01 Corrosion/Salt Spray Testing 

Overview of FLTM BI 103-01 Standard 

The FLTM BI 103-01 standard is a key method for Ford’s corrosion testing of painted panels and parts in the automotive industry. It uses a salt spray (fog) test based on ASTM B117 to assess coating durability under accelerated conditions. 

Conducted in a controlled chamber with a 5% sodium chloride solution, the test simulates harsh environments to evaluate corrosion resistance. This standard applies to various painted substrates, providing consistent benchmarks for performance and compliance. 

FLTM BI 103-01 is widely used for quality assurance, supplier validation, and product development. It is a critical part of Ford’s corrosion standards and supports both routine quality control and advanced testing of painted components. 

Importance of Corrosion and Salt Spray Testing 

FLTM BI 103-01 and the salt spray test are crucial for verifying the durability and safety of automotive coatings in harsh environments. Corrosion can cause functional failures, aesthetic damage, and costly warranty claims, making this testing essential throughout a product’s lifecycle. 

The salt fog test provides a fast, standardized way to evaluate painted panels and parts against salt corrosion, supporting compliance and quality control. Following FLTM BI 103-01 helps engineers identify coating or process weaknesses to ensure durable products reach the market. 

Regular testing detects issues early, reducing field failures and improving long-term durability. It supports R&D by enabling comparison and optimization of coatings. For suppliers, passing FLTM BI 103-01 is often required for Ford sourcing, with documentation supporting audits and continuous improvement. 

Key Features and Benefits of FLTM BI 103-01 Testing 

FLTM BI 103-01 provides a reliable, repeatable method for corrosion testing using controlled salt fog chambers. It uses a 5% sodium chloride solution, with pH monitored and temperature maintained at 35°C for consistent results. 

Proper sample preparation—including cleaning, scribing if needed, and correct positioning—is essential for accurate evaluation. Test duration and acceptance criteria vary by product, with regular checks for rust, blistering, and coating failure. 

The standard targets painted panels and parts, making it key for automotive paint durability testing. It requires detailed documentation, milestone inspections, failure analysis, and photographic records. 

The compliance report records test conditions and results, supporting regulatory and customer requirements. This thorough process ensures products meet Ford’s strict performance and safety standards. 

Risk Management and the Role of Testing 

Risk management is a key benefit of FLTM BI 103-01 and Ford testing, helping identify and address corrosion risks before they impact reliability or customer satisfaction. Integrating these tests into development and production reduces field failures, costly recalls, and reputational damage. 

The accelerated test provides quick feedback, allowing timely adjustments to materials, coatings, or processes. This proactive approach improves both performance and safety of critical automotive parts. 

Testing supports validation and ongoing quality assurance, ensuring regulatory compliance and process improvement. Detailed documentation offers traceability for audits and supplier evaluations. 

Benchmarking results against FLTM BI 103-01 drives continuous improvement and maintains high manufacturing standards. This disciplined testing is essential for staying competitive and meeting evolving automotive industry demands. 

Why Choose FLTM BI 103-01 as a Corrosion Testing Standard? 

FLTM BI 103-01 is the industry benchmark for corrosion and salt spray testing within the Ford supply chain, valued for its reliability and technical rigor. Its detailed procedures and equipment standards ensure components meet strict performance and safety requirements recognized by Ford and global OEMs. 

The standard’s versatility covers OEM coatings evaluation, painted component validation, and quality control. It is also referenced for metal finishing validation and automotive lab testing, demonstrating its broad applicability. 

FLTM BI 103-01 emphasizes documentation, sample preparation, and compliance reporting to ensure traceable and auditable results. Using this standard helps companies meet Ford’s requirements, improve product reliability, and stay competitive. 

Its alignment with best practices in chamber operation and equipment calibration supports engineers and quality professionals in delivering consistent, high-quality testing. 

How to Conduct FLTM BI 103-01 Corrosion/Salt Spray Testing 

Pre-Testing Preparation 

• Review the FLTM BI 103-01 standard and determine all relevant corrosion and salt spray test requirements for the component. 

• Prepare a detailed test plan, including: 

• FLTM BI 103-01 salt spray resistance test 

• FLTM BI 103-01 sample preparation and cleaning 

• FLTM BI 103-01 test setup and equipment requirements 

• Prepare the test setup with the following equipment: 

• Salt spray chamber or salt fog chamber 

• Sodium chloride solution (5% by weight) 

• pH meter and temperature controller 

• Specimen holder and humidity sensor 

• Scribe tool (if scribe and blister creepage measurement is required) 

Testing Procedures 

• Conduct sample preparation by cleaning all specimens to remove oils, greases, or contaminants, and dry them in lint-free conditions. 

• Prepare the salt solution by dissolving analytical-grade NaCl in deionized water, adjusting pH as specified, and filtering to remove particulates. 

• Position samples in the chamber for uniform exposure, ensuring condensate runoff and using non-corroding fixtures. 

• Maintain the chamber at 35°C and monitor humidity with the humidity sensor, ensuring continuous atomization of the salt solution. 

• Inspect samples at regular intervals for white rust, red rust, scribe and blister creepage, and record all findings according to the FLTM BI 103-01 documentation and reporting process. 

Testing Report 

• Prepare a comprehensive FLTM BI 103-01 compliance report, including: 

• Test setup diagrams and equipment used 

• Detailed results for each test phase, including visual inspection and scribe/blister measurement 

• Acceptance criteria for coatings and performance 

• Calibration records and traceability logs from pH meter, temperature controller, and humidity sensor 

• Any deviations, corrective actions, or retest outcomes 

Industry Applications and Relevance 

FLTM BI 103-01 is a key standard for corrosion, salt spray, and salt fog testing in the automotive industry. It supports Ford corrosion standards, supplier validation, paint durability, and quality control in manufacturing. 

This standard is widely accepted for evaluating OEM coatings, painted components, and metal finishing. Using FLTM BI 103-01 ensures products undergo thorough durability and performance testing, helping manufacturers meet regulations and improve corrosion resistance. 

Expert Laboratory Testing

Now part of the Applus+ Laboratories group, Applus+ Keystone partners with a global network to provide testing and certification services that take your product from development to approval. Our experts ensure your regulatory needs are met with precision.

Request a quote to discuss your certification testing requirements today.

For more information on automotive corrosion and salt spray testing standards, please visit: