What is Leak Testing?
Leak testing is an effective method used to determine whether a product meets specific leakage requirements. Even tiny holes, damaged seals, or countless other defects can lead to air leaks—causing serious issues. Everything from automotive radiators to medical devices and sprinkler system components must undergo air leak testing to ensure safe and proper functionality.
In general, air leak testing is clean, non-destructive, and highly repeatable. It can be applied to any product that requires an airtight or watertight structure. Beyond simply detecting the presence of a leak, this method provides objective data on leakage rates for further analysis.
Air leak testing enables OEMs to ensure that their products meet required leakage standards, while also helping to identify and eliminate design or manufacturing defects.
In general, air leak testing is clean, non-destructive, and highly repeatable. It can be applied to any product that requires an airtight or watertight structure. Beyond simply detecting the presence of a leak, this method provides objective data on leakage rates for further analysis.
Air leak testing enables OEMs to ensure that their products meet required leakage standards, while also helping to identify and eliminate design or manufacturing defects.
Benefits of Air Leak Testing
Compared to other leak testing methods, air leak testing offers significant advantages:
Time and Labor Efficiency
Quality Improvement
Cost Reduction
Time and Labor Efficiency
- Many air leak testing processes can be fully or partially automated.
- Most air leak testing equipment is user-friendly and does not require specialized training.
- Maintenance is generally simple and requires minimal effort.
Quality Improvement
- Leakage standards can be accurately measured.
- Product defect rates can be significantly reduced.
- Leak measurement data can be used for statistical analysis and process improvement in future product development.
Cost Reduction
- Higher product yield due to fewer rejects.
- Reduced testing time.
- Operating costs are relatively low for most air leak testing processes.
Methods of Air Leak Testing
Bubble Test / Submersion Test
Perhaps the most basic form of air leak testing, the bubble test involves pressurizing a part or container, submerging it in water, and observing for bubbles created by escaping air or gas. The size of the leak is directly related to the intensity and size of the bubbles formed.
While submersion testing is effective for locating the position of leaks, it is not suitable for accurately measuring or quantifying the leak rate.
Pressure Decay Test
In pressure decay air leak testing, the internal pressure of a sealed part or container is monitored. The container is first pressurized to a predetermined level, typically using dry air or nitrogen. Then, it is observed over a specified period of time. A drop in pressure indicates the presence of a leak.
The sensitivity of the pressure decay method depends on the total volume of the part, test duration, and the resolution of the pressure transducer. This method is generally easier to perform than many other leak detection processes and can detect leak rates as low as 10⁻² scc/s. However, it may be sensitive to environmental and mechanical instability.
Helium Accumulation Test
This air leak test method starts with the test part or container placed inside a sealed chamber connected to a vacuum pump and helium detection equipment. If a vacuum cannot be achieved, it indicates a leak. Once vacuum is established, the part is pressurized with helium to a predefined level.
The surrounding air inside the chamber is continuously mixed using a blower or fan to ensure uniform concentration. After a set duration, a sample of the chamber air is pumped through a helium sensor, which monitors the helium pressure and detects any increase above the baseline atmospheric level.
A change in pressure indicates the presence of a leak in the part.
The helium accumulation air leak test offers excellent sensitivity (as low as 10⁻³ mbar·L/s, depending on chamber size), high reliability, good repeatability, and is not sensitive to temperature variations.
Perhaps the most basic form of air leak testing, the bubble test involves pressurizing a part or container, submerging it in water, and observing for bubbles created by escaping air or gas. The size of the leak is directly related to the intensity and size of the bubbles formed.
While submersion testing is effective for locating the position of leaks, it is not suitable for accurately measuring or quantifying the leak rate.
Pressure Decay Test
In pressure decay air leak testing, the internal pressure of a sealed part or container is monitored. The container is first pressurized to a predetermined level, typically using dry air or nitrogen. Then, it is observed over a specified period of time. A drop in pressure indicates the presence of a leak.
The sensitivity of the pressure decay method depends on the total volume of the part, test duration, and the resolution of the pressure transducer. This method is generally easier to perform than many other leak detection processes and can detect leak rates as low as 10⁻² scc/s. However, it may be sensitive to environmental and mechanical instability.
Helium Accumulation Test
This air leak test method starts with the test part or container placed inside a sealed chamber connected to a vacuum pump and helium detection equipment. If a vacuum cannot be achieved, it indicates a leak. Once vacuum is established, the part is pressurized with helium to a predefined level.
The surrounding air inside the chamber is continuously mixed using a blower or fan to ensure uniform concentration. After a set duration, a sample of the chamber air is pumped through a helium sensor, which monitors the helium pressure and detects any increase above the baseline atmospheric level.
A change in pressure indicates the presence of a leak in the part.
The helium accumulation air leak test offers excellent sensitivity (as low as 10⁻³ mbar·L/s, depending on chamber size), high reliability, good repeatability, and is not sensitive to temperature variations.
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