LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS

Andrej Pregelj, Marjan Drab, IEVT, Teslova 30, Ljubljana Miran Mozetic, ITPO, Teslova 30, Ljubljana The 4th International Conference of Slovenian Society for Nondestructive Testing "Application of Contemporary Nondestructive Testing in Engineering" 24 - 25 April 1997, Ljubljana, Slovenia. Table of Contents

ABSTRACT
There is a constantly growing need for products and technologies that for their realisation require hermetically closed elements, vessels and tubes. Envelopes with greater or smaller vacuum tightness had to assure a satisfactory isolation between external atmosphere and inside over- or underpressure. Crytical leak spots in closed systems are usually: connections, gaskets, welded and brazed joints, defects in material etc. Regarding to quality demands in different production processes, technical people very often encounter with standards for tightness testing. Wishing to state if an element or system meets with corresponding standards we have to be familiar with the procedures enabling the following appointments: - question if there is leakage or not - settlement of the leak size - detection of leak locality For solving the mentioned problems different treatments and techniques are known but among them there is no an universal method, Each testing is suitable only for a selected leak rate or for fixed forms and technologies. Our article presents the leak types, their sizes and various leak detection techniques. Keywords: tightness, leakage, trace gas, helium mass spectrometer leak detector, hermetic sealing

1. INTRODUCTION
The words "leak" and "leakage" appear in the field of vessels' hermetical closing and do not confront only with vacuum technologists but also engineers working with high pressures. A leak means an unintended crack, hole or porosity in an enveloping wall or joint which must contain or exclude different fluids and gases allowing the escape of closed medium. The basic functions of leak detection are the localization and size measurement of leaks in sealed products and systems For majority of examples, a leak test procedure is a quality control step to assure a device integrity, and is one-time nondestructive test.

Tipical products in which the leak detection has to be used are: vacuum chambers, TV- , and other cathode tubes, hermetically sealed electronic components, pressure vessels, aerosol containers, vacuum thermal isolation (e.g. dewars), pumps, refrigerating systems, chemical and nuclear plants, beverage cans, products containing metal bellows, electron microscopes, peace makers, etc. In spte of modem technologies it is practically impossible to manufacture a sealed enclosure or system that can be guaranteed to be leakproof without first being tested. The main question is: what is the maximum acceptable leak rate consistent with resonable performance life of the product. We can distinguish different tipes of leak sources. Leaks caused by defects in the containing envelope. For example a too thin wall of a plastic bottle becomes microscopic cracked at enough high pressure difference, or in canning industry if the score mark is too deep in ring pull-tab can top, or porous cast in machine housing metallurgy, etc. Leaks in newly manufactured products are most commonly imperfect joints or seals by which various parts are assembled to form the final article. There are known demountable and fixed joints. Between them the most often used are welds, brazed and soldered joints glass-to-metal and ceramic-to-metal seals, O-rings and other gaskets, etc. Materials permitting gas diffusion and permeation through the wall. Virtual leak, a special type of leak in vacuum technique, which is not really a leak but is the internal source of gas or vapor. These are cavities in a chamber wall with thin connections to the inner vessel space such as improper welds, closed threads and holes etc.

2. LEAK SIZES AND MEASUREMENTS OF LEAK RATES

The shapes of leaks (cracks, fissures, porosity, damages, etc ... ) are very different, unknown and non-uniform. Therefore it is impossible to measure their sizes with any geometrical dimension except of course in the case of an ideal or artificial leak as used for calibration. How then to define the leak size? A generally accepted method became the observation of gas or fluid flow through it in certain conditions of temperature and pressure difference. Consequently leak rates can be defined in two ways:
o o

in terms of the application, e.g.: 3 g of refrigerant R-12 in 2 years at 5 bar, or 65 m of oil per year at 60 C at atmosferic pressure, etc... in terms of vacuum leak detection method, e.g.: 2 mbar pressure increase in I hour or 3x 10-7 mbarl/s helium (using He-detection method)

Each of the mentioned examples gives a legitimate description of leak rate but the generally accepted unit is the last one because of very simple and understandable helium leak detection. Its efficiency is the result of a fierce and highly competitive developments within the last 15-20 years.

