PV 1209-EN-2023带有锌或锌合金涂层的附加部件悬挂部件和铝制附加部件挂接部件 循环腐蚀试验

GroupstandardPV1209

Issue2023-09

Class.No.:50211

Descriptors:aluminum,battery,chargeaircooler,charger,climatetest,condenser,corrosion,corrosioncyclictest,electricairconditioningcompressor,high-voltagecomponent,high-voltageheater,radiator

Add-OnParts/Hang-OnPartswithaZincorZincAlloyCoatingandAluminumAdd-OnParts/Hang-OnParts(e.g.,HeatExchanger,

RefrigerantLine)

CorrosionTest(EnvironmentalCorrosionCycleTest)

Previousissues

PV1209:1996-01,2010-10,2016-02,2023-01

Changes

ThefollowingchangeshavebeenmadetoPV1209:2023-01:

a)

Section„Positioningcomponentsintest

3.7thethechamber“edited

Contents

Page

1

Scope

2

2

Designation

2

3

Test

2

3.1

Method

2

3.2

Specimen

2

3.3

Leaktestparts

foraluminumadd-onparts/hang-onthatformcavities

2

3.4

Testingequipment

2

3.5

Testsetup

2

3.6

Testing

solution

3

3.7

Positioningcomponentsintest

thethechamber

3

4

Evaluation

3

4.1

Leaktestparts

foraluminumadd-onparts/hang-onthatformcavities

3

4.2

Microsection

images

4

5

Applicable

documents

4

Alwaysusethelatestversionofthisstandard.

Thiselectronicallygeneratedstandardisauthenticandvalidwithoutsignature.Acommaisusedasthedecimalsign.TheEnglishtranslationisbelievedtobeaccurate.Incaseofdiscrepancies,theGermanversioncontrols.

Page1of4

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©VolkswagenAktiengesellschaft

VWNORM-2022-12

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PV1209:2023-09

1Scope

Thistestmethodisusedtoevaluatethecorrosionresistanceofcomponentssubjectedtohighcor-rosivestress.Itappliesparticularlytocomponentswithazinc-nickelcoatingwithpassivationandsealing.Italsoappliestoheatexchangers(e.g.,condensers,radiators,andchargeaircoolers),

lines,andotherpartsmadeofaluminumalloys,aswellashigh-voltage(HV)components(batter-ies,chargers,HVheaters,electricairconditioningcompressors,etc.).Performthetestonthefin-ishedpart.

Evaluatetheheatexchangersandlinesbymeansofasubsequentleaktestandonthebasisofmetallographiccrosssections.Alwaysapplythecorrosiveloadfromtheoutside.Donotapplyasimultaneouspressureload.Ifpaintedcomponentsareused,performthetestonpartswiththepaintfinish.

2Designation

EnvironmentalcorrosioncycletestasperTestStandardPV1209

3Test

3.1Method

Thetestisacombinationofthefollowingtests:

–Bodycorrosiontestasper

PV1210

–Environmentalcycletestasper

PV1200

.

3.2Specimen

Atleast5partsarerequiredforcompletetesting.

3.3Leaktestforaluminumadd-onparts/hang-onpartsthatformcavities

Priortothecorrosiontest,thecomponentsmustbetestedforleaks(see

section4.1

).Allopencon-nectionsmustbesealedpriortothecorrosiontestapplyingsuitablemeasures(e.g.,usingrubberplugsorplasticcaps).

3.4Testingequipment

Performthetestasper

PV1210

inatestingchamberasper

DINENISO

9227setupforacorro-sioncycletest.Performthetestasper

PV1200

inaclimaticchamber.

3.5Testsetup

Performthetestasper

PV1210

over5days.Thetestsequenceforeachdayisspecifiedbelow:

4hoursSaltspraytest,testmethodNSSasper

DINENISO

9227withmodifiedtestingsolution(see

section3.6

).

4hoursCooling-offphaseatroomtemperature(18°Cto28°C)and40%to60%relativehumidity.

16hoursDampheataging,standardatmosphereCHasper

DINENISO

6270-2.

Page3PV1209:2023-09

Thenagethecomponentsfortwodaysintheenvironmentalcycletestasper

PV1200

underthe

followingtestconditions:

Limittemperatures:80°Cand-40°C

Holdtimeatlimittemperature:4h

Heatingandcooling-offtime:2hRelativehumidityat80°C:80%Onetestcycletakesoneweektocomplete.

3.6Testingsolution

Amodifiedtestingsolutioncanbeusedforthesaltspraytestperformedaspartofthetestasper

PV1210

.Atestingsolutionasper

DINENISO

9227-NSScanalsobeuseduponagreementwithMaterialsEngineeringoftherespectivebrand.

Themodifiedtestingsolutionispreparedfromanalyticallypuretablesalt(NaCI,puritygradeasperGermanPharmacopoeiaDAB7),calciumchloride(CaCl2,anhydrous,mediumgrained,pure),anddeionizedordistilledwater(conductivity≤2mS/mat(23±2)°C).40gNaCIand10gCaCl2per

literofwaterareusedtopreparethetestingsolution.ThepHvalueofthecollectedcondensate

watermustbebetween6,5and7,2.ItmaybenecessarytoadddilutedhydrochloricacidtoobtainsaidpHvalue.Themeasurementisperformedelectrometricallyat(25±2)°Cusingaglasselec-trode.

3.7Positioningthecomponentsinthetestchamber

Placethepartsinthetestchambersintheas-installedposition(similartooperatingcondition).Therefore,rotatepartsthat,wheninthevehicle,areexposedfrombelowby180°andafterwardsplacetheminthetestchamber.Incasetheexposuresituationofpartsisnotspecified,theposi-tioningmustbeagreeduponwiththepurchaser.

Itmustalwaysbeensuredthattheelectrolyteisdrained.Therefore,partsthatarearrangedverti-callyinthevehiclemustbesetupatanangleofapproximately70°tothehorizontalduringthe

test.Testpartsthatarearrangedhorizontallywhiletheyaresetupatanangleofatleast20°tothehorizontal.

4Evaluation

4.1Leaktestforaluminumadd-onparts/hang-onpartsthatformcavities

Subjecttheheatexchangerstoaleaktesteverytwoweeks.Tothisend,pressure-testthepartsunderwater(temperature:18°Cto28°C)for30susingairand/ornitrogenasfollows:

–Condensers,gascoolers:2000kPa

–Radiators,evaporators,andchargeaircoolers:200kPa

Thecomponentsmustwithstandtherequiredtestwithoutanyleakage.

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PV1209:2023-09

4.2Microsectionimages

Afterthecorrosiontest,metallographicspecimensmustbecreatedfromthetransitionareasbe-tweenthepipeandcoolingfinandbetweenthepipeandreceiver/dryer.

Providedthatnoadditionalrequirementsarespecifiedinthepart-orproject-specificdocuments

(e.g.,TechnicalSupplySpecification,drawing,orPerformanceSpecification),thetestisconsideredpassedifthefollowingapplies:

Brazedjoints,e.g.,betweenflatpipeandcoolingfin,mustnotbeseparated.Minorselectivecorro-sionofthebrazedsurfaceispermissible.

Pittingandothercorrosiontypessuchasintercrystallinecorrosiononfluid-orgas-carryingpartsareonlypermissibleinasacrificialcathodicprotectivelayer.ThiscathodicprotectivelayermustbeverifiedinasuitableetchingprocessorbymeansofanenergydispersiveX-raylinescananalysis(e.g.,zinc)inthecrosssection.

5A