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SAE Cancels J1960 and J1885 Test Methods

Two long-standing and widely-used standards for accelerated testing of automotive materials were cancelled by the Society of Automotive Engineers (SAE). Both documents have been superseded by newer, performance-based standards as of January 11, 2008.

J1960 – Accelerated Exposure of Automotive Exterior Materials Using a Controlled Irradiance Water Cooled Xenon-Arc Apparatus, has been cancelled and replaced by J2527 – Performance Based Standard for Accelerated Exposure of Automotive Exterior Materials Using a Controlled Irradiance Xenon-Arc Apparatus (published February 2004).

J1885 – Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Water Cooled Xenon Arc Apparatus, has been superseded by J2412 – Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Xenon-Arc Apparatus (published May 2004).

According to the SAE Committee on Fade and Weathering, the rationale for cancelling the standards is that they were equipment-specific, applying only to certain models available from only one manufacturer. The change from standards specifically describing the type of hardware, to performance-based standards that describe test conditions, will reduce costs by allowing users to select from any type of equipment that meets the test parameters. Readers affected by these changes are reminded to update their scopes. BACK TO TOP

Chrysler Approves Q-Sun for Automotive Testing

Chrysler has approved the company-wide use of Q-Sun Xenon Test Chambers to meet SAE J2527 and J2412 requirements for testing of automotive exterior and interior parts, components and materials, as part of the growing trend toward more cost-effective, performance-based weathering and light stability testing. The decision was the result of five years of research. In addition to the Q-Sun’s reliability, major factors driving the decision were cost savings and confirmed correlation to outdoor results. All Q-Sun models cost much less to purchase and operate than comparable rotating-rack style xenon testers. A technical paper documenting a portion of the Chrysler/Q-Lab research that led to Chrysler’s accepting the use of Q-Suns in automotive testing, Automotive Xenon Arc Test Methods: A Correlation Study, is available from Q-Lab. For a copy of this technical paper, request 735 BACK TO TOP

Chrysler has approved the Q-Sun for testing of interior and exterior automotive materials.

Shown here is the 2008 Chrysler 300C. New Q-Lab Training Center Opens in China Q-Lab China has opened its new training center in Shanghai. Serving both customers and sales representatives, the center provides training in accelerated weathering, light stability and corrosion testing. The first training session was held in January, under the supervision of Joe Carney, CET, Q-Lab Corporation’s Service & Repair Manager. Q-Lab China’s new office in Shanghai features a well-equipped training center. Shown above, instructor Mike Garrett explains the Q-Sun’s operation. BACK TO TOP

Scientific Viewpoint
How Can I Tell If My Product Will Last Outdoors?

The first of this two-part series in LabNotes will address outdoor testing. The next installment will cover how to relate outdoor testing with accelerated testing for reliable results. Warren D. Ketola, WK Weathering Consulting During my long career, I’ve been asked many questions by customers about which weathering tests they should use to evaluate their polymer or product. In most cases, the questions are about use of artificial accelerated weathering tests and how they relate to actual outdoor performance. Some typical questions are: - How many hours does it take in this accelerated test to equal a year in Florida? - I want to warranty this product for five years – how long do I need to test in a QUV running UVA340 lamps? - If my product looks OK after 2000 hours in SAE J2527, how long will it last in Arizona?

The answer to all of these types of questions is, it depends. The answer will depend on how the polymer or product responds to the stresses produced by exposure to solar radiation, to temperature, and to moisture. There are many, many artificial accelerated tests that can be used, each producing a different combination of stress conditions. Selecting the optimum test condition can be a daunting task. However, there is one very simple answer to the question of how to tell if your product will last outdoors. That answer is, test your product outdoors. Outdoor testing needs to be the first test you start, before you begin any artificial accelerated weathering test. There are several critical reasons why starting outdoor exposures on your product must be done first.

Outdoor Exposures Are Never Wrong While it seems trite, one must remember that the same cannot be said for artificial accelerated weathering tests. Some of these have been shown to be very good predictors of outdoor durability for some materials. However, there are also instances where results from artificial accelerated tests proved to be very poor predictors of outdoor durability, to the point where the material performing best in the accelerated test was actually worst outdoors. You have many options to chose from when selecting an artificial accelerated test. Some might be good and some might be very bad. You don’t have to worry about making a wrong choice of tests when you test outdoors because the results from outdoor testing are never wrong. In fact, results from outdoor testing are now used to specify minimum durability performance for some materials. ASTM D 4956, Standard Specification for Retroreflective Sheeting Materials is an example, where three year exposures in hot/wet and hot/dry climates are required.

