The salt spray corrosion test of copper aluminum hybrid busbar joints is widely used in high-voltage connectors of new energy vehicles. It takes several years to show failure only by natural exposure, while the salt spray test can simulate 3-5 years of actual service damage within 72-168 hours, achieving accelerated verification. By conducting salt spray experiments, the influence of different material combinations, surface treatment processes, or protective measures on the corrosion resistance of copper aluminum joints can be evaluated, providing important data support for the reliability design and life prediction of high-voltage connectors for new energy vehicles.
GB/T 28046.4-2011 “Environmental conditions and tests for electrical and electronic equipment of road vehicles – Part 4: Climate loads”
Equivalent to ISO 16750-4, which is a mandatory reference standard for high-voltage connection systems in new energy vehicles, performance evaluation indicators are proposed for copper aluminum joints: contact resistance increment ≤ 10 m Ω, insulation resistance ≥ 100 M Ω, no visible corrosion penetration, no coating peeling, and no sealing failure after testing.
Salt spray experiments require recording changes in contact resistance and testing with low DC resistance. We recommend using the Meric RK2514N, which has a four wire measurement accuracy of 0.05% and a resolution of 0.1 μ Ω. It can accurately capture micro Euro level contact resistance drift during salt spray processes; Equipped with automatic data recording function, a curve graph is automatically formed to fully cover the resistance value changes of the salt spray test corrosion process, providing engineers with visual basis for corrosion dynamics and helping them accurately identify the key turning points of corrosion initiation and propagation, thereby predicting failure boundaries between nanometers; Its data not only maps the intrinsic degradation law of materials, but also reflects the deep correlation between design redundancy and process robustness.
Post time: Jan-30-2026
