Test Planning & Preparation
- 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.
- 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).
- Ensure proper selection and setup of instrumentation (e.g., strain gauges, corrosion sensors, temperature/humidity sensors) for data collection during testing.
Test Execution
– Durability Testing:
- 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.
- 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.
– Corrosion Testing:
- 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.
- 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.
Data Analysis & Reporting
- 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.
- 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.
Problem Solving & Troubleshooting
- Validate simulation models for durability and corrosion performance by comparing predicted results with real-world test data.
- Investigate the root causes of durability failures or corrosion-related issues, using root cause analysis techniques (e.g., 8D, FMEA) to identify potential improvements.
- 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.
Collaboration & Communication
- Collaborate closely with design, materials, and manufacturing teams to implement durability and corrosion-resistant solutions into vehicle production.
- 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.
- Provide input to the product development process, ensuring that durability and corrosion considerations are incorporated early in the design phase.
