Standard: STJLR.00.

5235 Jaguar Land Rover Limited - Engineering Standard

Issue: 3
Date: 16 May 2022 Title: Requirements for Cabinet Corrosion
Page: 1 of 17
Validation - Total Vehicle

A INDEX

A Index
B Scope
C Object
D Review
E Related Documents
F Laboratory Corrosion Test Requirements
G End of Test Assessment Criteria
Z Change History
Appendix A Application of Corrosion Acceptance Criteria

B SCOPE

This standard is applicable to the laboratory corrosion test requirements for components, joints,
assemblies, and sub-assemblies intended for use on all Jaguar and Land Rover vehicles.

This standard does not apply to functional testing of exhaust systems or the serviceability of
components due to the static nature of the test methods used.

C OBJECT

This standard defines the cabinet corrosion test requirements to qualify components, assemblies,
and sub-assemblies for use on the whole vehicle corrosion test (TPJLR.00.141). The whole
vehicle corrosion test and Brand Requirement STJLR.00.5180 must be met for engineering sign
off.

The requirements specified in this document have been aligned to the appearance and
functionality requirements defined in STJLR.00.5180 - Total Vehicle Corrosion Resistance.
Additional cabinet corrosion test requirements may still apply as defined in the relevant
engineering standard (STJLR) for metallic and non-metallic coatings.

It is the responsibility of the Commodity Owner to review this document and agree the
requirements with Materials Engineering to ensure compliance is met prior to the appropriate
PCDS gateway.

This document is approved for use by Jaguar Land Rover Limited

Prepared by: Matt Walters Authorised by: Rebecca Hitch
cdsid: mwalter1 cdsid: rhitch

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Standard: STJLR.00.5235 Jaguar Land Rover Limited - Engineering Standard
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Date: 16 May 2022 Title: Requirements for Cabinet Corrosion
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D REVIEW

This document must be reviewed at least every three years from the date of the last review or
update.

E RELATED DOCUMENTS

STJLR.00.5180 Total Vehicle Corrosion Resistance (JLR use only)

STJLR.00.5268 Vehicle Cosmetic Corrosion line of Sight
TPJLR.00.141 Global 12 Week Total Vehicle Accelerated Corrosion Test (JLR use only)
TPJLR.52.265 Laboratory Accelerated Cyclic Corrosion Test
TPJLR.52.351 Resistance to Humidity – General
SAE J400 Test for Chip Resistance of Surface Coatings
JLR-HTG-38932 Corrosion Avoidance Guidelines (JLR use only)
JLR-HTG-547103 Coating Selection Guide (JLR use only)
EN ISO 4628-2 Paint and Varnishes – Evaluation of Degradation of Coatings –
Assessment of Degree of Blistering
EN ISO 4628-3 Paint and Varnishes – Evaluation of Degradation of Coatings –
Assessment of Degree of Rusting
DRJLR.55.7026 Corrosion Protection of Steel Underbody Parts at High Risk of Stone Chip
Damage

F LABORATORY CORROSION TEST REQUIREMENTS

1 This section defines the cabinet corrosion test requirements for components, assemblies and sub-
assemblies that provides correlation to the salt spray and climatic loading part of the Gaydon
Proving Ground Whole Vehicle Corrosion Test (TPJLR.00.141):

1.1 The cyclic corrosion test specified in this standard is designed to maximize corrosion in
crevices, such as lap joints and hem flanges but is also applicable to painted aluminium and
steel substrates, galvanic corrosion of mixed-material joints and perforation of unpainted
surfaces.

1.2 It is intended that components and systems are tested in the vehicle orientation position
where possible, ensuring that exposure to salt solution can reach the target areas as defined
by a risk analysis or FMEA process.

1.3 Unless stated, coating systems shall not be scribed prior to test. Where component pre-
conditioning is required, the details shall be agreed with the Materials Engineering corrosion
specialist prior to testing.
1.4 Test requirements are arranged by vehicle zone in Sections F2 to F6 as defined below:
• Zone 1: Cabin and Load Space
• Zone 2: Engine Bay
• Zone 3: Exterior Body
• Zone 4: Exterior Underbody
• Zone 5: Wheel Housing, Wheels, Suspension and Braking System

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Date: 16 May 2022 Title: Requirements for Cabinet Corrosion
Page: 3 of 17
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1.5 Where a zone dictates both Appearance and Functional assessments, the total test duration
is taken as the functional test duration. Appearance is evaluated against the pass/fail criteria
provided in Section G1 and functionality is assessed with reference to the acceptance
criteria in Section G2.

