What factors can cause air leakage detectors to malfunction?

1. Test Time Error

When performing leak tests, it is also important to carefully consider the selection of time points during the production process. For component leak testing, each sub-component should be pre-tested. If a leak is only discovered after all assembly is complete, it will not only be difficult to find the leak point, but will also require time and effort to disassemble and test.

For example, in the case of leak testing a transmission, the sealing of the transmission housing should be checked before assembling the transmission.

2. Test Piece Contamination

It is also important to observe the operation of the pneumatic leak detector, that is, always perform leak tests or leak new, unused test pieces. If a component has already been running or filled with oil or water, its small leaks may be blocked. Compressed air or detection gas cannot escape (or enter) from the sample, so it cannot be determined whether it is leaking.

If machining cutting oil residue is found on the casting, the test sample must be cleaned before leak testing and then the test sample dried again to ensure that the cleaning solution does not block potential leaks in the short term.

3. Unstable Test Pressure

It is also important to always fill the test piece with the same fixed pressure to ensure reliable and consistent testing to determine the leak rate.

4. No Pre-evacuation Before Filling Leak Detection Gas

Before filling the leak detection gas, the pneumatic leak detector must first evacuate the sample. This is especially important for long and narrow geometric samples. If the sample is not evacuated before filling, the air in the sample will be pushed to the end of the geometry and leak detection will be performed. The gas cannot enter this area, so potential leaks will only release air and cannot be detected by the leak detector. Vacuuming is especially important if the test piece is filled with low-pressure leak detection gas.

5. Underestimation of Creep Leaks and Large Leaks

For airbag manufacturers, it is important to handle creep leaks containing similar capillary channels, and it must be considered how long it takes for the helium leak detection gas to uniformly distribute the test piece to expose these creep leaks.

In contrast to creep leaks are large leaks. If the test piece leaks heavily, the helium will escape from the test piece during the actual test. Due to the evacuation of the test chamber and the simultaneous departure of helium from the test piece, in order to identify large leaks before the test piece is filled with helium, a simple pressure decay test method needs to be integrated into the leak detection gas test system.

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