Case studies on improving testing processes for batteries, interior components, composites and electronics. Presented at Automotive Testing Expo Europe 2016.

1. CASE STUDIES
Traction Battery testing Services
Material Testing Services

2. 2
Nº1
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OFFICES AND
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14
GLOBAL
INDUSTRIES
GLOBAL
SERVICE
LOCAL
EXPERTISE
AT A GLANCE

3. 3
TRANSPORTATION: AUTOMOTIVE
SOURCE
We test
materials and
parts to OEM
and industry
standards to
facilitate the
supply chain
BUILD
We verify that
manufacturer
vehicle design
and quality
meets
regulations and
gains market
access
SELL
We audit
delivery and
aftermarket
operations to
ensure quality
and brand
guidelines
adherence
POWER
We enhance the
design,
construction and
operation of
motor vehicles,
testing fuels,
lubricants and
usability
SAFEGUARD
Our vehicle
testing centres
worldwide verify
safety and
minimise
environmental
impact
AMAZE
Annette loves
the feeling of
going for a drive
in her new car
DRIVING PERFORMANCE AND SAFETY WORLDWIDE

4. 4
TRANSPORTATION TESTING SERVICES
Bordeaux, Etupes FRANCE
Munich, Dortmund, GERMANY
Detroit,
Columbus (IN)
Denver,
USA
Manesar, Delhi
& Pune, INDIA
JAPAN
Changchun,
Guangzhou &
Shanghai, Tianjin,
CHINA
THAILAND
TAIWAN
KOREA
BRAZIL

5. 5
TESTING SERVICES: SEGMENTATION
 Power Train: engine, turbine, electric motor, transmission,
fuel system, emisson control
 Materials: raw materials, metal, polymere, elastomere,
ceramic, natural fibres, textiles, glass fibre, carbon fibre,
composite materials
 Dynamics: structural dynamics, aerodynamics, seat belts,
air bags, steering, suspension, brakes, shock absorbers,
chassis, NVH, stability
 Electronics: wiring, connectors, sensors, actuators,
electronic control units, batteries, communications,
entertainment systems, lighting

6. 6
SGS TESTING SERVICES: CASE STUDIES
1. Traction Battery testing Services (Matthias Popp):
 New nail penetration test
2. Material Testing Services (Antoine Bousquet):
 Rims: improving testing standards regarding new trends in
design and colors
 Accelerated ageing of metalized decorative parts

7. 7
2013: The Japan Airlines Boeing 787 Dreamliner is surrounded by emergency
vehicles at Logan International Airport in Boston as a fire chief looks into the
cargo hold.
Photo: AP http://images.smh.com.au/2013/01/08/3936893/art-Dreamliner-Japan-Airlines-Fire-2-620x349.jpg
CASE STUDY: AUTOMOTIVE TRACTION
BATTERIES: NEW NAIL PENETRATION TEST

8. 8
SEARCH IN THE HAY-STACK: CELL
EXPLORATION - DREAMLINER BOSTON EVENT
Source: FAA/Boeing 2013

9. 9
FORCED INTERNAL SHORT ACCORDING TO
JIS C 8714 (IEEE 1625 ANNEX D)
Cell preparation to insert Nickel particle
under safety precautions
1. Open the battery cell
2. L-shaped 1x1 mm Nickel particle inserted
3. Close battery cell
4. Crush cell at elevated temperature to induce
short circuit
Source: JIS C 8714

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WEAK POINTS OF L-PARTICLE INSERTION
The L-shaped-Ni-particle insertion has the following weak
points:
 Transportation of prepared cells is very difficult or even not
allowed
 Difficult to handle in a test laboratory under safety
precautions
 Crushing not possible for automotive hardcase cells if
casing is not weakened or opened
 Bad correlation with real life internal short curcuit

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WEAK POINTS OF COMMON STEEL NAIL
PENETRATION TEST
The common steel nail penetration test is no alternative, due
to the following weak points:
 Shorting all electrode layers by pushing the nail through
the entire cell
 Current flow across nail and cell housing possible
 Heat dissipation via the nail cools shortened cell layers. i.e.
does not represent worst case scenario