The basic experiment explaining the leakage of hermetic system (increasing pressure method) is presented in Figure 1. The tested vessel or system with known volume (Vo) is by a valve connected to pump. After evacuation the connecting valve should be closed and then the pressure in volume registered for a suitable long time periode. There are more possibilities: system is tight and clean (a), fight and not clean (b), not tight and clean, i.e.: ideal leak (c), not tight and not clean, i.e.: combination of leak and degassing. As we can see in each case (except for a tight vessel) we have pressure increase and regarding to the shape of diagram we can conclude the type of leak. Using the curve inclination data the leak size can be determined by the following formula: Q = ^p * Vo/^ t (mbarl/s) This simple test helps us to describe the situation at the begining of leak tracing procedure. Very similar test can be realized by pressurizing the the system (and detecting the pressure decay) but gives only data on leak size and is not used so often. The leak rate Q does not only depend on the geometric dimensions (diameter, lenght) of the leak but also on the physical properties of the gas (or the liquid), such as viscosity, relative molecular mass and on the pressure difference. For example: in the same environment conditions helium flows through orifices 2.7 times faster than air. Because of different results if the same leak is measured by various mediums it must be always noted with which gas a testing was performed. The maximum acceptable leak rate for a given product depends on the nature of product. Since the cost of leak detection (and manufacturing too hermetic envelopes) increases in inverse proportion to a leak rate, it follows that testing for unnecessary small leaks causes unnecessary rise of production costs. Some examples of tolerated leaks in different elements and systems are shown in Table 1. We can see very wide range of sizes: from great with some tenths mbarl/s in rough vacuum devices, to milion- and more- times smaller in hermetically closed electronic elements. It is possible to state there are no ideal products without leakage. We only can demand they have leaks smaller than the specified leak. Table 1. Leak rate specification for various elements and systems Element or System beverage can bottom IC-package pacemaker closed vacuum elements Max. permissible Leakage Remark great process flows retention of CO2 permanent pumping long time implanted in body e.g. TV- and Xray- tubes 10 to 10 mbar l/s
-5 -7 -7 -8 -5 -6

chemical process equipment 10-1 to 1 mbar l/s dynamic pumped vacuum s. 10 to 10 mbar l/s 10 to 10 mbar l/s cca 10-9 mbar l/s 10-8 to 10-10 mbar l/s

3. LEAK DETECTION METHODES

A few leak detection techniques are known. Their performances regarding to detecting sesitivity are presented in Fig 2. Because of their advantages we shall concentrate attention on the helium mass spectrometer tecniques but at first a short description of others is presented, The spark coil technique uses a high voltage or Tesla cod and sparkling point to create the electromagnetic radiation which causes the generation of glow discharge in neighbouring evacuated ampoules. Normally it is possible only in non metal envelopes, that means first of all in glass and plastic elements or tubing. Drawing the leak antenna along the tested element we can see plasma inside and coming to the leak, a sharp arc passage between plasma and antenna appears. The defect spot is very clearly marked and a skilled person can from the colour of plasma also estimate the inner pressure. This simple metod however has a number drawbacks; since besides the restricted application it is also to be avoided because of radiodisturbances. Pressure change method uses pressure gauges which are ordinary used to monitor the system performance. Suspected leak sites can be squirted with a solvent (i.e. acetone or similar) while watching the gauge for a pressure rise that occurs when the solvent enters the leak. This method has limited sensitivity (depending also on the type of pressure measurement cell) and some shortcomings (possibility of solvent freezing causes temporary stuffing of leak, solvents may attack vacuum grease and elastomer gaskets).

Figure 1. Testing of tightness by increasing pressure method and various possible results

Bubble test (soap painting) Bubble test (air, water) Bubble test (He, alcohol He sniffer

------ ------ ------ ------ ------ ------ -----> ------ ------ ------ -------> ------ ------ ------ ------ --------> ------ ------ ------ ------ ------ ------ ------ ------ ------ --->

