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Whether it’s through a manufacturing defect such as a crack or broken seal, or simply an imperfection in the product design, any gas or liquid that unintentionally flows through an object signifies a leak. Leak tests are used to identify a leak exists and measure the size of the leak.

While we’d like to believe every product on the market can offer a 100% leak-free guarantee, most manufacturers allow for a specified “leak limit” when approving products good for public use. It’s within this scale that a leak test is used to determine if the product or system is functioning properly.

There are several types of leak tests: pressure, pressure decay, mass flow, trace gas, flow tests, etc. How you decide which one to use depends on the product or system you are testing. For example, a mass flow test is highly effective in detecting small leaks in gas meters, appliances and exhaust systems. So, the next time you’re worried your car radiator is leaking coolant, you’ll know exactly which leak test would yield the most accurate results.

Industry-Specific Leak Tests

Automotive

The engines, fuel injectors, transmissions, and cooling systems of cars and buses need to be tested and retested before going to market.

Medical

Whether it’s for a regular check-up or a serious surgery, patients need to know the medical equipment being used can provide the best care. Extensive leak testing ensures this reliability.

Industrial

Industrial companies rely on tests to identify product flaws and faults. Leak tests are used on a variety of household and daily systems: beverage dispensers, coffee makers, faucets, and more.

Packaging

From kids’ applesauce to sterile surgical items, packaging must be leak-free to preserve safety and product quality.

We Need Leak Tests

Leak testing is an integral step in the manufacturing process. Without it, consumers could be exposed to faulty, unsafe, or hazardous products.

What Is a Leak Test?

Leak testing determines if an object, product, or system functions within a specified leak range. Air leak testers use pressure to generate and monitor flow from high to low pressure to detect any leaks.

How to Calculate Leak Rate (SCCM)

A leak rate is expressed as a volume per unit of time:

ATM = Atmospheric pressure (PSIA)

V = Test volume (cm³)

Δp = Pressure decay during test

Δt = Time of decay (min)

Formula: Leak rate = Δp/Δt * V / ATM

Example:
Leak rate = 0.02 psi / 0.05 min * 50 cm³ / 14.7 psia = 1.36 SCCM

Standard Types of Leak Tests

Air leak detection is an essential step in manufacturing. Common tests include:

Pressure Decay (PD)

Vacuum Decay (VD)

Occlusion (Occ)

Mass Flow (F)

Burst (B)

Crack (C)

Chamber (PR)

Pressure Decay

Used for small, sealed components with a single access port. A drop in pressure over time indicates a leak.

Mass Flow

Measures flow through a part with two open ports. Fails if flow rate is outside standard limits.

Other Types of Air Leak Testing

Backpressure Flow

Pressure Increase

Valve Reseat

Creep/Ramping Fill

Pressure Exercise

Vacuum Exercise

Additional Air Leak Detection Methods

Bubble/Submersion

Hard Vacuum (Helium)

Helium Accumulation, Sniff, or Spray

Tracer Gas

Ultrasonic

Leak Test: Methods, Benefits, and Considerations

What is a Leak?

A leak is an unintended escape of gas or fluid. It can be caused by cracks, holes, or even material permeability.

Three Types of Leaks

Gross Leak: Large, visible, easy to detect.

Fine Leak: Small, requires sensitive tools.

Permeation Leak: Molecular-level flow through material.

Leak Test Methods

Pressure Decay Testing

Mass Spectrometry

Bubble Testing

Ultrasonic Testing

Helium Leak Testing

Hydrostatic Testing

Vacuum Testing

Dye Penetrant Testing

Acoustic Emission Testing

Infrared Thermography

Pressure Decay Leak Testing

This method is effective, simple, and non-destructive. The product is sealed and pressurized. If pressure drops, a leak is present.

Pressure Decay Test Benefits

Cost-Efficient

Fast Results

Easy Setup

Minimal Resources

Highly Accurate Data

Non-Invasive

Streamlined Production

Pressure Decay Applications

Automotive & Aerospace: Fuel tanks, radiators, AC systems.

Electronics: Smartphones, sensors, batteries.

Medical: Infusion pumps, catheters, drug vials.

HVAC: Leak-free, energy-efficient systems.

Packaging: Seal integrity for food and pharma.

Chemicals: Safe containment and transport.

Leak Testing Considerations

Part’s Intended Function

Tested Medium

Material Compatibility

Pressure Range

Internal Volume

Design Complexity

Technological Advances

Operator Training

Environmental Factors

Acceptable Leak Rate

Regulatory Compliance

Record-Keeping

Leak Testing Regulations

Leak testing ensures safety, reliability, and compliance. It’s about product quality as well as environmental responsibility.

Dažnai užduodami klausimai

What is the most common leak?

Gas leaks, such as natural gas or air, are the most common.

What is a positive leak test?

A test that introduces a substance to detect leaks by observing its presence.

What is a negative leak test?

Uses vacuum or pressure differential to detect leaks by air ingress.

What is an air leak test?

Detects leaks using compressed air and monitoring for pressure change.

What role does technology play?

Advanced technology enables better accuracy, automation, and efficiency.

What are the risks of not performing leak tests?

Product failure, safety hazards, environmental pollution, and recalls.

How often should leak testing be done?

It varies by industry, regulation, and product criticality, but should be done regularly.

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