Many industries require some form of leak testing, and here are five uses of leak testing that business leaders should know about!
It’s normal for the many different leak testing methods and technologies to seem daunting for business leaders and entrepreneurs, and the truth is that many different manufacturing industries require some form of product leak testing.
So, how should business leaders choose the most appropriate leak testing products for their unique applications? And how can they know when their leak testing methods are producing accurate, helpful results?
The Zaxis team is here to answer these crucial questions, and below, we’ll explore some of the most common types of leak testing that are utilized within manufacturing and other commercial settings. We’ll also let you know about the benefits and drawbacks of each air leak application, which will ultimately help you narrow down your best options!
Pressure Decay Leak Testing
Pressure decay leak testing is by far one of the most common leak test methods. It involves pressurizing a product or assembly, isolating test pressure within the product, and measuring the amount of pressure loss over a pre-determined amount of time.
In today’s business world, pressure decay leak testing is capable of accurately detecting even the smallest non-water leak rates. Some of the common products that require pressure decay leak testing include:
- IV sets
- Tubing
- Catheters
- Bags
- Needleless injections
- Infusion sets
- Implantable devices
- Metering devices
- Sensors/Indicators
Benefits: Pressure decay leak testing is incredibly accurate and fast, and this type of testing can also be calibrated for standardized volumetric flow measurements.
Drawbacks: This type of leak testing usually doesn’t identify the specific source of a leak, and it’s possible for the testing to be slower when testing large products with low leak rates. Testing larger products/parts can also take longer due to variable pressure changes.
Vacuum Decay Leak Testing
Vacuum decay leak testing evacuates the air within a product/assembly in order to detect potential leaks, and this type of leak testing is incredibly useful for products that could potentially experience external leak sources. This includes things like pipes, underwater sensors, outdoor electrical housings, packaging, radios, smartwatches, cell phones, implantable devices and much more.
Benefits: A lot of business leaders prefer vacuum decay leak testing because it’s incredibly efficient and yields reliable results. It’s also a very sensitive type of testing that’s somewhat similar to pressure decay testing, but it’s less susceptible to environmental changes. This means that vacuum decay leak testing is a great option when temperature control is a testing factor.
Drawbacks: Surface outgassing, liquid evaporation and reduced product sensitivity can sometimes affect this type of testing. This test usually can’t singlehandedly test air pressures greater than 14.7 psi.
Mass Flow Leak Tests
With mass flow leak tests, business teams will pressurize air into a product/part and measure the flow rate when the tester is holding a constant pressure. This helps to verify a part’s leak integrity, and it can also help to identify potential blockages.
This type of test evaluates flow rates between predetermined maximum and minimum flow values. Products that fall within a leak test’s criteria will be confirmed for proper functionality. Mass flow leak testing is used in the automotive, medical, and various other industries. Some of the most common products that require mass flow leak tests include:
- IV sets
- Catheters
- Infusion sets
- Check valves
- Needleless injections
- Tubing
- Metering devices
Benefits: This is a non-destructive leak test, which makes it ideal for restrictions in part channels, large leaks and blockages.
Drawbacks: This testing sometimes has low sensitivity, which can make it less applicable for smaller leaks. The test accuracy is often dependant upon factors like test air cleanliness, flow meter measurement ranges, and supply pressure stability.
Occlusion Leak Testing
Occlusion leak testing measures the amount of air that passes through a product/part, and it helps business teams recognize whether or not passageways are clear or blocked.
This test requires a product to be filled with regulated air, until a test port’s valves are closed off at a desired pressure level. A downstream port valve is then opened, and pressure loss is measured.
Some common products that frequently require occlusion leak testing include:
- IV sets
- Catheters
- Tubing
- Check valves
Tracer Gas Leak Testing
When products or systems have very low leak rate requirements, tracer gas leak testing is often a go-to option. This can include various types of tests, including:
- Nitrogen purge leak testing
- Sniff leak testing
- Hard vacuum helium mass spec leak testing
- Accumulation leak testing
Benefits: This type of leak testing isn’t impacted by pressure or temperature changes, which makes it a good option when products are tested at inconsistent temperatures.
Drawbacks: These tests are very sensitive, so it’s possible for them to be impacted by atmospheric trace gas. This is why tech-savvy advancements are often necessary for this type of leak testing to be consistently accurate.
Differential Pressure Testing
Differential pressure testing is a type of pressure decay test that also measures air volume pressure changes. It utilizes two unique pressure readings through cutting-edge differential pressure transmitters to identify leaks in products and assemblies.
This means that if pressure doesn’t drop during a differential pressure test, the product is good, and the production process can continue. However, if pressure does drop during these tests, manufacturing teams need to consider further evaluation.
Benefits: Differential pressure testers are very sensitive and accurate, and they make it easier for production teams to continue their daily requirements without delays or interruptions. This type of testing is also useful for steam, gas, and liquid leak applications.
Drawbacks: Subtle erosion can impact this test’s accuracy, and freeze protection is sometimes needed for steam and liquid meters.
Other Common Types of Leak Testing Include:
Reach out to Zaxis When Your Business Needs Leak Testers & Leak Testing Services!
Zaxis is a world leader in engineering state-of-the-art leak testing and precision pumping technologies. We work with many household name companies throughout the United States and around the globe.
The Zaxis team is always available to answer your questions and point you in the right direction toward the correct type of leak testing that applies to your company’s unique needs and requirements. You can reach out to us online or give us a call at 801-264-1000 to get in touch with us today and learn more about our leak testing technologies!