------ ------ ------ ------ ------ ------ ------ ------> ------ ------ ------ ---------> ------ ------ ------ ------ -----Acoustical -> Vacuum ------ ------ ------ ------ ---------> decay Spark ------ ------ ------ ------ -----tester > Thermal ------ ------ ------ ------ ------ ------ ------ -----conductivit > y Radioisoto ------ ------ ------ ------ ------ ------ ------ ------ ------ ------ ------ ------ -----pe > Halogen ------ ------ ------ ------ ------ ------ ------ ------ -----detector > Mass -------- ------ ------ ------ ------ ------ ------ ------ ------ ------ ------ ------ -----spectromet --er > Dye ------ ------ ------ ------ ------ ------ ------ -----penetrant > 10 10 mbarl/s 100 10 1 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 -11 -12 Halogen sniffer Pressure decay Figure 2. Sensitivity ranges of various leak detection methods Overpressure methods can be performed by fluid or gas with which the tested element must be filled. As a fluid usually the water from house installation is used. Observing the outside surface the wetted areas show us great leaks and smaller ones up to approx. I mbarl/s. Testing with gas, the vessel is subjected to overpressure of some bars (depending on material and wall thickness) and immerged into the water. At leaks the gas bubbles begin to escape. In this manner the leaks up to 1. 10-3 mbarl/s can be detected. If the vessel is too great for immersion, the suspected points should be painted by soap solution and again we can see the bubbles escaping if there is a leak. This method enables detecting the leakage up to 10-5 mbarl/s and is usable also for very large systems. Halogen leak detectors are used in the detector-probe mode (to 10-3 mbarl/s), requiring that the system be pressurized with a gas containing an organic halide, such as one of the Freons. The exterior of the system is then scanned with a sniffer probe sensitive to traces of the halogen -bearing gas (Fig. 3). The principle is based on the increased positive ions (K or Na) emission because of sudden halide composition presence. The ion current is the measure for a leak size. Halogen detectors can be used also in turned mode: evacuated vessel is connected to detecting instrument and is sprayed by freon. In this manner its performance is up to 5.10-7 mbarl/s and is used in rough, medium and high vacuum.

Figure 3. Halogen leak detector

Dye penetrant method is an adaptation of a technique used to find cracks in metals and defects in welds. It uses a low viscosity fluid that exhibits a high rate of surface migration. This fluid is painted on one side of a suspected leak site, and after a time, it is detected on the other side of the wall. The test is simple, low cost, it leaves records, the sensitivity can be as high as 10-6 mbarl/s Acoustical leak detection uses the sonic or ultrasonic energy generated by gas as it expands through an orifice. Pressurized gas proceeds from tested system through leaks which are detected outside by sensible microphone (tipically about 40 000 Hz). Acoustical leak detection is widely used in testing high pressure lines, ductworks etc. It requires modest instrumentation; it is simple and fast but is limited to about 10-3 mbarl/s. Radioisotope method is useful only for testing hermetically sealed components. They are placed in a chamber which is to be evacuated and filled with radioactive tracer gas (tipically krypton 85). It difuses through present leaks in the components and after removing it from environs test gas expands through leaks back and can be detected by radiation sensor. The instruments for this type leak tracing are very expensive but they enables the measurement of flows up to 10- 11 mbarl/s. Mass spectrometers as leak detectors are used as most sensitive instruments for stating leak existance and presence in vacuum systems. They are adjusted on the atom respectively molecular weight of tracer gas. It is usually helium because of. - its small mass and atom volume assures good supply of gas through a leak -relative great mass distance from neighbour mass enables greater sensitivity - its partial pressure in air is low, approx. 4.10-3 mbar The first next suitable gas for leak detection purposes would be H2 but it is dangerous and residual atmosphere in vacuum systems always contains this gas. There are also spectrometers adjustable to other gases e.g. argon.

4. HELIUM MASS SPECTROMETER (MS-) LEAK DETECTION

Helium leak detection systems work as follows: He is introduced to a test part that is connected to the leak detector. The helium travels through leak into the leak detector, its

partial pressure is senzed respectively measured and results are displayed on istrument as flow rate. The main part of the device is mass spectrometer, a sensor for different gas masses. In very low pressure (or vacuum) the molecules of rest gasses are transformed in ions by electron impact. Separating the ionized particles of different mass to charge ratios (q/m) it is possible to state the partial pressures of present gases - in our case also the presence of the sought gas helium. For helium MS- leak detectors, magnetic sector type mass spectrometers are preferably used as gas search sensors. The low pressure (less than 2x10-4 mbar) required for operation of the mass spectrometers is produced by an integrated high vacuum pump system. The auxiliary vacuum pump required for rough pumping the tested equipment is either incorporated or can be attached via suitable connection. As the necessary pressure for the mass spectrometer cannot always be attained in the tested equipment within a resonable pump-down time, various types of MSleak detectors with different performances have been developed. The most used are constructions with "full flow operation" (conventional) and with "contra-flow operation", regarding to the way in which He is supplied towards MSsensor. For example the figure 4 shows schematically the conventional type MSleak detector. In presented system, vacuum is maintained in the spectrometer Figure 4. Conventional type of the helium leak tube by use of a diffusion pump in detection apparatus combination with mechanical pump. A cold trap pumps condensable vapors such as oil and water. A roughing pump is provided to evacuate the test port (and the connected sample to be tested) to a pressure level that will not disrupt diffusion pump operation. Reaching a suitable vacuum the sample is valved off from the rough pump and by opening test valve joint to the MS- vacuum system. Helium sprayed near the leak on the sample surface has now an open way to the MS-tube and there it is detected. After completing procedure the test port is valved off from the leak detector and vented to air; than we can change the sample.

