Influence of test parameters in an automotive cyclic test on the corrosion and mechanical performance of joined materials

The effect of selected climatic parameters including the freezing temperature (+20, -15, and -25 degrees C), the composition of the salt solution (NaCl or a mixture of NaCl, and CaCl2) in an accelerated corrosion test cycle as per VDA233-102 was investigated using 20 different assemblies with a lap-shear design. These joined materials included steel based substrates such as carbon steel, high strength steel, zinc coated steel (conventional zinc coating and ZnAlMg coating) and as well as hot stamped steel (Usibor 1500P with AluSi coating) and, two different aluminium alloys (AA6016, AA5182). Joining techniques integrated spot welding, clinching, adhesive bonding. No significant influence of the freezing phase, of the substitution of some NaCl for CaCl2 in the salt solution could be observed on the mechanical properties, corrosion behaviour of the different combinations after 25 weeks of accelerated testing in a VDA 233-102 cycle.