Designation: D 2803 – 03

Standard Guide for Testing

Filiform Corrosion Resistance of Organic Coatings on
Metal1
This standard is issued under the fixed designation D 2803; the number immediately following the designation indicates the year of 
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope D 1654 Test Method for Evaluation of Painted or Coated

1.1 This guide covers three procedures for determining the Specimens Subjected to Corrosive Environments
susceptibility of organic-coated metal substrates to formation D 1730 Practices for Preparation of Aluminum and
of filiform corrosion. Aluminum-Alloy Surfaces for Painting
1.2 This guide is limited to the determination of whether E 104 Practice for Maintaining Constant Relative Humidity
filiform corrosion will occur between the organic coating and by Means of Aqueous Solutions
substrate. 2.2   International Standard:3
1.3 The values stated in SI units are to be regarded as the ISO 4623–1 Paints and Varnishes—Determination of resis-
standard. The values given in parentheses are for information tance to filiform corrosion–Part 1: On steel
only. ISO 4623–2 Paints and Varnishes—Determination of resis-
1.4   This standard does not purport to address all of the tance to filiform corrosion–Part 2: On aluminum
safety problems, if any, associated with its use. It is the ISO 4628–10 Paints and Varnishes—Evaluation of degrada-
responsibility of the user of this standard to establish appro- tion of coatings–Designation of quantity and size of 
 priate safety and health practices and determine the applica- defects and of intensity of changes–Part 10: Assessment of 
bility of regulatory limitations prior to use. filiform corrosion

2. Referenced Documents 3. Terminology

2.1   ASTM Standards:  2 3.1   Definitions:
B 117 Practice for Operating Salt Spray (Fog) Testing 3.1.1   filiform corrosion —a special type of corrosion that
Apparatus occurs under coatings on metal substrates that is characterized
D 609 Practice for Preparation of Cold-Rolled Steel Panels by a definite threadlike structure and directional growth.
For Testing Paint, Varnish, Conversion Coatings, and 3.1.1.1   Discussion—Filiform corrosion usually occurs be-
Related Coating Products tween 20 and 35°C (70 and 95°F), with a corresponding
D 823 Practices for Producing Films of Uniform Thickness relative humidity range of 60 to 95 %; above 95 % humidity,
of Paint, Varnish, and Related Products on Test Panels blistering rather than filiform corrosion may occur.
D 1005 Test Method for Measurement of Dry-Film Thick-
4. Summary of Method
ness of Organic Coatings Using Micrometers
D 1186 Test Methods for Nondestructive Measurement of  4.1 Coated metal specimens are scribed and placed in a
Dry Film Thickness of Nonmagnetic Coatings Applied to corrosive atmosphere to initiate corrosion. The specimens are
a Ferrous Base then exposed to controlled temperature and humidity condi-
D 1400 Test Method for Nondestructive Measurement of  tions known to be conducive to filiform corrosion.
Dry Film Thickness of Nonconductive Coatings Applied to 4.2 In Procedure A, panels are subjected to a preliminary
a Nonferrous Metal Base exposure in the salt spray cabinet to initiate corrosion, rinsed,
and placed in a humidity cabinet. In Procedure B, based on ISO
4623, panels are either exposed to salt spray or dipped in a salt
1
This guide is under the jurisdiction of ASTM Committee D01 on Paint and solution but not rinsed before placing in the humidity cabinet
Related Coatings, Materials, and Applications and is the direct responsibility of  operated at a higher temperature than in Procedure A. In
Subcommittee D01.27 on Accelerated Testing.
Procedure C, specimens are exposured as in Procedure A
Current edition approved Dec. 1, 2003. Published December 2003. Originally
approved as D 2803 – 69 T. Withdrawn June 2002 and reinstated as D 2803 – 03. except the humidity cabinet is operated at a higher temperature.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [email protected]. For  Annual Book of ASTM 
3
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the ASTM website. Floor, New York, NY 10036.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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D 2803 – 03
4.3 The procedures contained in this guide differ signifi- 9.2 Remove from the salt-fog cabinet and thoroughly rinse
cantly in method of initiation, and or temperature, or both, and with distilled or demineralized water. Do not permit specimens
humidity of exposure and therefore may not yield comparable to dry before placing in the humidity cabinet.
results. 9.3 Place the specimens in the humidity cabinet so they are
no closer together than 40 mm (1.5 in.) and not in contact with
5. Significance and Use
any metal. Operate the cabinet at 25  6  2°C (77  6  3°F) and 85
5.1 Some organic coatings applied to metal substrates ex- 6  2 % relative humidity unless otherwise agreed upon between
hibit filiform corrosion when there is a break in the coating film the producer and user.
and the relative humidity is in the 70 to 95 % range.
NOTE   5—The recommended means of maintaining the specified rela-
5.2 This guide can be used to determine the susceptibility of 
tive humidity is to utilize trays of saturated potassium chromate solution
organic coated metal substrates to the formation of filiform
(650 g/L). Practice E 104 describes other methods for maintaining relative
corrosion. humidity, but they may affect the degree and rate of filiform corrosion.
6. Apparatus 9.4 Inspect the specimens at intervals of approximately 168
6.1   Salt-Spray Chamber  as described in Practice B 117, for h for development of threadlike filaments from the scribe.
salt-spray (fog) testing. Exercise care to maintain wetness of specimens during inspec-
tion, since drying stops the original pattern of filiform corro-
NOTE   1—The preferred initiator of corrosion at the scribe is the salt-fog sion. New filiform may develop on continued exposure but at
atmosphere described in Practice B 117. Exposure of the specimens for 2
different points.
to 4 h in a closed cabinet to the atmosphere above a 1 % acetic acid
solution is an acceptable alternative. 9.4.1 Filiform corrosion will be noted as threadlike fila-
ments (see Note 6), initiating at the scribe. A standard method
6.2   Humidity Cabinet —Any cabinet with suitable tempera-
of rating failure due to filiform is not available. The uniformity
ture and humidity controls with air circulation may be used.
of filament growth in direction, width, height and frequency
The size and detailed construction of the apparatus are op-
precludes a precise rating system. Photographs of filiform
tional, provided the conditions meet the requirements of this
failure are preferred for recording test results. Otherwise, a
method.
brief description of the filament growth and their frequency can
7. Test Specimen be made. ISO 4628–10 provides a method for the measurement
7.1 The composition, surface preparation, and number of  of filiform filaments. Filiform corrosion may continue to
test specimens shall be agreed upon between the producer and develop after specimens are removed from the humidity
the user. Steel is the preferred substrate, but other metals such cabinet.
as aluminum, copper magnesium, and stainless steel may be NOTE   6—The nature of grinding and grain direction on panels can
used. Zinc and zinc-coated steel are not recommended because influence the direction of filiform growth.
filiform corrosion generally does not occur on zinc. 9.5 The normal test period is 6 weeks (1008 h). Other
NOTE   2—Applicable test panel description and surface preparation periods may be used at the option of the producer and user.
methods are given in Practice D 609 and Practices D 1730.
10. Procedure B (ISO 4623)
7.2   Preparation of Test Specimens —The method of appli-
10.1 Two alternative initiations of corrosion are available,
cation, film thickness, curing, and conditioning shall be agreed
based on initiation by dipping in sodium chloride solution (see
upon between the producer and user.
Note 7) or exposure to salt fog. The dipping technique is
NOTE   3—Test Methods D 823 gives application methods that can be generally preferable for air drying and low-durability materi-
used to produce films of uniform film thickness. als. For high-durability systems such as automotive finishes
NOTE  4—Test Methods D 1005, D 1186, and D 1400 give procedures
applied to phosphated steel, the dipping technique may not
that can be used for measurement of dry film thickness.
produce filiform corrosion and for these systems, it is prefer-
7.3 Scribe the test specimen in accordance with Test Method able to adopt the salt-fog technique. In such cases, the
D 1654 or as agreed upon between the producer and user. necessary period of exposure to salt fog depends on the
7.4 The back and edges of the panel should be protected durability of the material under test but should rarely need to
with an anti-corrosion coating or tape, unless edge failure is exceed 24 h.
being evaluated.
NOTE   7—Sodium chloride 0.1 % (w/v) solution (for dipping technique)
8. Use of Control or Reference Materials is prepared by dissolving 1 g of reagent grade sodium chloride (NaCl) in
8.1 When several coatings are being compared, select a 1 L of distilled or demineralized water. Place this solution in a vessel
suitable for complete immersion of the test panel.
coating as a control. Apply the control coating to the same
substrate as the test coatings. For best results there should be 10.2  Dipping Technique:
two controls, one known to perform well and one known to 10.2.1 Immerse the scribed specimen for 30 to 60 s in the
perform poorly. sodium chloride solution (see Note 7).
10.2.2 Take the specimen out of the solution and remove
9. Procedure A any drops of liquid adhering to it, taking care not to remove the
9.1 Expose the test specimens to the salt-fog atmosphere in solution from the scribed marks.
accordance with Practice B 117 for at least 4 h and not more 10.2.3 Place the specimen in a humidity cabinet maintained
than 24 h, or as agreed upon between the producer and user. at 40   6  2°C (104   6  3.5°F) and 80   6  5 % relative humidity.

