Shanghai – BOTO GROUP, a global frontrunner in advanced corrosion testing equipment, has unveiled a new line of electric vehicle (EV)-specific salt spray test chambers, engineered exclusively to address the unique corrosion challenges facing new energy vehicle components—including EV battery enclosures, fast-charging connectors, undercarriage structural parts, and onboard charging modules. As the global EV market expands rapidly, traditional salt spray testing systems have struggled to replicate the dual stresses of high-voltage electrical loads and real-world road corrosive conditions, such as winter road de-icing salts, coastal salt mist, and battery thermal cycling; BOTO’s new EV-focused chambers fill this gap with integrated, EV-tailored testing capabilities, marking a significant leap forward in ensuring the safety and longevity of next-generation electric vehicles.
The EV industry faces a distinct set of corrosion-related hurdles that generic salt spray chambers cannot adequately address: EV battery enclosures must resist salt intrusion while withstanding the thermal expansion and contraction from repeated charging and discharging cycles; fast-charging connectors handle high current (up to 350A) alongside exposure to road salt and moisture, with corrosion here posing risks of electrical arcing or charging failures; undercarriage components like motor mounts and suspension links are lower to the ground and more vulnerable to splashed de-icing salts than those in internal combustion engine (ICE) vehicles; and onboard charging modules require protection from both salt corrosion and high-voltage electrical leakage. These challenges demand a testing system that merges salt spray exposure with EV-specific operational stresses, a capability that BOTO’s new chambers deliver through purpose-built design and proprietary technology.
At the core of BOTO’s EV-specific salt spray test chambers is a suite of integrated features tailored to the automotive sector’s rigorous standards and EV-specific demands, starting with a high-voltage-salt corrosion integration module that allows for simultaneous salt spray exposure and electrical load simulation (up to 400A DC, matching the output of ultra-fast EV chargers). This module enables clients to test fast-charging connectors and battery terminal blocks under realistic high-current conditions, replicating the way electrical resistance from corrosion can lead to overheating or charging interruptions. Complementing this is the thermal cycling-salt spray system, which pairs 3.5–5% NaCl salt mist (mimicking road de-icing salts and coastal air) with precise temperature cycling between -30°C and 60°C—mirroring the thermal fluctuations of EV battery packs during charging, discharging, and ambient weather changes. The chambers also feature a road-splash simulation tool, which uses pressurized saltwater jets (adjustable to speeds of 20–40 km/h, matching typical highway driving) to replicate the force of salt-laden water splashing onto EV undercarriage components, a critical capability for validating the corrosion resistance of motor housings and suspension parts. Additionally, the chambers boast ultra-precise salt concentration control (±0.05% NaCl accuracy) and a non-conductive, high-voltage-safe fixturing system that prevents electrical shorting during testing, while their cloud-based data platform generates reports aligned with key EV industry standards, including ISO 12944-5 (automotive corrosion protection), SAE J2334 (automotive salt spray testing), and GB/T 30038 (EV battery enclosure safety). The chambers also support dual-scale testing, accommodating large components like full-size battery enclosures (up to 5m in length and 3 tons in weight) as well as micro-components such as charging port contact pins (as small as 0.3mm in diameter), eliminating the need for automakers to invest in multiple specialized testing setups and reducing overall testing costs by 25%.
BOTO GROUP has a 15-year legacy of delivering industry-specific corrosion testing solutions to sectors ranging from marine science and defense to food processing and railway transit, with a dedicated R&D team of 30+ materials engineers and corrosion specialists focused on solving emerging industry challenges. The company’s global footprint includes testing labs and support centers across North America, Europe, and Asia, enabling it to serve clients in key automotive manufacturing hubs with localized expertise and rapid response times.
Sherry, Director of Communications at BOTO GROUP, is the primary media contact for all inquiries related to the new EV-specific salt spray test chambers, and can be reached at Info@botomachine.com or +86 13761261677 for press interviews or additional product details.
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