New DaimlerChrysler Corporation Facility to Aid in Fight Against Rust
26 April 2000
New DaimlerChrysler Corporation Facility to Aid in Fight Against Rust
AUBURN HILLS, Mich. and STUTTGART, Germany, April 26 DaimlerChrysler Corporation has a new weapon in its fight against rust -- the
Accelerated Corrosion Facility located at the company's Chelsea, Michigan,
Proving Grounds. Not only does the facility incorporate the largest test
chambers in North America, but it's also the first in the automotive industry
to take full advantage of the latest computer technology.
The goal of the new facility is to be able to develop vehicles that meet
the company's future corrosion goals, ultimately leading to greater customer
satisfaction with longer-lasting vehicles.
"This facility enables us to replicate the worst possible conditions that
customers can put their cars through, and we make sure our vehicles are
designed to withstand those conditions," said Rick Reuter, Director of
Chelsea/Arizona Proving Grounds.
The state-of-the-art facility's computers control conditions to replicate
the environmental elements found in the North American salt belt, mainly the
northern United States and Eastern Canada or anywhere where roads are salted
to combat ice and snow. Within six months, the test chambers simulate 10
years of real-world driving exposure to the type of severe weather conditions
that aggravate corrosion. This boosts product reliability, as potential
trouble areas are dealt with more efficiently.
"Switching from manual to computer control not only significantly reduces
testing time, but results in more precise testing, ensuring the quality
customers expect," said John Fillion, Senior Manager Body Materials
Engineering.
The facility's test procedures are based on a 10-year study by the Society
of Automotive Engineers (SAE) and the Auto Steel Partnership, which includes
DaimlerChrysler, Ford, General Motors, and major steel companies.
"This is the fastest and most accurate test available today. By
implementing this new method of testing, we are the first in the industry to
apply the combined wisdom of all the corrosion experts," Fillion said.
During the six-month testing process, future production vehicles and
components are abused in every possible way. Each vehicle rotates through the
corrosion chamber and road tests on the Chelsea Proving Grounds. Every other
day the vehicles are driven for 84 miles (135 kilometers) over gravel roads
and through troughs of salt water to induce stone impingement, mud packing,
and salt contamination. The vehicles are returned to the corrosion chambers
where temperatures can reach 140 degrees Fahrenheit (60 degrees Celsius), 20
degrees hotter than at the old facility. Add high humidity levels, fog and a
salt-water mist, and you have the perfect environment for the start and
acceleration of corrosion.
"Gravel chips away at every nook and cranny of a vehicle. We evaluate 280
different parts and study how corrosion starts in paint finishes, materials,
sealings and weldings and find ways to prevent it. When a weakness is found,
corrective action is taken," Fillion said.
For example, when excessive corrosion was detected in rear suspension
parts in an early mule of the Neon, materials and coatings were changed and
again tested. The new components performed well and the Neon was launched
with these new materials in use. "Being able to test faster permitted the
early discovery of this potential problem and allowed the fix to be identified
well before the Neon's launch," Fillion said.
Two corrosion chambers are currently in operation, testing a total of
eight vehicles at a time. A third chamber will be added in 2000, expanding
the capacity of the new facility to test a total of 24 vehicles a year.