How to use a helium MS- leak detector? There are basically four different techniques for finding leaks: two "OUTSIDE-IN" and two "INSIDE-OUT" methods (Fig.5). In the most commonly used "outsidein" technique, the sample to be tested is connected to leak detector and evacuated (Fig.5a). Than its surface is "probed" with a pointed jet of helium. Coming over a leak detector gives an acoustic or visible sign (exactly location) and the data about leak size. The second technique (Fig.5b) consists of evacuating and hooding the sample with something like a plastic sheet and flooding the hood with helium. So it is possible quickly to establish whether or not a sample leaks and to establishe the total leak rate. This technique is most useful on production lines where a test piece must be accepted or rejected.

In "inside-out" techniques the test configuration is reversed. Instead of being evacuated, the sample is pressurized with He. In this case the leak detector is equipped with so called detector probe and it can be used in two modes presented in figures 5c and 5d. In mode c) the test piece is probed with the detector probe around suspected leak sites. This method sensitivity (up to 1. 10-6 mbarl/s) is not as good as by others because the helium in the air is constantly being admitted into the detector. Mode d) allows testing of a large number of samples simultaneously. It is often called the bombing technique because the parts are previously placed in a pressurized He vessel where the helium leaks into the parts which leak. All parts are than exposed to detector probe in closed container. The mentioned leak test techniques are the main methods for establishing whether leaks exist and for locating where they are. Each has its own advantages and shortcomings, each has also its own individual set of variations.

Figure 5. Main leak detection techniques with MS-leak detector and He tracing gas. In one mode (examples a and b) He flows from outside into vacuum and in other it expands from inner overpressure in atmosphere

5. CONCLUSION
Resarchers, technicians, scientists, producers etc who in their work need hermetically closed elements and vessels, vacuum or only tight seals have to become familiar with measurements and localization of leaks. In Slovenia there are already exist some groups

(first of all on fakulties and institutes) which have mentioned knowledge and there are also a few of technologies that use leak detection technique in manufacturing and in production lines as a 100 % quality control. But in general engineering and also in important projct organisations this technical field is nearly unknown. Wishing to progress on our way towards more developed countries this situiation must be changed. Department for vacuum elements and systems in Institute for electronics and vacuum technique (IEVT) is, beside others, permanently occupied by tightness testing and leak detection for our own needs and as service for customers. In cooperation with the Slovenian Vacuum Society we prepare every year educating courses for vacuum techniques, where also this knowledge and skills are represented. Regarding to mentioned circumstances this contribution with basics about leaks and detection methods was prepared as information.

6. LITERATURE
1. J.L Ryan, D.L.Roper: Process vacuum system, design and operation; McGrawHill Book Company, New York etc-, 1986 2. Nigel Harris: Modem vacuum practice, McGraw-Hill Book Company Europe, Berkshire, England, 1989 3. Varian: Introduction to Helium mass spectrometer leak detection; Varian Associates Inc., Palo Alto, 1980 4. E. Kansky: Hermetologija sticnih ploskev in spojev, predavanja na III. st.Vakuumistika.; FERI Maribor, IEVT, Ljubljana; 1983 5. L.C.Beavis: Real leaks and real leak detection, Vacuum, Vol.20, No.6, p233, Pergamon Press, London,1970 6. M.Wutz, H.Adam, W.Wachler Theorie und Praxis der Vakuumtechnik, F. Vieweg & Sohn Verlag GmbH, Braunschwieg, 198"

Leak testing equipment is a type of nondestructive testing equipment used to measure the escape of liquids, vacuum or gases from sealed components or systems. Some configurations require a separate leak detector or sensor as an input. They are often equipped with various other components such as pumps, calibrators, gages and cases. A leak is a hole or porosity in an enclosure capable of passing a fluid from the higher pressure side to the lower pressure side. There are many basic leak test methods and a few variations. The most familiar are dunk testing, pressure decay, mass flow, mass spectometer and ultrasonics. Dunk testing is still the most popular method, with pressure decay and mass flow rapidly gaining in use. Mass flow is the de facto test method of choice in automotive applications. An exception is pressure decay testing on a brazing fixture. If there is a situation where a no leak application is required, there is only one choice mass spectrometerregardless of cost. This application uses helium and hydrogen gases as part of its inspection process. The good news is the leakage may be so microscopic it is rarely detrimental to product performance.

