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MIL-STD-810 Salt Fog Compliance Testing Method 509

The salt fog lab testing method is performed to determine the effectiveness of protective coatings and finishes on materials. As a MIL-STD-810 certified lab, we realize the importance of MIL-810 salt fog testing. We understand the challenges and guide companies through the process. Meeting the MIL-810 corrosion resistance requirements can be difficult.

Keystone provides the peace of mind that all of your needs will be met. We have a reputation of helping customers achieve their MIL-STD product certifications. Our proven process helps avoid product launch delays. Keystone Compliance partners with customers to achieve MIL-STD-810 product compliance. We provide comprehensive reports shortly after completion of the MIL-810 standard testing.

Request a quote to learn why we are one of the fastest growing compliance test labs in the country. Contact us to receive more information on MIL-STD-810H salt fog compliance testing.

The Importance of MIL-810 Salt Fog Compliance Testing

This 810-test can be applied to determine the effects of salt deposits on the physical and electrical aspects of material.

Salt fog method 509 is used specifically for screening purposes. This evaluates the effectiveness and quality of protective coatings and finishes on material and material couples. It is also used to locate potential problem areas, quality control deficiencies, design flaws, etc., in a relatively short time. In general, it is noted to only apply this MIL-810 test to material that will be exposed to high levels of salt in the atmosphere.

Keystone Compliance is a fully equipped military testing lab with experience in MIL-810 Salt Fog compliance testing. The following information contains the testing language and summary from test method 509 Salt Fog test.

How MIL-STD-810H Salt Fog Testing Affects Products

Salt is one of the most persuasive chemical compounds in the world and impossible to avoid. The worst effects occur in coastal regions. The effects of material to an environment where there is a corrosive atmosphere can be divided into three broad categories. Corrosion effects, electrical effects and physical effects.

The test specifications below are some of the typical problems corresponding to salt mist lab testing. These specifications can help when considering if this method is appropriate for the material being used. The MIL-STD-810 test list is not intended to be all inclusive.

Corrosion Effects

  • Corrosion due to electrochemical reaction.
  • Accelerated stress corrosion.
  • Formation of acidic/alkaline solutions following salt ionization in water.

Electrical Effects

  • Impairment of electrical material due to salt deposits.
  • Production of conductive coatings.
  • Corrosion of insulating materials and metals

Physical Effects

  • Clogging or binding of moving parts of mechanical components and assemblies.
  • Blistering of paint as a result of electrolysis.

Information on MIL-STD-810 Salt Fog Test Standards

The MIL-810 salt mist test only has one procedure to consider. However, the test has multiple variations to note when discussing the shock testing method.

Salt Solution – Unless otherwise specified use a 5 ± 1 percent salt solution concentration. This is to not introduce contaminants or acidic/alkaline conditions that may affect the test results.

Test configuration – Unless otherwise specified, configure the test item and orient it as would be expected during its storage, shipment, or use. Examples would include in a shipping container, outside of its container and set up in its normal operating mode. Modified kits for special applications or to compensate for mating components are normally present but are not used for this specific purpose.

Duration – Alternating 24-hour periods of salt fog exposure and drying conditions for a minimum of four 24 hour periods. This provides more realistic exposure and higher damage potential than does continuous exposure to a salt atmosphere.

If this option is not acceptable, perform 48 hours of exposure followed by 48 hours of drying. Lastly, the number of cycles are increased. This provides a higher degree of confidence in the ability of the materials involved to withstand a corrosive environment.

Temperature – Maintain the temperature in the chamber at 35 Degrees C or 95 Degrees fahrenheit. This temperature has been historically accepted and is not intended to simulate actual exposure situations. Other temperatures may be used if appropriate environmental conditions arised.

Limitations of Salt Fog MIL-810 Testing

This MIL-STD 810 compliance method does not attempt to duplicate the intricate environment. Rather, it provides a situation that may reveal potential problem areas in material. Specifically, this MIL-STD 810 lab method does not address: 

  • There is no relationship between this MIL-STD 810 test and any real world exposure duration.
  • It has not been demonstrated that a direct relationship exists between salt fog corrosion and corrosion testing conditions due to other media.
  • It has not been demonstrated that withstanding the effects of this test guarantees material will survive under all corrosive conditions.
  • The salt mist method 509 test has proven to be generally unreliable for predicting the service life of different materials or coatings.
  • Lastly, the MIL-STD-810 salt mist test is not a substitute for evaluating corrosion caused by humidity and fungus. Their effects differ from salt fog effects and the tests are not interchangeable.

Keystone Compliance Provides Test Method 509 Salt Fog and Mist Testing Services

Keystone has a full lab of test equipment which permits us to provide short lead times on scheduling. In addition to MIL-STD-810H salt fog compliance testing, Keystone has a full scope of expertise including solar radiation, sand and dust, pyroshock, and rain. Our team strives to give our customers more time and energy on product development instead of testing. 

Keystone Compliance has been one of the best Military Standard testing labs in the country. We employ expert test engineers and properly equip our MIL-810 Salt Fog test laboratory in order to provide certifications for MIL-810 compliance testing. 

Contact us to receive more information on MIL-STD 810 salt fog lab testing. Request a quote and learn why so many manufacturers and even the United States armed forces rely on Keystone Compliance to meet their MIL-STD-810 standard compliance testing needs.