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THE NEW CERAMIC NAIL TEST:
New procedure:
1. 3 mm Zirconium dioxide ceramic nail
with 45° tip
2. Cell fixture with thermal and electrical
isolation for limited heat dissipation
3. Very slow nail displacement velocity:
(0.02 – 0.05 mm/s)
4. Displacement limitation by drop of cell
voltage, (U ≥ 10 mV for the test
program)

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THE NEW CERAMIC NAIL TEST: SUMMARY:
Advantages of cermaic nail test:
 No cell opening for preparation
 High current density and localized heat generation
 No cooling by metal nail
 No short circuit with metallic cell housing
 Penetration depth and position can be chosen as required
 New method proposed for IEC 62660

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CASE STUDY: IMPROVING OEMS MATERIALS
STANDARDS THROUGH TESTING EXPERTISE
FEEDBACK
 1 – Rims: improving testing standards regarding new
trends in design and colors
 2 – Accelerated ageing of metalized decorative parts

15. 15
RIMS: IMPROVING TESTING STANDARDS REGARDING
NEW TRENDS IN DESIGN AND COLORS
 Complex design can create testing issues

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SCRATCHES & SCRIBES + CORROSION TEST
 Most of automotive testing standards for rims (through Production
Parts Approval Process – PPAP) require performing scratches to
challenge the coating through accelerated cyclic corrosion (CCT)
Cyclic Corrosion Chambers in SGS Sercovam

17. 17
STANDARD SCRATCHES ON 2 COLORS RIMS
 Standard scratches
before Cyclic
Corrosion Test (tool
made)
Diamond cut part
Painted part

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INFLUENCE OF POSITION OF RIMS UNDER TEST
 Due to rim design and position in the test chamber, some
scratches can show more severe results than others
 SGS Corrosion experts provided technical feedback &
liaison between Tiers & OEM
 Decision of the OEM to improve test standard by
specifying exact position of rims under test
Scratch
position 2
Scratch
Positio
n 1

19. 19
INFLUENCE OF SCRATCH WIDTH FOR
FILIFORM CORROSION TESTING
 Filiform corrosion on a crosscut

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INFLUENCE OF SCRATCH WIDTH FOR
FILIFORM CORROSION TESTING
 Influence of scratch width to declare conformity to requirements
 One tool can’t fit for all scratches  several tools
 Thickness of scratch has to be considered to give correct
result regarding corrosion propagation length, unless
requirements can’t be met in some cases
 Traceability of width is essential
 Decision of the OEM to improve standard
Filiform corrosion on a crosscut
Corrosion
propagation
length

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ACCELERATED AGEING OF METALIZED
DECORATIVE PARTS

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ACCELERATED AGEING OF METALIZED
DECORATIVE PARTS
 Metalization, as every coating
process, has to be validated
through test standards (for
interior or exterior of body)
 Beside control of coating
thickness, scratching,
accelerated corrosion, light &
weather aging is crucial
 Aesthetic parts, especially big
logos, do not support any
failure in aspect (fading,
cracking, …)
Interior fading failed test
on metalized sample
Non exposedExposed

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ACCELERATED AGEING OF METALIZED
DECORATIVE PARTS
 Parts must often be cut to fit the
standard fixture of UV light testers
 Cutting process can induce
additional defects in the sample
(cracks)
 Lab feedback & process
improvement:
 Protection of cutting edges
before test
 Avoid cutting and test entire
part (when possible)
Heat-resistant tape

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CONTACT:
Matthias Popp
Transportation
Global VP Testing Services
Hofmannstrasse 50,
81379 München, Germany
t: +49 160 9011 5957
E-Mail: matthias.popp@sgs.com
Antoine Bousquet
SGS SERCOVAM General Manager
Transportation
Global Manager Materials Testing Services
BP 10 - 21 chemin de Marticot
33611 CESTAS – France
T : +33 (0) 5 57 97 02 35
Email : antoine.bousquet@sgs.com
www.sgs.com/transportation