D AIMLER C HRYSLER CORPORATION No: CS-CORROSION Characteristic Standard Date Published: 2004-06-22 Category Code: A-5 Change: B EASL Req.: NoRESTRICTED: NoCORROSION REQUIREMENTS - SYSTEMS AND COMPONENTS1.0 GENERAL1.1 PurposeThis standard describes corrosion-related functional and appearance objectives for systems and components, which were agreed to by the Product Quality Committee at the meeting of August 26, 2002. It also describes the corrosion test requirements for engineering development (ED), design verification (DV), product validation (PV), and continuing conformance (CC) testing.1.2 Coverage of this StandardThis standard applies to vehicles and service parts built by the Chrysler Group of DaimlerChrysler Corporation (DCC). It may be referenced within other system standards or performance standards. The requirements of this standard are in addition to those contained within any applicable material or process standards.1.3 Limitations on UsageThis standard may be applied by copying the appropriate performance requirements given in Section 3.0 and the test requirements given in Section 5.0 of this standard into to the following engineering documents:- Pre-source package- CATIA model or Performance standard (PF)- Design Verification Plan & Report (DVP&R)- Product Assurance Plan (PAP)This standard may be released directly on a CATIA model if no PF exists, or if the PF cannot be revised to include these requirements in time to meet program requirements.1.4 Location of Definitions/ Abbreviations/ AcronymsDefinitions/ Abbreviations/ Acronyms can be found in Section 6.0 of this standard.2.0 CORROSION PERFORMANCE REQUIREMENTS2.1 Appearance RequirementsAppearance requirements are defined in terms of a maximum allowable corrosion rating after a given length of service. The definition of the corrosion rating system appears in section 5.0 of this standard. 2.1.1 Class I Surface AppearanceDefinition:Class I appearance items are defined as exterior surface items that are readily visible to the customer without opening any closure panels, except as defined in paragraph 2.1.4, or that are in plain view within the vehicle interior.Requirements:- 1 year in service with a corrosion rating of 0, and- 5 years in service with a maximum allowable corrosion rating of 1.2.1.2 Class II Surface Appearance.Definition:Class II appearance items are defined as those items that are visible upon opening closure panels, e.g. - Door jambs and hardware,- Liftgate or decklid drain troughs, or truck tailgate surrounds,- Fuel filler door opening.Class II appearance items also includes interior items that are not in plain view, but are commonly visible to the customer in the course of normal ownership and maintenance activities.Requirements:- 1 year in service with a maximum allowable corrosion rating of 1, and- 5 years in service with a maximum allowable corrosion rating of 2.2.1.3 Underhood Appearance.Definition:Underhood appearance items are defined as those underhood items that are readily visible to the customer in the course of normal ownership and maintenance activities.Requirements:- 1 year in service with a maximum allowable corrosion rating of 1, and- 5 years in service with a maximum allowable corrosion rating of 2.2.1.4 Underbody Appearance.Definition:Those underbody items that are readily visible to the customer when viewed from outside of the vehicle, with the vehicle on the ground (i.e. not on a hoist or lift), with the eye at a distance of not more than 5 meters and at a height of not less than 1 meter from the ground shall be subject to this requirement. Consideration shall be given to the position of the front wheels when assessing the visibility of chassis components, with regard for the showroom appearance of those items that may be visible with the wheels turned.Requirement;- 1 year in service with a maximum allowable corrosion rating of 1, and- 5 years in service with a maximum allowable corrosion rating of 2 only for those items that are in plain view directly through the face of the wheels, except brake rotors;.2.2 Functional RequirementsDefinition:Functional requirements are defined as those physical, electrical, or mechanical attributes that describe the function of an item, e.g., structure, output, or serviceability. Design life is defined as the required period of time that the item must retain its functional requirements. This may be less than the life of the vehicle if it is