Leak Testing Solutions for Effective Leak Detection

Leak testing is generally carried out to determine whether assembled products pass quality standards as tested to a specified leak limit. Leaks typically occur when a product has permeable areas, weak seals, cracks, holes, and assembly defects that liquids or gas may flow into our out of during normal operational.

All fluid and gas leaks can reduce product performance and result in system failure. In addition, leaks can pose serious threats, particularly those involving combustive or noxious substances. Therefore, 100% leak testing during a manufacturing process is carried out to make sure that leaks are detected before they cause product warranty claims or worst case, induce serious personal harm or property damage.

Cincinnati Test Systems (CTS) specializes in designing and developing some of the industry’s best-performing and most technically sophisticated leak detection equipment, leak test systems, gas charge and reclaim handling instruments, and associated accessories and components.

CTS offers a variety of products, such as helium recovery systems, bench-top leak testing devices, custom-made solutions, etc., and therefore the company has the right technology to meet customers’ leak detection needs. Customers can contact CTS to request a quote or learn more about the company’s air leak testing solution that suits their requirements.

A range of industries such as industrial, power and energy, aerospace, automotive, medical, pharmaceutical, packaging, etc. use leak testing services. Many different machines and tools are provided for leak detection, with each offering different levels and benefits of sensitivity:

  • Bubble or Submersion Testing: This is a basic air and gas leak detection technique in which a vessel or part is sealed, pressurized, and then sprayed with soapy water, or immersed in water. Any bubble formation denotes that air or gas is leaking. While this leak testing technique does not give a precise measurement of the leak, it is effective for detecting the location of a leak.
  • Hard Vacuum Leak Detection: When performing this gas leak testing process, parts are loaded onto a sealed chamber and a vacuum is utilized to remove all the air from the part and chamber. Then, helium  gas is utilized to fill the part to test pressure. The presence of any leaks is then detected by a Helium Mass Spectrometer integrated into the vacuum system. This process is extremely sensitive and utilized for detecting low level gaseous leaks.
  • Helium Accumulation Leak Detecting: This is a highly sensitive leak testing technique and involves linking the part to a leak detection instrument and subsequently positioning the part in a test chamber. The part is evacuated and then back filled with a Trace Gas (Helium or Forming Gas). The leak detector measures a trace gas accumulation rate of rise in the chamber to determine the leak rate of the part.
  • Helium Sniff Leak Detection: This leak detection technique is highly sensitive and accurate. In this method, helium or forming gas is used to charge parts to a given pressure level, and once pressurized, a sniffer device checks the surface to identify leaks. While this method is ideal for air leak testing, it may not identify leaks that fall below the level of testing sensitivity.
  • Nitrogen Purge Technology with Clam Shell: This is a CTS patented testing process that supplies high precision leak testing wile controlling atmospheric background. The technology utilizes a leak detection device integrated with a gas management system that introduces a Nitrogen air curtain around a sealed part in a small chamber. Nitrogen is introduced into the chamber to purge atmospheric background, the part is evacuated and charged with tracer gas and the leak detector measures the presence of trace gas leaking from a tested part.
  • Pressure Decay Leak Detection: This method utilizes dry, inert gas to pressurize a part under test, isolate pressure in the part, then a high precision pressure measurement instrument measures a pressure drop over a set amount of time associated with a leak.
  • Vacuum Decay Leak Detection: This is similar to a Pressure Decay Leak Testing in which parts are evacuated to a vacuum pressure and tested for an increase in pressure. It offers accurate measurements and is not as affected by temperature produced by the compression of gas.
  • Ultrasonic Leak Detection: This method is only suitable for detecting larger leaks by indicating the presence of a sound frequency produced by an air or gas leak.

CTS Provides Various Leak Testing Equipment Options to Meet Customers’ Requirements

Factors that need to be considered while choosing a leak testing solution includes leak limits, the number of parts being tested, the size of the component, and any hidden internal volumes or surface finishes that are likely to impact the testing process.

CTS provides a wide portfolio of test and reclaim systems, making it easy for users to identify the right system for their specific requirements. CTS’ leak detection products are given below:

  • Function Test Systems: Function test solutions integrate design versatility with solid engineering and offer repeatable and consistent results in various function test applications.
  • Tracer Gas Leak Test Systems: CTS leak test devices are the ideal choice for repeatable and quantifiable SCC/SEC testing in high production settings, irrespective of the type of technology or gas used.
  • Mass Flow Test Systems: CTS provides a wide range of mass flow test equipment, which collectively offer excellent repeatability and precision, and decrease ambient test noise that can impact results.
  • Pressure Decay Test Systems: CTS has pioneered various new and novel technologies for pressure decay testing, and provides easy-to-implement and high-solutions for high-volume production testing.
  • Pressure Gain Systems: CTS advanced pressure gain test solutions help measure parts under test, with excellent accuracy and at lower leak specifications.
  • Pressure Testing Systems: Pressure testing equipment offered by CTS deliver optimal results over a variety of testing techniques, such as proof testing, occlusion testing, hydrostatic/hydraulic testing, etc.
  • Vacuum Leak Test Systems: One of the most significant leak test techniques available today is vacuum leak testing. Users can make sure that they are getting precise and reliable results with one of the many high-performance vacuum leak test devices available from CTS.
  • Gas Handling and Detection Equipment: CTS provides a wide range of sophisticated gas handling and leak detection systems that not only detect equipment inefficiencies but also protect users against gas leaks.

Customers can Contact CTS to Discuss Leak Testing Solutions for their Products

In addition to regular leak test systems, CTS also provides customized leak detection equipment to fulfill the requirements of any application. Customers can contact CTS for a custom quote or further information. The company looks forward to meeting customers’ unique leak test requirements.

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