Predicting and Extending Polymer Service Life With Accelerated Aging Tests
Did you know that global plastics production has doubled between 2000 and 2019, reaching nearly 460 million tonnes per year? Yet, despite their ubiquity, up to 30% of polymers used in critical applications still fail to meet durability requirements.
Take a simple example: a plastic patio chair left in the sun. After a few seasons, it yellows, cracks, and eventually breaks. Though commonplace, this phenomenon illustrates the challenge faced by polymer product designers: ensuring lasting strength and performance under often extreme conditions.
In a world where polymers are ubiquitous – from our vehicles to our medical devices – their durability is not a luxury but a necessity. How can we predict their behaviour after years of exposure to UV, humidity, or temperature cycles? Accelerated aging tests offer precise, reliable answers, simulating in just a few weeks what years of exposure would cause in real life.
At Micom Laboratories, we use these tests to help companies assess the quality, safety, and long-term performance of their products. But beyond their technicality, these tests serve as a guide to finding the right balance between consumer expectations, industrial requirements, and environmental issues.
Polymer Challenges: When the Environment Becomes an Adversary
Every polymer is designed with a specific mission in mind: to resist, to perform, to last. Yet certain environmental factors put these materials to the toughest test:
- UV Rays: Prolonged exposure triggers a photo-oxidation reaction, which causes yellowing, cracking, and brittleness. Did you know that UV rays are responsible for 70% of visible damage to polymers used outdoors?
- Temperature: High temperatures accelerate chemical reactions such as depolymerization, compromising material integrity.
- Humidity and Thermal Cycles: Hot-cold alternation or constant humidity can cause swelling and cracking.
- Saline Environments: In coastal or marine applications, reinforced or coated polymers must resist corrosion.
These challenges, if not anticipated, can lead to costly, even critical, failures. Accelerated aging tests reproduce these conditions with scientific precision, offering a predictive view of polymer performance.
Why Test Polymers?
To ensure better management of plastic waste
Every year, over 60 million tonnes of plastic end up in landfills, and only 9% are recycled. Improving their durability through aging tests could considerably reduce this waste.
By extending the life of polymers through optimized formulations, companies can reduce waste, cut replacement costs, and contribute to a circular economy.
To limit UV degradation
UV represents a major challenge: according to analyses, polymers exposed to unprotected sunlight can lose up to 25% of their mechanical strength in less than 1,000 hours.
Advanced Accelerated Aging Tests at Micom Laboratories
At Micom, we offer a wide range of materials testing services to meet the requirements of modern industries. Here are just a few examples.
1. UV Exposure Tests
Polymers intended for outdoor use, such as bumpers or coatings, need to withstand prolonged exposure to sunlight, which is why UV testing is so important.
Our solutions:
- ASTM G154: Simulation with fluorescent UV lamps.
- ASTM G155: Use of Xenon lamps to reproduce the full spectrum of sunlight.
- SAE J2412 and J2527: Standards specific to the automotive industry.
What we measure:
- Colour change (ASTM D2244).
- Loss of mechanical strength (ASTM D638).
- Crack formation or loss of gloss.
- Hardness (ASTM D3363 or ASTM D2240)
- Visual changes such as cracking or gloss loss
These measurements allow for a precise assessment of how aging affects both the appearance and mechanical performance of the material.
2. Thermal Aging
Polymers in motors or electronic enclosures need to retain their integrity in the face of extreme temperatures, and thermal aging tests help us ensure their resistance.
Our method:
- Exposure to controlled temperatures, often exceeding 150°C, to assess chemical and mechanical degradation.
What we measure:
- Changes in mechanical properties (strength, flexibility)
- Visible physical changes (discoloration, embrittlement, cracking
3. Humidity Tests and Thermal Cycles
Climatic variations strongly affect polymers in industries such as medical devices and packaging. Porous or moisture-sensitive materials are particularly vulnerable under these conditions. Temperature variations are also used to evaluate resistance to extreme temperatures or to ensure that material expansion or contraction does not negatively affect product integrity.
Our method:
- Exposure to relative humidity up to 98%
- Temperature cycles from –68°C to +200°C
- Use of muffle furnaces up to ~1000°C for extreme cases
We measure:
- Moisture absorption and swelling
- Dimensional changes due to expansion or contraction
- Loss of mechanical strength or cracking
4. Salt spray testing
Salt spray tests are particularly useful for evaluating the corrosion resistance of reinforced or coated polymers intended for marine and coastal environments. For example, in the maritime sector, these tests help validate the durability of anticorrosion coatings used on port infrastructure and other exposed surfaces
Our approach:
- Exposure to constant salt spray in accordance with ASTM B117
- Use of additional corrosion methods as needed (ASTM G85, GM, SAE, and others)
What we measure:
- Formation of rust, pitting, or blistering
- Durability of protective coatings
- Comparison of different surface treatments
For more information, please visit our dedicated corrosion testing page.
