ISO 16750-4 Figure 4 Thermal Shock with Splash Water Tester

The KingPo ISO 16750-4 Figure 4 Thermal Shock with Splash Water Tester is a specialized environmental testing equipment designed for automotive electrical and electronic components. It rigorously evaluates resistance to rapid thermal shocks combined with ice-cold water exposure, replicating real-world winter driving conditions where hot parts encounter splashed road water or snowmelt. This stainless steel test setup ensures reliable validation of sealing integrity, material durability, and functional performance under extreme climatic stresses, fully complying with ISO 16750-4:2023 (Road vehicles — Environmental conditions and testing for electrical and electronic equipment — Part 4: Climatic loads), specifically the splash water test in clause 5.4.2 (Figure 4 configuration).

Why Thermal Shock with Splash Water Testing Matters in Automotive Applications

Automotive components, particularly those in splash-prone areas such as engine compartments, underbody shields, chassis-mounted sensors, lamps, controllers, and electronic modules, face severe environmental challenges. During winter driving on wet roads or through puddles, hot operating parts can suddenly be exposed to near-freezing water, inducing thermal shock. This causes differential thermal expansion and contraction between materials, leading to potential failures like cracking, seal breaches, water ingress, electrical malfunctions, or loss of tightness. The ISO 16750-4 splash water test (also known as ice water shock test) simulates these abrupt temperature gradients to verify component reliability and prevent field failures. It is a critical requirement for OEMs and suppliers in the automotive industry, often referenced alongside standards like VW 80000 K-12 or similar manufacturer specs.
Failure modes addressed include mechanical cracking due to mismatched expansion coefficients, loss of sealing allowing water intrusion, and functional degradation in powered components. The test ensures the Device Under Test (DUT) maintains Class A functional status (full operation with no loss) during and after exposure, as defined in ISO 16750-1.

Key Features and Technical Specifications of the KingPo Tester

This KingPo model (KP-IW16750A or equivalent) features robust construction for long-term laboratory use:
• Inner chamber dimensions: 1300 × 900 × 900 mm (D × W × H)
• Maximum DUT size: Approximately 700 × 700 × 500 mm
• Maximum load capacity: 150 kg
• Temperature range: Room temperature +10°C to 200°C
• Temperature fluctuation and deviation: ±2°C each
• Splash parameters (per ISO 16750-4 Figure 4):
• Water temperature: 0°C to +4°C (de-ionized ice water, maintained by built-in refrigeration)
• Splash duration: 3 seconds
• Water flow: 3–4 liters per splash
• Nozzle distance to DUT surface: 325 ± 25 mm (ensuring full width coverage)
• Cycle count: Default 100 cycles (adjustable 0–9999)
• Holding time at Tmax: 1 hour or until DUT temperature stabilizes
• Transition time: <20 seconds
• Control system: PLC with 7-inch color touch screen for intuitive parameter setting, mode selection (continuous/intermittent), alarms, and data monitoring
• Materials: SUS316 stainless steel inner liner (mirror finish for corrosion resistance), high-density fiberglass insulation, multi-layer tempered glass observation window, and double-layer high-temperature seals
• Power requirements: AC380V 50Hz, total ~25 kW (three-phase industrial supply needed)
The equipment supports single-direction splashing (DUT fixed in vehicle orientation) or multi-direction via turntable rotation or separate DUTs per direction, aligning with standard recommendations for realistic exposure simulation.

Standard Test Procedure Overview

The procedure follows ISO 16750-4 clause 5.4.2 precisely:
1. Heating phase: Place the DUT (powered or unpowered, per functional mode) in the hot air chamber and heat to Tmax (up to 200°C, customizable based on component specs).
2. Holding phase: Maintain until thermal stability or for the specified time (typically 1 hour).
3. Splash phase: Rapidly transfer and expose the hot DUT to a 3-second ice water jet from the prescribed direction(s), covering the full DUT width.
4. Return and cycle: Move back to heating for the next cycle, repeating up to 100 times (or more if customized).
5. Evaluation: Post-test inspections include functional testing, insulation resistance, visual checks for cracks/leaks, and sealing verification.
The DUT must remain operational (Class A) throughout, with no ingress or performance loss. This accelerated test reveals weaknesses not apparent in gradual temperature cycling.

Applications and Benefits

Primarily used for automotive electronics in exposed locations, this tester supports compliance testing for global standards and OEM requirements. It helps manufacturers identify design flaws early, improve material selection, and ensure long-term reliability in harsh climates. KingPo’s stainless steel build guarantees durability against corrosion, high/low temperatures, and wet conditions, making it ideal for R&D labs, quality assurance, and certification testing.
Customization options are available for higher temperatures, larger chambers, automation enhancements, or integration with additional monitoring. For precise automotive validation, this equipment provides a comprehensive, standards-compliant solution to thermal shock and splash water challenges.