intended that the part be serviced or replaced. The responsible engineering department shall define the functional requirements and design life of the item under test.Requirement:- 10 years in service with no loss of function due to corrosion, unless the design life is otherwise specified. - For fasteners; 10 years in service with a maximum allowable corrosion rating of 3.3.0 CORROSION TESTING - GENERAL3.1 Compliance to Material and Process Standard requirementsPrior to corrosion testing of an item according to this standard, the engineer must verify that the materials and processes used meet the requirements of the applicable DaimlerChrysler Material and Process Standards or other industry specifications; otherwise, the test results shall be considered inconclusive. Examples of requirements found within material or process standards are;- Coating thickness- Coating composition- Resistance to salt spray- Resistance to humidity- Cycle cracking- Ultraviolet exposureNOTE: Corrosion and other environmental tests are included as characterization tests within materialand process standards. In this case, such tests are used for material or process characterization and do not directly correlate to in-service corrosion performance.3.2 Full-Vehicle Corrosion TestingFull-vehicle corrosion testing according to LP 461H-117 is preferred at all levels of the product creation process because corrosion performance of an item is dependent upon its position on the vehicle. Where both full-vehicle and laboratory methods are prescribed, the full vehicle method shall be the preferred test.In the Engineering Development (ED) phase testing may be conducted on a mule or other program vehicle. Information may also be drawn from previous tests conducted on similar vehicles.In the Design Verification (DV) phase, testing conducted on an S0 level vehicle is preferred. If an S0 vehicle is not available a full-vehicle test on an earlier-level vehicle may be substituted.In the Product Validation (PV) phase, only full-vehicle testing performed on an S0 (or later) level vehicle is permitted because the position of the item on the vehicle must be considered.3.3 Laboratory TestingIn the ED and DV phases laboratory testing may be utilized if full vehicle testing is not possible. However, THE ENGINEER MUST CONSIDER environmental factors that affect corrosion which may be absent in the laboratory test. Some examples are:- Splash- High temperature- Road blast- Mud packing- Water poolingThe laboratory test method may be altered in order to consider these or other environmental factors with the concurrence of the design engineer and the Corrosion Prevention Group, Body Materials Engineering.Laboratory testing is not permitted in the PV phase because the influence of component location on the vehicle must be included in the test.Results of full-vehicle corrosion testing supercede those of laboratory corrosion testing.3.4 Continuing Conformance (CC) or Quality Control TestingCC or quality control testing shall be based upon the requirements defined within the specified DaimlerChrysler standards (MS or PS) or other industry specifications. Performance testing done prior to the CC phase demonstrates that the chosen materials and processes fulfill the functional requirements of a particular item in a particular application. CC testing demonstrates continuing conformance of the materials and processes to the requirements of their specifications. Such requirements may be environmental tests such as resistance to salt spray or humidity. It is important to recognize that these are characterization tests that DO NOT DIRECTLY CORRELATE TO IN-SERVICE CORROSION PERFORMANCE. Refer to CS-9801 for general quality requirements.4.0 CORROSION TESTING - SPECIFIC REQUIREMENTSBecause corrosion severity varies with component location on the vehicle, five groups have been defined to facilitate specification of the appropriate test requirements. The acceptance criteria for the following test requirements shall be as specified in Section 3.0. Where both laboratory and full-vehicle test requirements are given, the tests shall be considered as alternates, although the full-vehicle test shall be the preferred method. The following test requirements are summarized in Table 1.NOTE: Certain exceptions to the following test requirements appear in section 5.6 of this standard.4.1 Systems or components that are located on the exterior surface or