1.6 Refer to JLR-HTG-547103 for guidance on coating selection for steel substrates (for JLR use
only).

1.7 Refer to JLR-HTG-38932 for guidance on designing for corrosion protection (for JLR use
only).

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2 Zone 1: CABIN AND LOAD SPACE

Area Scope of Application Test Method Test Duration

Interior cabin and load space:
1A Appearance of visible metallic components and brackets behind interior trim. TPJLR.52.351 72 hours
Functional testing of electronic devices and sealed electronic enclosures.

Interior areas at risk of wetting from spillages, wet luggage, melted snow from shoes etc.:
1B Appearance of metallic parts in customer-visible areas such as deployable load space floor, front TPJLR.52.265 4 cycles
load space (BEV) and metallic features in floor/load space mats.

Figure 1. Example zones for interior cabin (left), front load space in BEV (middle) and deployable load space floor (right)

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3 Zone 2: ENGINE BAY & UNDER BONNET:

Area Scope of Application Test Method Inspection Points

Front end behind grille and under bonnet mechanisms: e.g. bonnet hinges, latches, strikers, Appearance: 14 cycles
2A TPJLR.52.265
deployable bonnet actuator, front-end carrier – Also applies to BEV Functional: 35 cycles
Appearance: 7 cycles
2B* Upper engine bay above wading line TPJLR.52.265
Functional: 14 cycles
Appearance: 7 cycles
2C Plenum/cold zone: e.g., wiper mechanisms TPJLR.52.265
Functional: 28 cycles
Appearance: 7 cycles
2D Lower engine block below wading line TPJLR.52.265
Functional: 35 cycles
* Elevated temperature pre-conditioning of parts prior to corrosion testing may be required as identified by the risk analysis or FMEA process

Figure 2. Example zone definitions for engine bay & under-bonnet components

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Date: 16 May 2022 Title: Requirements for Cabinet Corrosion Validation - Total Vehicle
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4 Zone 3: EXTERIOR BODY:

Area Scope of Application Test Method Inspection Points

Appearance: 42 cycles
3A* Exterior body mounted trim TPJLR.52.265
Functional: 42 cycles
Appearance: 14 cycles
3B Wiper Arm Assemblies TPJLR.52.265
Functional: 28 cycles
Appearance: 7 cycles
3C Closure hinges, latches and locks located between primary and secondary BIW seals TPJLR.52.265
Functional: 21 cycles
3D Functional testing of joints and mechanisms between inner and outer skin panels TPJLR.52.265 Functional: 35 cycles

3E Functional testing of sealed electronic systems: e.g., test for moisture ingress TPJLR.52.351 Functional: 168 hours

* Areas at risk of stone chip damage to be pre-conditioned using the SAE J400 stone chip test as identified by the risk analysis or FMEA process for the vehicle
class or usage profile

Figure 3. Example zone definitions for exterior mounted components

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5 Zone 4: EXTERIOR UNDERBODY:

Area Scope of Application Test Method Inspection Points

PDI: 1 cycle
Generic underbody requirement
4 TPJLR.52.265 Appearance: 14 cycles
1 cycle PDI assessment only applies to ‘visible’ surfaces (see STJLR.00.5268)
Functional: 56 cycles
SAE J400 + Appearance: 14 cycles
4A Steel components at high risk of stone chip damage (see DRJLR.55.7026)*
TPJLR.52.265 Functional: 42 cycles

4B Stainless steel exhaust trim finishers (appearance only) TPJLR.52.265 Appearance: 7 cycles

* Stone chip the exposed surface using the SAE J400 stone chip test as identified by the risk analysis or FMEA process for the vehicle class or usage profile

Figure 4. Example zone definitions for exterior underbody components

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Date: 16 May 2022 Title: Requirements for Cabinet Corrosion Validation - Total Vehicle
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6 Zone 5: WHEEL HOUSING, WHEELS, SUSPENSION AND BRAKING SYSTEM:

Area Scope of Application Test Method Inspection points

Appearance: 28 cycles
5A Brake calipers and coated areas of brake disc hub TPJLR.52.265
Functional: 56 cycles
Components in wheel housing area (e.g., springs, damper modules, brackets behind PDI: 1 cycle
5B wheel arch liner). TPJLR.52.265 Appearance: 14 cycles
1 cycle PDI assessment only applies to ‘visible’ surfaces (see STJLR.00.5268) Functional: 42 cycles

5C* Aluminium and steel road wheels (appearance only) TPJLR.52.265 Appearance: 42 cycles

* Paint system to be scribed prior to testing as advised by the corrosion test specialist

Figure 5. Example zone definitions for wheels, suspension and braking systems

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G END OF TEST ASSESSMENT CRITERIA

1 Acceptance criteria for simulated PDI and appearance testing:

1.1 The following assessment criteria is necessary to qualify components for vehicle-level
corrosion testing.

1.2 Visible components located in Zones 4 and 5B shall be assessed after 1 cycle of
TPJLR.52.265 with a requirement of no red rust on visible surfaces.

