Multi-Mode Salt Spray Chambers: Switch Between Neutral/Acidic Salt Tests

Shanghai – TOBO GROUP, a leader in industry-specific corrosion testing solutions, is proud to launch the NeoEnergi Corr Salt Spray Tester—a purpose-built system engineered to address the unique corrosion challenges of new energy sectors, including hydrogen storage, lithium-ion batteries, and offshore wind. Unlike traditional salt spray testers that fail to simulate the compound stressors of new energy environments (e.g., salt fog + high pressure for hydrogen tanks, saltwater ingress + temperature cycles for battery packs), this platform combines multi-factor condition simulation, new energy-specific material compatibility, and compliance with emerging industry standards—critical for manufacturers, R&D teams, and certification bodies ensuring the safety and longevity of next-gen energy technologies.
At the core of the NeoEnergi Corr is its Multi-Factor Corrosion Simulation Module, designed to replicate the real-world stressors that plague new energy components. For hydrogen storage systems (e.g., 70MPa high-pressure tanks), the module integrates a pressure chamber that maintains 0–100MPa pressure while delivering salt fog—mimicking how saltwater exposure (from coastal refueling stations) interacts with high-pressure hydrogen to accelerate corrosion and hydrogen embrittlement. For lithium-ion battery packs (used in EVs and energy storage), it combines salt fog with programmable temperature cycles (-40°C to 85°C) and humidity swings (10–95% RH)—reproducing the “thermal cycling + salt fog ingress” that causes battery seal failure and performance degradation. A hydrogen tank manufacturer using this module discovered that 300 hours of “pressure + salt fog” testing revealed micro-cracks in welds that traditional salt spray tests (no pressure) missed—letting them reinforce the welds before pilot production. The module also supports “electrochemical corrosion” simulation for fuel cell bipolar plates, where it applies a 0.6–1.2V voltage (matching fuel cell operating conditions) alongside salt fog to test corrosion resistance of coated metals like titanium or stainless steel.
Complementing the simulation module is the New Energy Material Compatibility Suite, which avoids the damage traditional testers inflict on sensitive energy materials. Traditional salt spray testers use aggressive 5% NaCl solutions that degrade battery electrolytes or react with hydrogen tank liners; NeoEnergi Corr offers tailored fluid options: a “Hydrogen-Compatible Salt Blend” (low-chloride, pH-neutral) that won’t react with hydrogen or tank polymers, and a “Battery-Safe Solution” (0.9% NaCl with corrosion inhibitors) that prevents electrolyte contamination if salt fog seeps into test samples. The system’s chamber is lined with ETFE (ethylene tetrafluoroethylene)—a chemically inert material that resists attack from battery electrolytes (e.g., LiPF₆) and hydrogen, unlike the stainless steel liners that corrode or leach metals into test environments. An EV battery manufacturer testing pack seals found that traditional testers’ salt solution caused electrolyte oxidation (skewing test results), while NeoEnergi Corr’s Battery-Safe Solution kept electrolytes stable—delivering accurate data on seal performance. The suite also includes non-conductive specimen racks (made of glass-reinforced epoxy) to prevent electrical short circuits when testing battery components, a risk with metal racks in traditional systems.
Real-world applications across new energy sectors highlight the system’s impact: An offshore wind developer used NeoEnergi Corr to test monopile foundations, combining salt fog with wave-induced vibration (simulated via a 5–50Hz shaker) to validate corrosion resistance of anti-corrosion coatings—ensuring 25-year service life in North Sea conditions. A fuel cell manufacturer tested bipolar plates with the electrochemical corrosion simulation, confirming that their new nickel coating reduced corrosion current density by 60% compared to industry benchmarks—speeding up fuel cell stack development. An energy storage firm used the temperature cycle + salt fog feature to optimize battery pack gaskets, finding that a silicone-fluoropolymer blend retained 90% of its sealing force after 500 cycles—outperforming the original EPDM gaskets (which dropped to 60%).
“New energy components face corrosion challenges no industrial part has seen before—high pressure, thermal cycling, reactive chemicals, and tight safety margins,” said TOBO GROUP’s New Energy Testing Director. “NeoEnergi Corr doesn’t just test corrosion—it tests how corrosion interacts with the unique demands of clean energy. For teams building the future of energy, that’s the only way to ensure safe, reliable products.”
For more information about the NeoEnergi Corr Salt Spray Tester, including pressure/temperature range specs, compatible new energy standards, and custom simulation setups, visit Info@botomachine.com.