Evaluating the Validity of Accelerated Weathering Tests As stated above, you have many options to choose from when selecting an artificial accelerated weathering test. Some might be good choices and some very bad. If you do not have results from outdoor exposures, you have absolutely no basis for assessing the validity of your artificial accelerated test. Let’s use an example to illustrate this point. Suppose you had five different options to use for a new product being introduced by your company. Your company wanted to warranty the outdoor durability of the product for three years. All the options met the performance and cost requirements and you used an accelerated test that had given you good information for other products to select the option that would be used for the new product. After the product had been on the market for 18-24 months, your company started to get quite a few warranty claims, because the product was failing outdoors. Everyone is asking about whether the other options could be substituted. Unfortunately, you only had weathering data from the one test. You didn’t think it would be necessary to do outdoor weathering because the test had given reliable results before. Any information you given about whether one of the other options could be used is only a guess. If you had started outdoor weathering on the product, you would have been able to see the marginal performance of the option that was selected and would have been able to make sound recommendations for an alternative. Are you willing to take the risk inherent with not starting your outdoor weathering exposures first?

The desert conditions at Q-Lab Arizona feature intense sunlight, high temperatures, and very low humidity. Test specimens may also experience large temperature fluctuations. This extreme climate has been proven useful for testing coatings, plastics and building materials. Subtropical conditions at Q-Lab Florida (located south of Miami) are generally hot and humid. Lots of sunshine and abundant rainfall create an environment that is ideal for testing exterior durability and moisture sensitivity. BACK TO TOP

Outdoor Testing Is Inexpensive

Contrary to what people might think, outdoor weathering testing is very inexpensive when compared to the costs for artificial accelerated testing. Consider the following example.

Suppose you need to choose between three formulation options for a new polymer that is critical to your company’s success. You have chosen to use an artificial accelerated test for which the cost is $0.20 per specimen per hour of exposure. You are testing two replicates of each of the three formulations and your test time is 2000 hours. The cost for the artificial accelerated test is $2400, assuming that the 2000 hour exposure is sufficient for you to choose between the materials. In many cases, longer exposures are needed. For your outdoor testing, let’s assume that you will send out separate sets of specimens for 12 months, 24 months and 36 months. Assuming the cost is $.50 per specimen per month, the total cost for the outdoor exposure is $432, which is likely to be spread out over the three years of exposure.

It has been my experience that when conducting comprehensive programs of artificial accelerated and outdoor weathering exposures, about 90% of the total cost is for the artificial accelerated testing

Outdoor Exposure Factors Now that you are convinced that outdoor testing is the first exposure test you will start, there are a few additional things to consider when setting up your outdoor testing.

The first is using multiple locations for outdoor exposures. Your company is going to be making one version of the product you will be testing and it is going to be used in all kinds of climates. The effects of different types of climates can have a profound effect on the type and rate of degradation your product could experience.

The chart shown in Figure 1 is one example of these differences. The x-axis is the amount of total solar radiation received by the test specimens. It is clear that the higher temperatures experienced in the hot desert exposures of Arizona produced much faster degradation. Moisture is another factor. Some polymers degrade much faster in Florida’s wet climate. For some materials, other effects such as thermal shock or cycling that would be experienced in a northern climate, could have significant effects. From these examples, you can see that you cannot predict durability in all locations using weathering results from only one location.

Since you want your outdoor test results to be as “fast” as possible, you need to consider exposures in locations that will provide the most aggressive conditions, and where there is a considerable “history” of exposure information on a variety of materials. You also want to use locations where climate data such as solar radiation, temperature, and moisture for the exposure conditions you choose is readily available. These requirements are met by exposures conducted in the hot/wet climate of south Florida and the hot/desert climate near Phoenix, Arizona. Exposures in these types of climates are considered as international benchmarks for evaluating durability of materials.

When setting up your outdoor exposure experiments for each type of climate, you also can choose the angle of exposure (vertical, 45 degrees, or 5 degrees to the horizontal), the type of backing for your test specimens, and whether your materials are exposed directly to the sun or behind window glass. You might also want to choose a solar concentrating exposure where you can accumulate five year’s worth of solar UV radiation in about one year of testing. Outdoor weathering experts can help you in making these choices that are best for your product.