1.3 Part visibility may be evaluated by virtual or physical vehicle assessment with reference to
STJLR.00.5268 Vehicle Cosmetic Corrosion Line of Sight.

1.4 Refer to Table 1 for the acceptance criteria and allowable exceptions on appearance.
Allowable exceptions are based on part visibility when fitted to vehicle.

1.5 Photographic references A1 to A14 in Appendix A provide guidance on the application of

pass/fail criteria given in Table 1 of this section.

1.6 Requirements for materials/coatings not covered in Table 1, or any deviations from the
appearance requirements listed in Table 1, must be agreed with the Materials Engineering
corrosion specialist before DV/PV testing is conducted.

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TABLE 1: Acceptance criteria for APPEARANCE

MATERIAL/COATING PASS/FAIL CRITERIA ALLOWABLE EXCEPTIONS

Zone 1:
Hidden parts may show localised rust spots (<10% surface
area) provided there is no rust bleed to visible surfaces or
transfer of rust on to trim surfaces (A1). Parts with metallic
coatings may show rust spots at cut edges.

Zones 2, 4, 5A & 5B:

Parts with metallic coatings may show white corrosion and
pitting of the metallic coating (A2, A3).
Iron and steel*
No rust allowed:
substrates Zones 2, 4 & 5B:
Ri0 to EN ISO 4628-3.
Rust spots on threaded areas of fixings is allowed. Complete
*Not applicable to
Painted parts: No blistering or loss consumption of a metallic coating is not allowed.
stainless steels. See
of paint adhesion allowed (A5).
requirements below Painted parts may show small, isolated rust spots at edges
and welds (A4, A5).

Parts or areas of components which are considered

obscured from line of sight when fitted to the vehicle may
show localised red rust on welds and edges (A4 to A6), but
not if associated with paint blistering or delamination.

Painted areas purposely damaged prior to testing (e.g., by

stone chipping) may show white corrosion (A7).

Zones 1, 2, 4 & 5B: Light surface corrosion in hidden areas is

No visible white corrosion product acceptable (A1, A8).
allowed (A8).
Zones 2, 4 & 5B: Bare aluminium may show surface
Aluminium and Painted parts: No blistering/filiform discolouration and light pitting (A10).
magnesium substrates or loss of paint adhesion allowed.
Zones 3A & 5C: Painted surfaces scribed through to
No evidence of galvanic corrosion substrate may show filiform corrosion up to 3 mm
from adjoining materials (A9). perpendicular from the scribed line. However, merging of
filaments along the scribed line is not acceptable (A13).

Zone 4B: Isolated rust spots, less than 0.5 mm in diameter

No rust allowed on visible surfaces,
on visible surfaces is acceptable (A11).
nor rust bleed from hidden areas on
to customer-visible surfaces.
Stainless steels Zones 2 & 4: Isolated rust spots and staining on open
surfaces is acceptable, provided the affected surface area is
No galvanic corrosion of adjoining
no greater than 0.3%. Rust around welds in hidden areas is
materials.
acceptable (A11)

No evidence of distortion, cracking,

crazing, blistering, gloss change, Evidence of discontinuous micro-pores on the surface of
discolouration, staining or chromium-nickel plating is allowed (A12).
Decorative finishes
dimensional change allowed.
(Zones 1 and 3A)
Zone 3A: Notwithstanding the pass/fail criteria opposite, any
No green corrosion product allowed. tarnishing at the end of test which can be removed with a
(1) Chromium-nickel
microfibre cloth and nonabrasive car polish (e.g. Autoglym
systems
No merging of discontinuous micro- Super Resin Polish) is acceptable for exterior parts. Parts
(2) Copper plating
pores and no corrosion in the semi- must not be polished until the end of test and the polishing
bright nickel layer in chromium- media used must be stated in the final test report.
nickel systems.

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2 Acceptance criteria for functionality:

2.1 The minimum end of test requirement is ‘no impaired function due to corrosion’. Refer to
Table 2 for guidance on the evaluation of functional degradation indicators due to corrosion.

2.2 The definition of component-specific functionality (e.g., by mechanical or electrical actuation)

to be applied at the end of the test period shall be defined by the commodity owner following
a risk analysis or FMEA process.

2.3 Where further clarification of functional test requirements is needed, consult the Materials
Engineering corrosion specialist.

TABLE 2: Acceptance criteria for FUNCTIONALITY on systems and components intended to

function throughout the normal service life of a vehicle
SYSTEM Requirement:

General requirement No impaired function due to corrosion at the end of the test period.

