Test Planning & Preparation
Ensure proper selection and setup of instrumentation (e.g., strain gauges, corrosion sensors, temperature/humidity sensors) for data collection during testing.
Work closely with materials, design, and manufacturing teams to define test criteria and performance targets based on real- world conditions and industry standards.
Plan for both accelerated environmental tests (e.g., salt spray, humidity, thermal cycling) and real- world durability tests (e.g., rough road simulation, long- term field testing).
Develop comprehensive test plans to assess the durability and corrosion resistance of EV components and systems, including chassis, body panels, battery enclosures, and electrical connectors.
Test Execution
– Durability Testing:
Test the mechanical reliability of components subjected to repeated loads, stresses, and environmental conditions, such as road shock and off- road driving conditions.
Monitor real- time performance of key subsystems such as the battery pack, motor mounts, suspension components, and vehicle frame for wear, deformation, or potential failure modes.
Conduct durability tests to evaluate the lifespan and structural integrity of key vehicle components under simulated long- term use, including mechanical fatigue, vibration, and impact testing.
– Corrosion Testing
Evaluate the corrosion performance of critical EV components such as high- voltage connectors, battery enclosures, power electronics housings, and suspension parts.
Investigate the effectiveness of protective coatings, sealants, and materials designed to prevent or mitigate corrosion in harsh environments.
Perform corrosion tests to assess the impact of various environmental factors (e.g., salt, moisture, temperature) on vehicle materials, including aluminum, steel, and composite components.
Use industry- standard methods like salt spray testing (ASTM B117), cyclic corrosion testing, and immersion testing to evaluate the corrosion resistance of coated and uncoated surfaces.
Data Analysis & Reporting
Identify trends, failure points, and degradation mechanisms, providing actionable insights to improve material selection, component design, or protective treatments.
Prepare detailed technical reports summarizing test results, including charts, graphs, and recommendations for design improvements or material changes.
Collaborate with cross- functional teams to validate findings and propose solutions to improve overall vehicle longevity and corrosion resistance.
Collect and analyze test data using software tools (e.g., MATLAB, Python, Excel) to evaluate the performance of components under durability and corrosion testing conditions.
Problem Solving & Troubleshooting
Validate simulation models for durability and corrosion performance by comparing predicted results with real- world test data.
Work with suppliers to validate the durability and corrosion resistance of sourced materials and components, ensuring they meet company standards.
Support the development of new corrosion- resistant materials, coatings, and manufacturing processes aimed at improving vehicle durability and reducing long- term maintenance costs.
Investigate the root causes of durability failures or corrosion- related issues, using root cause analysis techniques (e.g., 8D, FMEA) to identify potential improvements.
Collaboration & Communication
Present test procedures, results, and recommendations to internal stakeholders, including design teams, product management, and quality control departments.
Work with external testing facilities, suppliers, and regulatory bodies to ensure compliance with industry standards and best practices in durability and corrosion testing.
Collaborate closely with design, materials, and manufacturing teams to implement durability and corrosion- resistant solutions into vehicle production.
Provide input to the product development process, ensuring that durability and corrosion considerations are incorporated early in the design phase.