High Reliability, Low Cost In summary, the simple reason I recommend starting your product durability testing outdoors is this: Nothing else gives more accurate results, and nothing costs less – except for not testing at all, which can be a costly mistake. Some Polymers Degrade Faster in Arizona’s Hot Climate

Figure 1. Outdoor testing in multiple locations is important because there may be significant differences in environmental stresses. Shown here are Arizona and Florida exposures of a vinyl acrylic polymer.

Q-Rack outdoor exposure rack kits allow you to supplement your current testing program with additional data from other locations. The direct exposure rack shown has additional panel flaps to expand its specimen capacity.

Warren Ketola is a noted authority on weathering and a leader in ASTM, ISO, and other standards organizations. He is currently principal of WK Weathering Consulting in St. Paul, Minnesota, after a 37-year career with 3M Commercial Tape and Traffic Safety Systems Divisions. Starting with this issue, he will be a frequent editorial contributor to LabNotes. BACK TO TOP

Data Point
Why the QUV’s Condensation Cycle Is the Most Realistic Acceleration Possible

Time of Wetness (TOW) research conducted in North America indicates materials exposed outdoors are wet a surprisingly high percentage of the time. Our data indicates that, on average, they are wet 30% of the time. This means that, on average, outdoor materials are wet 7.2 hours/day, or over 2,600 hours per year!

But that is just an average. In places like Seattle, materials are frequently wet for 12 hours a day, or even more in some seasons. This startlingly high incidence of wetness is caused primarily by dew, not rain. Our data actually shows that, typically, the days with the higher TOW occurred in the absence of rain.

In laboratory weathering, it is relatively easy to accelerate the damage caused by sunlight. Accelerating the effects of outdoor moisture is much more difficult. Because materials exposed outdoors are already wet for such a long time under natural conditions, it is effectively impossible to accelerate by increasing the hours of moisture exposure.The only effective way is to accelerate by increasing the temperature of the exposure.

The QUV’s long, hot, condensation cycles are superior to methods of moisture simulation commonly used in other testers such as water spray, immersion and high humidity.

The QUV produces condensation by heating water into a vapor and then recondensing it onto the surface of the test specimen. Because the water is purified in the process, this precludes water-spotting problems and, since there is no need for stills or deionizers, it simplifies QUV installation and operation.

The QUV’s hot condensation mechanism brings highly oxygenated, liquid water into test specimen. Because the water is purified in the process, this precludes water-spotting problems and, since there is no need for stills or deionizers, it simplifies QUV installation and operation.

The QUV’s hot condensation mechanism brings highly oxygenated, liquid water into intimate contact with the test material for an extended period of time. A typical QUV condensation cycle lasts for 4 hours at 50˚C. Based on the ‘rule of thumb’ that a 10º increase in temperature can double the rate of the reaction, this provides significant acceleration. Consequently, the QUV both simulates and accelerates outdoor moisture attack.

For more information on the QUV, request 200 TOW in South Bend, Pennsylvania
Materials exposed outdoors are wet a remarkably high percentage of the time. Research indicates that dew (condensation), not rain, is the major source of wetness outdoors. BACK TO TOP

Look for the Q-Shaped Hole: Panels Are Available in Special Shapes, Sizes, Materials

Among the millions of Q-Panel brand test substrates shipped out of Cleveland, Ohio each year are a growing number of special panels that don’t fit the traditional pattern of a rectangular metal panel with a Q-shaped hanging hole. Special shapes and sizes range from 1" (2.54 cm) circles to 15" x 24" (38 cm x 61 cm) formed automotive panels, used for testing, display, or training. Custom, 3-D fabricated assemblies are occasionally requested as a special order. Customers such as architectural firms specify aluminum panels in unusual sizes to coat and use as sales samples. Special order panels offer clean, consistent material quality and finishes at an affordable price.

Materials and Surface Treatments Steel panels are made from standard low- carbon, cold-rolled steel complying with ASTM standards. Types include smooth finish, matte finish, ground (polished) finish, thin/flexible, tinplate, adhesion and abrasion panels, and stainless steel. Aluminum panels are lighter and corrosion resistant. They are available in bare or chromated types, adhesion, automotive styling, or large display panels. Iron phosphated panels are made from the same premium steel as our standard panels and are available in two finishes.