Dunk Testing Dunk testing, sometimes called bubble testing, is used for applications that do not require high sensitivity. With dunk testing, the part under test is pressurized, submerged in a liquidtypically waterwhile the operator looks for bubbles. Bubbles form at the source of the leak as a result of air pressure, and the amount of bubbles per minute can signify the size of the leak. Automotive radiators often are checked for leaks this way. If a leak is present, the bubbles indicate where and the leak can be repaired. Leak testing works best when speed is not a factor. On a production line where test time is critical, leak testing is not the best choice. While the initial cost of a dunk tank is low, in production it is expensive primarily because the water becomes contaminated, thus producing a hazardous toxic waste requiring special disposal. Tramp oil on the parts, as well as residual brazing flux are the main problems. Tramp and brazing flux from the parts leech into the water causing water contamination and costly special disposal. In one plant, aluminum condensersAC radiatorsare tested on four lines, six tanks total. Each operator has 19 seconds to determine if the bubbles represent air trapped in the fins or an actual leak. The operator is solely responsible for quality control prior to final mass spec testing. Failure of the operator to find a leak of 3.5 standard cubic centimeters per minute (sccm) or greater can shut the mass spec line down for hours. In addition to disposal, maintenance of the water for pH, bacteria and skimming the surface to control skin rashes is a big factorpossibly $30,000 per year for maintenance of each tank. In the above mentioned condenser plant, each 3- by 3- by 12-feet tank is said to cost $30,000 per year to maintain. This is an example of a familiar process for low-volume applications and repairs but an inappropriate use in high-volume applications. High-speed leak testing in a production line situation hampers the operators ability to accurately identify bubbles. However, dunk testing can be used on fuel tank filler assemblies and fuel tanks themselves. One advantage of water dunking is temperature stability. The large volume does not change temperature, which affects most of the more sophisticated testers.

Pressure Decay

Dry testing a radiator, this pressure decay tester inspects with a test cycle time of 16 seconds at 95 psi. This is the same tester

 The pressure decay testing method measures the decrease in that tested the brazing pressure in an object. A test object is initially inflated and then a fixture. Source: Stewart Ergonomics reference pressure is established. After a designated amount of time, the pressure is monitored again, and the initial and final measurements are Inc. compared. The change in pressure can be used to calculate the leak rate given the internal volume of the device. Pressure decay is able to detect minute changes in pressure. A drop in pressure signifies a leak; the greater the pressure drop, the larger the leak. This method is convenient in that it is easily automated and dry. Years ago, the operator drew a grease pencil mark on a gage and came back a while later to see if the gage pointer had moved. If it had, this meant that pressure decayed. Today, electronics monitor to 0.00001 psi and the test is fastthe fastest on small-volume parts. During the past 20 years, electronics have progressed from a 12-bit analog to digital converters, which provided a resolution of 0.0012 to 5 psi. This reduced to 0.0244 psi at 100 psi, far too coarse to be practical. One way around this problem was the differential pressure tester. Two sensors, having a 5-0-5 psi range, could be set up at 100 psi and provide a resolution of 0.0012, which was usable. Presently, 24-bit resolution is available which provides 16,777,215 steps or 0.0000002 psi at 5 psi and 0.000059 psi at 250 psi. Consequently, differential testing has practically been phased out. The pressure decay method can be used to test small parts at high speeds. A 0.3-inch diameter by 1.2-inch long medical filter can be tested to see if the filter is in place, if it is plugged and if it allows for correct air flow. Test time from clamp to next clamp is 0.85 second at 15 psi. Also, a molded vacuum tube connection for the automotive industry is 12 inches of 0.2inch inner diameter tube with circular molded fitting can be tested. Its test time is 3.5 seconds, clamp-to-clamp at 15 to 30 psi, depending on part. Each test result is permanently recorded and traceable if required. Communication has become a significant quality tool. Sometimes, only a permanent record of key test parameters and results are sufficient. Other times, a label is printed out and permanently affixed to the part. Still others apply a permanent paint spot or stamp a mark. On certain safety-critical parts, a guillotine destroys a bad part. Temperature variation is a concern. It is widely believed that pressure testing a gas tank filler assembly while red hot on the braze fixture is impossible. The part in the brazing fixture is approximately 1200 F in the brazing area. Room temperature air fills the part to test pressure, then the fill valve closes. A 30 psi test would normally be considered incorrect at 29.9 psi. However, the pressure is rising, not decaying. The pressure will climb to 34 to 35 psi before starting to decay. It will require at least 15 minutes to reach 29.9 psi and will not be repeatable enough to be practical. The required test time is 20 seconds maximum.

