How Mixed Flowing Gas Testing Helps You Predict the Future

In industries where reliability is critical understanding how materials and components will hold up overtime is essential. Mixed Flowing Gas (MFG) testing provides a powerful way to simulate long-term corrosion effects in an accelerated timeframe, helping manufacturers and engineers to predict and mitigate material degradation before it becomes a problem.

What Is Mixed Flowing Gas Testing?

Mixed Flowing Gas (MFG) testing is an advanced corrosion test that replicates real-world atmospheric conditions by exposing materials to a controlled blend of corrosive gases, including:

·   Sulfur dioxide (SO₂)

·   Chlorine (Cl₂)

·   Hydrogen sulfide (H₂S)

·   Nitrogen oxides (NOₓ)

By controlling temperature, humidity and gas concentrations with high-level precision, MFG testing simulates years or even decades of environmental exposure in just a matter of days or weeks. This method allows engineers to predict how materials and coatings will respond to long-term oxidative and electrochemical reactions, helping to enhance durability and prevent failures.

How Is Mixed Flowing Gas Testing Conducted?

The MFG corrosion test accelerates aging for electronic products and components by simulating the environmental conditions they would experience over time. The process involves:

·   Test Chamber Setup: Engineers utilize a climatic chamber equipped with a gas delivery system to maintain precise control over temperature, humidity and gas concentrations.

·   Exposure to Corrosive Gases: A combination of NO₂, SO₂, H₂S and Cl₂ is introduced at controlled levels, typically under conditions like 30°C with 70% humidity or 25°C with 75% humidity.

·   Use of Control Coupons: Copper or gold-plated coupons are placed alongside test articles to measure the rate of corrosion over a set period (often 10-21 days). The weight loss on these coupons provides a benchmark for evaluating material degradation.

·   Simulating Years of Exposure: By adjusting variables, engineers can extrapolate corrosion effects equivalent to 10-20 years of real-world aging in just 10-14 days.

Why MFG Testing Is Critical for Predicting Corrosion Effects

Corrosion is one of the biggest challenges in situations where critical components must endure harsh environmental conditions. With mixed flowing gas tests, companies can:

·   Evaluate Material Longevity: Simulate 10-20 years of corrosion exposure to predict long-term performance.

·   Optimize Protective Coatings: Assess how different finishes, coatings and surface treatments stand up to real-world conditions.

·   Ensure Reliability in Extreme Environments: Test metals, electronics and other elements used in satellites, defense systems and high-performance vehicles.

·   Reduce Failure Risks: Identify weaknesses before deployment, preventing costly system failures.

Industry Standards for MFG Testing

To ensure accuracy and reliability, MFG testing is conducted according to industry-recognized standards, including:

·       IEC 60068-2-60 – Environmental testing for electrical and electronic products.

·       GR-63-CORE – Telecommunications equipment environmental standards.

·       MIL-STD-810 – Environmental engineering considerations for defense applications.

·       ASTM Standards – Guidelines for material and corrosion testing in industrial applications.

These standards ensure that MFG testing meets the stringent reliability requirements demanded by industrial and defense sectors.

How Element U.S. Space & Defense Uses MFG Testing

At Element U.S. Space & Defense, we conduct rigorous MFG testing to support industries that demand the highest level of reliability. Our state-of-the-art corrosion testing facilities allow us to replicate extreme environments and provide actionable insights for materials improvement. Our experts help manufacturers make data-driven decisions that improve product longevity and performance.

The Future of Corrosion Testing

As industries continue to innovate, the demand for advanced corrosion prediction tools like MFG testing will only grow. By leveraging accelerated aging techniques, engineers can confidently design materials that withstand the test of time—literally predicting the future of their products by ensuring long-term resilience.

To discover how Mixed Flowing Gas testing can help your business prevent material failures and enhance reliability, contact the expert engineers at Element U.S. Space & Defense today.