Summary Table of Main Accelerated Aging Methods Used at Micom
Accelerated aging tests at Micom Laboratories are conducted in accordance with strict international standards. They are designed to evaluate the impact of various environmental factors on the long-term performance of polymers. The table below presents some of the most commonly used accelerated aging test methods performed at Micom.
Table of Main Accelerated Aging Methods at Micom
| Standard | Application | Tested Properties |
| ASTM G154 | UV simulation with fluorescent lamps | Colour change, mechanical resistance |
| ASTM G155 | Full solar spectrum (xenon lamps) | Chemical degradation, cracking |
| ISO 4892-2 | UV testing for outdoor materials | Loss of gloss, thermal stability |
| ASTM B117 | Salt fog exposure | Corrosion, delamination, oxidation |
| ASTM F1980 | Thermal aging for sterile-barrier and medical devices | Mechanical strength, dimensional stability |
| SAE J2412 / SAE J2527 | Automotive weathering | UV and heat degradation |
| Micom internal procedure | Humidity/temperature cycles (–68 °C to +200 °C) | Swelling, cracking, cohesion loss |
These aging methods can be complemented by specific tests designed to measure the tangible effects of aging on the mechanical, aesthetic, or dimensional properties of polymers.
Complementary Tests for Evaluating the Effects of Aging
Once materials have been exposed to accelerated aging conditions, complementary tests are often required to quantify the changes that have occurred. These tests measure losses in mechanical properties, aesthetic variations, and other physical alterations resulting from exposure.
| Standard | Application | Tested Properties |
| ASTM D638 | Tensile testing after aging | Mechanical strength, elongation, rupture |
| ASTM D2244 | Colorimetry after exposure | Colour variation (ΔE), yellowing or whitening |
| ASTM D523 / ASTM D3363 / ASTM D2240 | Gloss or hardness | Surface changes due to aging |
Case study: Extending the Lifespan of an Automotive Bumper
A major automotive manufacturer wanted to evaluate a new polymer formulation intended for bumpers exposed to prolonged UV radiation.
- Tests used: SAE J2527 standard with alternating heat and UV cycles.
- Results: After 1,000 hours of exposure, the material showed visible discoloration and a 20% reduction in mechanical strength.
- Solution: Our tests enabled the client to reformulate the polymer by adding UV stabilizers, thereby increasing its expected durability by 50%.
This approach allowed the manufacturer to anticipate potential degradation, optimize the material formulation, and significantly extend the service life of the final product.
Reducing Waste by Optimizing Material Sustainability
The environmental impact of polymers can be significantly reduced through improved durability.. According to Greenpeace, a polymer designed to last 10 years instead of 5 can reduce its environmental footprint by 30%.
Accelerated aging tests play a key role in this transition toward more durable materials. By validating the long-term performance of materials, they help reduce the frequency of replacements, as well as overall costs and waste generation.
There’s no doubt that accelerated aging tests are much more than just a technical assessment. They serve as a guarantee of quality, safety, and innovation, while promoting a more responsible approach to material design.
Thanks to technological advances such as digital twins and artificial intelligence, we can assume that advanced numerical models could one day predict with even greater accuracy the combined effect of factors such as UV, heat, and humidity. This would not only enable faster testing but also better reflect the reality of complex environments.
At Micom Laboratories, we believe that the durability of polymers is a cornerstone for building a safer, more reliable, and environmentally responsible future.
Contact us today to benefit from our tailored expertise and obtain accurate, fast, and dependable results.
Frequently asked questions
How long do accelerated aging tests last?
Test duration can vary from a few days to several weeks, depending on the simulated conditions and the materials being tested.
For example, a UV simulation may estimate that 1,000 hours of exposure in our equipment corresponds to approximately one year of natural exposure in a sunny region such as the southern United States. Thermal aging, on the other hand, often relies on the Arrhenius equation to predict material degradation over time.
Are these tests representative of real-life conditions?
Yes, although they typically isolate one stress factor at a time (UV, heat, or humidity). That’s why we recommend combining multiple tests to obtain a more comprehensive view of the material’s actual aging behaviour in service environments.
Why choose Micom for these tests?
At Micom Laboratories, we combine deep technical expertise, state-of-the-art equipment, and a personalized approach for every client. Our protocols are tailored to your specific needs to ensure accurate, reliable, and actionable results.
