In order to support a knowledge-based system, preliminary corrosion (continuous and cyclic salt spray) tests were conducted on powder coated AZ91 cast prototype components. Coating performance during accelerated testing was followed by mapping the location of coating failure as a function of time. Time-delayed video recorded the deposition and removal of electrolyte species during accelerated tests, and allowed information to be gathered regarding the influence of geometric features on electrolyte movement and coating failure. The two accelerated tests revealed significantly different mechanisms of coating failure. Optical microscopy was utilised to explore the relationship between component geometry and coating performance. Outcomes from the initial laboratory trials are discussed in terms of their relevance to predicting actual field performance.