Mass Flow With the mass flow method, the part is pressurized throughout the test. Any pressure change measured by a pressure sensor is compensated for by inputting air into the test part, therefore exact pressure control is critical. The amount of air entering a part is

measured by a flow sensor, directly determining the leak rate of the part. Leakage flow is directed across a heating element. The temperature change across a temperature transducer bridge results in an output voltage proportional to mass flow. If there is a leak, air will flow into the part. This flow is monitored electronically and processed directly in sccm. Because the flow of air into the part is equal to the leak loss, large-volume parts may be tested with relative ease. The problem with testing large parts is long settle or stabilize time. Because precise pressure control is critical, any oscillation during testing will compromise the test. Several types of electronic sensors are available. One has a fine tube through which air flows to the part. An electric heater at the input heats the air slightly and that temperature is precisely measured just beyond the heater. The change in temperature is proportional to the flow of air. Another application measures the milliampere (mA) of current needed to maintain temperature. Ambient incoming air temperature will affect the test. Most production systems are recalibrated every morning, noon and late afternoon. Large parts, such as truck radiators, are commonly placed in a wooden coffin to protect against air currents from fans and open doors. The slow test with long-settling time requires protection from thermal changes for repeatability. Mass flow is the process of choice in many automotive applications such as air conditioning condensers, radiators and some fuel lines.

Mass Spectrometer

The mass spectrometer method involves pressurizing the test object with a helium mixture and placing it in a snug-fitting vacuum chamber. The air is then evacuated from the chamber, creating a pressure gradient between the internal volume of the part and the vacuum. The helium molecules move out of the part through any porosity, holes and cracks. A mass spectrometer then samples the air inside the chamber and finds individual atoms of A wand testing system, while not as helium. accurate as placing This is the most sensitive test presently available. These testers the part in a vacuum are capable of detecting a leak of R600a refrigerant as small as 0.0028 ounce per year. In use, the helium is usually a disposable chamber, is superior to any other kind of item adding cost, although recovery systems are now available. Electronic parts often are tested by placing them in a chamber and test, and substantially pressurizing with helium, then placed in the vacuum chamber of less expensive than the vacuum chamber the mass spectrometer to see if helium is drawn out. This method system. Source: also will find porosity. Galileo TP Inc. The initial cost of a snug-fitting chamber is high, requiring precise machining and extremely tight seals, limiting the practical part size. A basic operation limitation is that a large leakmore than 4 sccmwill saturate the vacuum container with helium. This requires several hours of flushing to lower the helium background to a workable level. A pre-test can be employed to weed out the gross leakers. As with dunk testing, a 19-second inspection has proven troublesome and is slowly giving way to pressure decay testing, with or without permanent recording. Even a condenser 16- to 18-inches high, and 24-inches long can be easily tested to 3 sccm in 12

to 15 seconds at 200 psi. Many air conditioner condensers (radiators) are quite large, but they still must not leak for 8 to 10 years. For these applications, a wand testing system has been developed which, while not as accurate as placing the part in a vacuum chamber, is superior to any other kind of test, and substantially less expensive than the vacuum chamber system.

Ultrasonics Ultrasonic leak testers, sometimes called sonic, choked flow or turbulent flow, analyze the turbulent flow of a fluid across a pressure boundary that creates acoustic waves. These waves can be transmitted through the medium of the fluid itself, through the containment structure or through the air surrounding the containment structure. Because gas escaping through small holes generates ultrasonic sound, an array of ultrasonic sensors can be placed around the part. Computer control permits leak detection and, in certain circumstances, exact leak position may also be obtained, similar to dunk testing. Ultrasonic testing has become so widely used to test bearings, gearboxes and general mechanical inspection wear trends over time that it is often overlooked in leak detection. Part size is usually not a problem, nor is thermal variation. Arrays of sensors are used to pinpoint a leak. In some instances, pressure decay testing and mass flow testers have been integrated with ultrasonics to provide increased sensitivity. While this method has not been widely used, it has potential for larger parts. In the future, leak testing will experience faster cycle times, improved reliability and validation. Leak testing will continue to be integrated into the assembly process and its accuracy and sensitivity will become higher. NDT