Panel Trends Robert Little, Q-Lab’s Panel Product Engineer, says that the impact of quality and environmental regulations is being felt in the panel markets. For example, U.K. orders for aluminum panels (including extruded aluminum) are specifying Qualicoat standards. “As regulations get tougher, it will be more important than ever for panel users to be able to rely on the high quality materials and production standards that the Q-Panel brand provides,” he concluded. For more information on panels, request 502 Steel panels are packaged with corrosion inhibiting materials and have a shelf life of up to 10 years. Panels receive minimal handling. Large automotive panels can be used for training or display. BACK TO TOP

Meet the Q-Sun Xenon Family

When Q-Lab introduced the Q-Sun Xenon Test Chamber in 1998, its flat array design was considered a major change from the rotating rack technology that was widely used at the time. Less than a decade later, the Q-Sun family has grown to include several flat array models, as well as the new Q-Sun B02 – which updates the traditional rotating rack design to create a more affordable textile lightfastness tester for the 21st century. Q-Suns are used worldwide for accelerated weathering and light stability testing of products used indoors or outdoors. The testers meet a wide range of ISO, ASTM, AATCC, SAE, DIN and other standards. Each Q-Sun model has special features that make it the right choice for specific tests, product applications, or budgets. But all Q-Suns share some common “family” characteristics.

Simple and Cost-Effective The design of every Q-Sun xenon tester is as simple as possible, making it easy to install, operate and maintain. This reduces both the initial purchase price and operating costs for the life of the equipment.

Large Specimen Capacity Q-Sun Xe-1 and Xe-3 models feature a slide-out specimen tray that can hold unusual shapes and sizes, even large 3-D parts. The Model B02’s specimen capacity is 48% to 92% larger than comparable models.

Efficient Lamps & Filters The Q-Sun’s air-cooled xenon arc lamps reproduce the full spectrum of sunlight. They cost much less than competitive lamps, are easier to install, and have a long service life. Optical filters are used to realistically reproduce sunlight, sunlight through window glass, or other spectra required by test methods.

Superior Control Systems Solar EyeTM Irradiance Control ensures maximum repeatability and reproducibility. Calibration is quick and easy with the patented AutoCal system. All Q-Sun models control specimen temperature, and many models feature chamber air temperature and relative humidity control.

Model B02 is a new design rotating rack tester specifically designed to meet the requirements of ISO 105 B02 for lightfastness testing of textiles. Thanks to the simple, practical design of this tester, xenon testing now is more affordable for textile labs around the world. Q-Sun Model B02 Mounting textile specimens on the rotating rack of the Model B02’s large capacity chamber (367 in2/2.362 cm2). For Q-Sun B02 information, request 733

Q-Sun Xenon Test Chambers are used for accelerated weathering and light stability testing of products used indoors or outdoors.

Model Xe-1 is an economical, table top tester with one lamp. It is designed for labs with smaller budgets, tight space, or where less testing is performed. Its specimen tray is 9.88" x 18" (251 mm x 457 mm). Options include water spray and a chiller.

Model Xe-3 is a full-size unit with three lamps and a 17.75" x 28.26" (451 mm x 718 mm) specimen tray. Options include water spray, dual spray for acid etch, chiller, chamber air temperature and relative humidity controls. Even with its multiple capabilities, the Xe-3 costs much less to purchase and operate than comparable xenon testers. Q-Sun Models Xe-1 (left) and Xe-3 For Q-Sun Xe-1/Xe-3 information, request 700 BACK TO TOP