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D 2803 – 03
10.2.4 Repeat the immersion procedure every 3 or 4 days 11.2 Remove from the salt-fog cabinet and thoroughly rinse
until the end of the test cycle (21 days) or as agreed upon with distilled or demineralized water. Do not permit specimens
between the producer and the user. to dry before placing in the humidity cabinet.
10.3  Salt-Fog Technique : 11.3 Place the specimens in the humidity cabinet so they
10.3.1 Expose the scribed test specimen to the salt-fog are no closer together than 1.5 in. (40 mm) and not in contact
atmosphere in accordance with Practice B 117 for at least 4 h with any metal. Operate the cabinet at 40  6  2° C (104  6  3° F)
or not more than 24 h or as agreed upon between the producer
and 80   6   5 % relative humidity.
and the user.
10.3.2 Remove the test specimen from the salt-fog cabinet 11.4 Follow the procedures in 9.4 and 9.4.1.
and remove any drops of liquid adhering to it, taking care not
to remove the solution from the scribed marks. 12. Report
10.3.3 Place the specimen in a humidity cabinet maintained 12.1 The report shall include the following:
at 40  6  2°C (104  6  3.5°F) and 80  6  5 % relative humidity for
12.1.1 Initiation procedure,
the specified period agreed upon between the producer and the
user. 12.1.2 Humidity cabinet operating temperature,
10.4 Follow the procedures in 9.4 and 9.4.1. 12.1.3 Exposure period, and
12.1.4 Rating of coatings as described in 9.4.1.
11. Procedure C
11.1 Expose the test specimens to the salt-fog atmosphere 13. Keywords
in accordance with Practice B 117 for at least 4 h and not more
than 24 h, or as agreed upon between the producer and user. 13.1 filiform

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