directly on the underbody of the vehicle.4.1.1 One year appearance requirement (if applicable; see Section 2.0)- Laboratory testing: 15 cycles SAE J2334 – immersion method- PG testing: 3 weeks LP-461H-1174.1.2 Five year appearance requirement (if applicable; see Section 2.0)- Laboratory testing: 60 cycles SAE J2334 – immersion method- PG testing: 12 weeks LP-461H-1174.1.3 Ten year functional requirement- Laboratory testing: 120 cycles SAE J2334 – immersion method- PG testing: 24 weeks LP-461H-1174.1.4 Fifteen year functional requirement (if required)- Laboratory testing: 180 cycles SAE J2334 – immersion method- PG testing: 36 weeks LP-461H-1174.2 Systems or components that are located on secondary exterior surfaces, such as door jambs, etc., or in the underhood area, but not directly exposed to road spray and splash;4.2.1 One year appearance requirement (if applicable; see Section 2.0)- Laboratory testing: 8 cycles SAE J2334 – spray method- PG testing: 3 weeks LP-461H-1174.2.2 Five year appearance requirement (if applicable; see Section 2.0)- Laboratory testing: 30 cycles SAE J2334 – spray method- PG testing: 12 weeks LP-461H-1174.2.3 Ten year functional requirement- Laboratory testing: 60 cycles SAE J2334 – spray method- PG testing: 24 weeks LP-461H-1174.2.4 Fifteen year functional requirement (if required)- Laboratory testing: 90 cycles SAE J2334 – spray method- PG testing: 36 weeks LP-461H-1174.3 Systems or components that are located within the cavities of doors with moving glass.4.3.1 Appearance requirements – NOT APPLICABLE4.3.2 Ten year functional requirement- Laboratory testing: 60 cycles SAE J2334 – spray method- PG testing: 24 weeks LP-461H-1174.4 Systems or components that are located on the floor of the interior of the vehicle. NOTE: These are minimum requirements, which may be extended or increased in the case of convertible, Jeep(TM), or other activity vehicles at the initiative of the releasing group.4.4.1 One year appearance requirement (if applicable; see Section 3.0)- Laboratory testing: 5 cycles SAE J2334 – spray method- PG testing: Not applicable4.4.2 Five year appearance requirement (if applicable; see Section 3.0)- Laboratory testing: 20 cycles SAE J2334 – spray method- PG testing: Not applicable4.4.3 Ten year functional requirement- Laboratory testing: 40 cycles SAE J2334 – spray method- PG testing: Not applicable4.5 Systems or components that are located within the vehicle interior, but not on the floor. NOTE: These are minimum requirements, which may be extended or increased in the case of convertible, Jeep(TM), or other activity vehicles at the initiative of the releasing group.4.5.1 One year appearance requirement- Laboratory testing: Humidity test per ASTM D1735, 24 hours- PG testing: Not applicable4.5.2 Five year appearance requirement- Laboratory testing: Humidity test per ASTM D1735, 120 hours- PG testing: Not applicable4.5.3 Ten year functional requirement- Laboratory testing: Humidity test per ASTM D1735, 240 hours- PG testing: Not applicable4.6 Special CasesThe SAE J2334 and LP-461H-117 test methods are either not sufficient or not appropriate for the following components;- Brake rotors- Aluminum heat exchangers- Stainless steel underhood and underbody components- Aluminum body panels- Decorative trim- ExhaustAny corrosion requirements that appear within applicable DaimlerChrysler performance standards (PF) for these components take precedence. Contact the Corrosion Prevention Group, Body Materials Engineering for specific advice regarding these components.TABLE 1: CORROSION TEST REQUIREMENTSpara. designlevel criteria laboratorytestduration Full-vehicletestduration MAXIMUMcorrosion rating4.1 ED, DV 1 yr.appearance (1)J2334(immersion)15 cy. CPG 3 wks. class I: 0class II: 15yr. appearance(1) J2334(immersion) 60 cy. CPG 12 wks. class I: 1class II: 210 yr. function J2334(immersion)120 cy. CPG 24 wks. 415yr. function(1) J2334(immersion)180 cy. CPG 36 wks. 4PV 1yr.appearance N/A N/A CPG 3 wks. class I: 0class II: 15yr. appearance N/A N/A CPG 12 wks. class I: 1class II: 210 yr. function N/A N/A CPG 24 wks. 415yr.function(1)N/A N/A CPG 36 wks. 44.2 ED, DV 1 yr.appearance(1) J2334(spray)*** 8 cy.