Personnel Profile Melissa Precise, Order Department Supervisor

If the job involves orders coming in, or products shipping out from Q-Lab’s Instruments Division, the person in charge is Melissa Precise, Order Department supervisor since mid-2006. A real success story, Melissa joined Q-Lab in 1997 as the receptionist and now supervises a department of five. She is accustomed to comments about her surname being such a good fit with the nature of her work, which demands “precise” accuracy. Q-Lab’s Order Department is responsible for shipping and billing. All outgoing deliveries and freight shipments are handled by the department. This includes everything from container shipments to Europe to trade show display materials. To keep up with the complex demands of global logistics, Melissa currently is taking courses in preparation for her Customs Broker licensing examination. She cited major growth in Q-Lab’s international customer base, as well as the company’s expansion of product categories with customers in India and the Far East, as trends that keep her job interesting every day and make the extra time she spends studying for the exam worthwhile.
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Representative Profile South African Firm Gains Success Through Teamwork and Local Investment
Apollo Scientific’s sales staff at the 2007 Lab Africa trade show. The firm is known for its dynamic sales and marketing efforts, as well as its strong support for the South African business community. Like the ancient Greek god Apollo, Q-Lab’s South African representative, Apollo Scientific, is multi-talented. The firm’s leadership in business, investment, training and marketing – in a part of the world where positive change is urgently needed – consistently earns recognition at home and abroad. Apollo Scientific was founded in 1998 by Craig and Nicki Blignaut and Dion Keet, who currently hold the positions of Sales/Marketing Director, Administrative Director and Technical Director, respectively.

Their aim was to supply quality laboratory instrumentation coupled with unequalled service and after-sales support in southern Africa. The firm represents 10 different product lines (including familiar companies such as Instron, Binder, and Erweka). Apollo became a Q-Lab representative in 2002. Offices in the four major cities of South Africa include new headquarters in Johannesburg and branches in Port Elizabeth, Cape Town, and Durban. Apollo has an ISO 17025 accredited laboratory and is certified by the South African National Accreditation System to calibrate instruments dealing with force, speed, displacement, and temperature. Q-Lab Corporation’s Sales Director Ron Roberts cited Apollo’s strong commitment to marketing, training, and community as the basis for its excellent customer service and respected position in the marketplace. Through continuous learning and teambuilding activities, staff members work together to provide customers with the highest quality products and services. Their slogan states this objective: “As Precise As It Gets”. Apollo’s focus on increasing the region’s scientific knowledge, and investing in infrastructure and trained personnel, has created an impact extending beyond its four offices and 40 employees. They regularly participate in South African business events, use local services to create highly visible marketing campaigns, maintain memberships in regional business associations, and regularly advertise in the country’s publications.

The firm is especially proud of its Broad-Based Black Economic Empowerment rating. “South Africa is entering its 13th year of democracy,” said Craig Blignaut. “There are many challenges, but many more opportunities. We are uniquely positioned to capitalize on the growth of industry throughout South Africa. We have the geographical coverage and top-notch people and skills. As South Africa’s industry grows, so does Apollo.” To learn more, visit www.apollosci.co.za. Apollo Scientific’s sales staff at the 2007 Lab Africa trade show. The firm is known for its dynamic sales and marketing efforts, as well as its strong support for the South African business community. Sales/Marketing Director Craig Blignaut.  BACK TO TOP

Societies & Standards ASTM D7356

After five years of correlation research, the BASF and Q-Lab accelerated acid etch test method was recognized by the ASTM in 2007 as ASTM D7356, Test Method for Accelerated Acid Etch Weathering of Automotive Clearcoats Using a Xenon Arc Exposure Device. For more information, request 732 John Boisseau of BASF spoke about accelerated acid etch test research and ASTM D7356 at Q-Lab’s Automotive Weathering Symposium last October in Detroit. ISO TC 38/SCI Textiles Several Q-Lab representatives participated with representatives from 10 countries in the ISO TC 38/SCI Textiles meeting in Las Vegas last July.

The WG1 Light & Weathering Working Group discussed standards affecting the textile industry, hearing arguments for changing ISO 105 B02 from a hardware based to a performance based method. Patrick Brennan from Q-Lab will lead a six-country group performing additional testing and standard drafting for possible revisions in ISO/DIS-B10. Raymond Ramrajkar (left), representing the Bureau of Indian Standards, shares a moment between meetings of the ISO textile group in Las Vegas with Patrick Brennan, a U.S. delegate from Q-Lab Corporation. BACK TO TOP

Justin Kowallek Joins U.S. Sales

Justin Kowallek has joined Q-Lab as a Sales Representative serving the U.S. and Canadian markets. He is based at the company’s headquarters in Cleveland, Ohio. Justin previously worked for CEC Combustion Services Group, where he was responsible for client relationship management, sales training and support, parts management, as well as various marketing functions. He is a graduate of Baldwin-Wallace College.

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Q-Panel, QUV, Q-Lab, Q-Sun, Q-Fog, and Solar Eye are trademarks of Q-Lab Corporation.

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