Painted surfaces
Loss of paint adhesion or delamination surrounding the point of corrosion is not
including edges and
allowed (See A14 in Appendix A).
welds

No evidence of crevice or galvanic corrosion that could result in functional failure

Joints, flanges, and
over the normal service life of the vehicle (e.g., complete consumption of protective
confined areas
metallic coating).

Sealing surfaces (e.g., Corrosion must not have propagated more than 50% into the designated sealing
O-rings, gaskets) area.

Electrical distribution No corrosion on busbars, connections or contact surfaces of ground

(junction boxes, studs/connectors that degrades conductor resistance or functional performance
ground connectors) (e.g., ground attachments evaluated to requirement ED-5435).

No ingress of corrosive media into electronic devices.

No interior corrosion accepted in encapsulations intended to be fully sealed-off.
No corrosion propagation into normal sealing area after test.
Electronic devices
No corrosion undermining seals with an adhesive function.
(Sealed enclosures)
No significant base metal corrosion in metallic covers/heat exchanging surfaces
that could lead to loss off function.
No base metal corrosion along sealing planes or within associated crevices.

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Z CHANGE HISTORY

Issue Date Description of Change

1 13 Sep 2018 First issue
Section H removed. Updates to test duration and zoning definitions with
2 20 Nov 2019 correlation to TPJLR.00.141. Appearance acceptance criteria and
photographic references updated in Appendix A.

3 16 May 2022 Updates to Section G text, Table 1, and images in Appendix A.

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APPENDIX A: APPLICATION OF CORROSION ACCEPTANCE CRITERIA

The following examples provide guidance on the end of test assessment criteria and allowable
exceptions defined in Table 1 and Table 2 (Section G).

APPEARANCE:
A1: Hidden parts in Zone 1

RESULT = PASS.

Ferrous substrates: Hidden parts may show localised rust spots

(<10% surface area) provided there is no rust bleed to visible
surfaces or transfer of rust to trim surfaces

Non-ferrous substrates: Light surface corrosion in hidden areas is

acceptable

A2: Zinc plating on ferrous substrate

RESULT = PASS. No visible red rust. Pitting of the zinc

layer is acceptable as this supports the intended corrosion
mechanism

A3: Aluminium-silicon (AlSi) coating on ferrous substrate

RESULT = FAIL. Visible red rust is not allowed

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A4: Painted steel

RESULT = FAIL. Rust spots on main surface, bleed from balance weight and rust around the weld resulting in
e-coat blistering is not acceptable

RESULT = PASS. No red rust on main surface. Localised rust at weld, joint and balance weight that does not
result in paint blistering is acceptable in areas that are shielded from direct line of sight

A5: Painted steel

RESULT = PASS. Small, isolated rust spots are allowed

RESULT = FAIL. Edge corrosion has resulted in
at edges as long as it is not associated with blistering or
blistering of the paint layer
paint delamination.

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A6: Painted steel

RESULT:
FAIL. If the areas are visible on ramp, then
localised rust at edges and welds is not acceptable

PASS. If the area is covered from view when fitted

to vehicle (e.g. by under tray), and inspected on
ramp, this level of rust is acceptable as there is no
associated paint blistering

A7: Painted surfaces stone chipped surface prior to corrosion test

RESULT = PASS. Only white corrosion in areas damaged RESULT = FAIL. Visible red rust in areas
by pre-test stone chipping damaged by pre-test stone chipping

A8: Powder coated cast magnesium alloy

RESULT = PASS. Light surface corrosion in non- RESULT = FAIL. White corrosion product on
visible areas of the component is acceptable customer visible surfaces is not acceptable

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A9: Steel fixings into aluminium

RESULT = FAIL Galvanic corrosion is not acceptable

A10: Aluminium damper yoke

Before test After test

RESULT = PASS. Surface discolouration and light pitting is acceptable

A11: Stainless steel

RESULT = PASS. For underbody Zone 4, isolated rust spots and

staining on open surfaces is acceptable, provided the affected
surface area is no greater than 0.3%

RESULT = PASS. For underbody Zone 4, rust around welds in

hidden areas is acceptable.

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A12: Chromium-nickel plated lettering

RESULT = FAIL. Visible corrosion pits and blistering of micro-discontinuous chromium/nickel layer is not
allowed

A13: Aluminium alloy with organic coating scribed through to substrate

RESULT = PASS. Individual filament growth less RESULT = FAIL. Merging of filaments along scribed
than 3 mm from scribed line line and growth exceeding 3 mm

COATING FUNCTIONALITY:
A14: Delamination of paint layer on steel substrate

RESULT = FAIL. Delamination of the paint layer

represents a functional failure of the coating
system

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