***CPG 3wks. 15yr. appearance(1) J2334(spray)30 cy. CPG 12 wks. 210 yr. function J2334(spray)60 cy. CPG 24 wks. 415yr. function(1) J2334(spray)90 cy. CPG 36 wks. 4PV 1yr.appearance(1)N/A N/A CPG 3 wks. 1 5yr.appearance(1)N/A N/A CPG 12 wks. 2TABLE 1: CORROSION TEST REQUIREMENTSpara. designlevelcriteria laboratorytestduration Full-vehicletestduration MAXIMUMcorrosion rating10 yr. function N/A N/A CPG 24 wks. 415yr.function(1)N/A N/A CPG 36 wks. 44.3 ED, DV 1 yr.appearanceN/A N/A N/A N/A n.a.5yr.appearanceN/A N/A N/A N/A n.a.10 yr. function J2334(spray)60 cy. CPG 24 wks. 4PV 1yr.appearanceN/A N/A N/A N/A n.a.5yr.appearanceN/A N/A N/A N/A n.a.10 yr. function N/A N/A CPG 24 wks. 44.4 ED,DV,PV 1 yr.appearance(1) J2334(spray)5 cy. N/A N/A Class I: 0Class II: 15yr. appearance(1) J2334(spray)20 cy. N/A N/A Class I: 1Class II: 210 yr. function J2334(spray)40 cy. N/A N/A 44.5 ED,DV,PV 1 yr.appearance(1) Humidity 24 hrs. N/A N/A Class I: 0Class II: 15yr. appearance(1) Humidity 120 hrs. N/A N/A Class I: 1Class II: 210 yr. function Humidity 240 hrs. N/A N/A 4 NOTE 1: Only if requiredJ2334 (immersion): Cyclic corrosion test per SAE J2334 with full immersion in salt water solutionJ2334 (spray): Cyclic corrosion test per SAE J2334 with salt water solution by hand sprayerCPG: DCC Chelsea, MI Proving Grounds full-vehicle corrosion test per LP 461H-117Humidity: Humidity test per ASTM D17355.0 DEFINITIONSThe corrosion performance of an item under corrosion test is assessed according to the rating system described in Table 2.TABLE 2: CORROSION RATING SYSTEMRATING DEFINITION0 Nocorrosion1 Light paint blistering and / or light rust, powder or blush (discoloration of surface).2 Medium paint blistering and / or medium rust; light scale (irregular surface with pieces or layers of oxide that do not fall off with light tapping).3 Heavy paint blistering and / or heavy rust (scabbing), rust bleed; medium scale / flake (small pieces of oxide that fall off with light tapping).4 Severe red rust, scabbing, rust bleed, paint peeling; heavy flake (layers or chunks of oxide that fall off with light tapping).TABLE 2: CORROSION RATING SYSTEMRATING DEFINITION5 Perforation / broken / loss of function.Road Blast: The abrasion or erosion due to stones and grit thrown by the tires of the vehicle. Road blast can significantly add to the effects of corrosion in causing loss of function.ED, DV, PV, CC: The various stages of the product creation process; defined further in DCC “PAP4CDS manual”.SO: The program vehicle build level characterized by utilization of design-intent materials and processes, but not necessarily production tooling; defined further in DCC “PAP4CDS manual”.6.0 GENERAL INFORMATIONThree asterisks “***” after the section/paragraph header denotes multiple technical changes to the section/paragraph. A triple asterisk before and after a string of text (***text***) identifies a single change.Certain important information relative to this standard has been included in separate standards. To assure the items submitted meet all of DaimlerChrysler requirements, it is mandatory that the requirements in the following standards be met.CS-9800 - Application of this standard, the subscription service, and approved sourcesCS-9003 - Regulated substances and recyclabilityWithin Engineering Standards, the Regulatory (Government-mandated) requirements are designated by <S>, <E> and <H> which correspond to Safety, Emission and Homologation Shields respectively. The DCC-mandated requirements are designated by <D>, <A> and <T> and correspond to the Diamond, Appearance and Traceability symbols respectively.For specific information on this document, please refer to the contact person shown in the "Publication Information" Section of this document. For general information on obtaining Engineering Standards and Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department atengstds@.7.0 REFERENCESCS-9800CS-9801CS-9003LP 461H-117PF-8500Chrysler Corporation Product Assurance Planning Manual (84-231-1232)Chrysler, Ford, and General Motors manual, Quality System Requirements QS - 9000 DaimlerChrysler, “Product Assurance Testing” manualASTM D1735SAE Recommended Practice J2334, “Cosmetic Corrosion Test”8.0 ENGINEERING APPROVED SOURCE LISTNot applicable.9.0 PUBLICATION INFORMATIONContact/Phone No: M.L.Stephens, (248) 576-7452Alternate Contact/Phone No: A.K. Desai, (248) 576-7455Dept. Name & Dept. No. /Tech Club/Organization: Body Materials Engineering, Dept. 5820 / Scientific Laboratories & Proving GroundsDate Standard Originally (Initially Issued): 2000-12-07Date Published: 2004-06-22Change Notice:Description of Change: Editorial; corrected typographical error in Table 1.# # # # #。
