Testing Lab of Power Supply/ IT / AV Products

Whether your power supply product requires salt spray testing depends on its application environment and customer specifications. This step-by-step guide walks you through the complete salt spray testing workflow for power supply products — from determining whether testing is needed to interpreting the final report.

Step 1 — Determine Whether Salt Spray Testing Is Required

Not every power supply needs salt spray testing. Assess the following criteria:

• Indoor-use power supplies　Desktop adapters, indoor chargers — typically no salt spray requirement unless specified by customer
• Outdoor power supplies　Solar inverters, outdoor energy storage, EV charging stations — salt spray testing strongly recommended
• Automotive power supplies　OBC, DC-DC converters — mandatory per ISO 16750-4
• Customer specifications　If the customer document explicitly requires salt spray data, it becomes a mandatory test regardless of product type

Step 2 — Identify the Components to Test

Salt spray testing is typically performed on individual components and coating samples rather than complete power supply units:

• Metal enclosures　Zinc-plated steel, powder-coated aluminum — test as flat panels or actual housing pieces
• Heat sinks　Extruded or die-cast aluminum with anodized finish
• Connectors and terminals　Tin-plated or nickel-plated contacts
• Fasteners　Zinc-plated screws and hardware

Step 3 — Select the Test Method and Duration

Match the test method to the coating system and application severity:

• Zinc plating (electroplated)　NSS 24–96h — check for white rust and red rust
• Hot-dip galvanizing　NSS 96–480h — extended duration for thick zinc layers
• Anodized aluminum　CASS 24–48h — accelerated method for thin oxide layers
• Powder coating　NSS 240–480h + scribe creepage evaluation

Step 4 — Prepare and Submit Samples

• Submit 3–5 samples per test condition (including unexposed reference specimens)
• Mask non-test surfaces with corrosion-resistant tape or wax
• If scribe assessment is required, have the lab create the scribe under controlled conditions
• Provide coating process documentation (type, thickness, curing conditions)

Step 5 — Evaluate Results and Obtain Report

After the test concludes, the lab performs the following evaluation:

• Gentle rinse to remove salt deposits (no scrubbing)
• Drying period (minimum 24 hours under standard conditions)
• Visual assessment per ISO 4628 (blistering, rusting, flaking)
• Scribe creepage measurement (if applicable)
• Photographic documentation and formal test report

Anci provides end-to-end salt spray testing for power supply products — from initial assessment of whether testing is needed, through method selection and sample preparation, to final reporting. One lab, one project, all standard methods covered.

This article was generated with AI assistance. Content is for reference only and does not constitute any testing commitment or legal advice. Always refer to the latest official standards.

Contact: net01@gtggroup.com