Differential Pressure Decay Leak Testing

Differential pressure (DP) decay leak testing is a non-destructive leak testing method used to detect leaks in a wide range of products, from automotive parts, medical devices, to industrial components. This technology involves pressurizing a sealed part and a reference volume (dead volume) and then monitoring the difference in pressure between the device under test and the master volume over time. If the pressure difference between the two volumes changes too much, it indicates the presence of a leak.
 

How It Works

1. Sealing the Component: The part being tested must be sealed so the test gas can be delivered to the inside of the device under test (DUT).
2. Pressurization: The device under test (DUT) and a master volume is pressurized with a gas (usually air or nitrogen).  A precision pressure regulator is set to determine the setpoint pressure delivered to the device under test.
3. Stabilization:   After reaching the target pressure, isolation valves close to trap the pressurized gas in the device under test and the reference volume.  The test pressure is allowed to stabilize which allows for stretching/cooling of the device under test. A balance valve stays open to the device under test and the reference volume to allow both cavities to perfectly balance.
4. Leak Detection: After stabilization, the balance valve closes to isolate the device under test from the reference volume. The Differential pressure sensor measures the difference in pressure between the device under test and reference volume.
5. Analysis and Reporting: The pressure change between the device under test and the reference volume is analyzed. If the pressure decays at a rate above a predefined threshold, the component is deemed defective. A pass or fail determination is then made based on the test results.

Key Benefits of Differential Pressure Testing

• Non-Destructive: Differential Pressure Decay leak testing does not alter or damage the component, making it ideal for sensitive or expensive parts.
• Simple and Fast: The process is relatively quick, with results often available in just a few seconds to minutes, depending on the size of the part being tested and the size of leak that you are trying to detect.
• High Sensitivity: This method is more sensitive than standard pressure decay leak testing or mass flow leak testing because the full scale of the differential pressure sensor is so small (typically less than 1.5 PSI full scale)  This method is sensitive enough to detect extremely small leaks, which is crucial in applications where even smallest leaks can compromise performance or safety.
• Versatile:  Differential Pressure Decay leak testing is widely used across industries such as aerospace, automotive, electronics, medical devices, and more. It is suitable for testing a wide variety of shapes and sizes, from small individual components to large assemblies.
• Quantitative Results: The test provides numerical data, making it easy to determine the severity of leaks and to make precise decisions about part integrity.

Industry Applications

• Automotive Industry: Testing fuel delivery systems, exhaust systems, lighting, brake systems, sensors, radiators, and drive train components for leaks.
• Aerospace: Ensuring that critical components like hydraulic systems, valves, sensors, and pressure vessels are leak-free.
• Medical Devices: Verifying the integrity of drug delivery systems, surgical instruments, ventilators, catheters, and other medical equipment.
• Consumer Goods: Leak testing for electronics, vacuum-sealed packages, or components requiring airtight seals.

Since our inception in 2006 LeakMaster has been manufacturing high-precision Differential Pressure Leak testers. LeakMaster provides many leak tester options for Differential Pressure including our Guardian, 700 Series and Stealth modules. Providing a choice of enclosure sizes and performance levels for your unique application.

The Guardian is our flagship Differential Pressure instrument, utilizing several cutting-edge features and our latest differential pressure sensors and communications. The instrument provides steady, highly accurate performance over a wide pressure and leak rate range.

The 700 Series Differential Decay leak testers are versatile and offer high sensitivity. Hallmarks of the 700 Series are its rugged design, steady performance and user friendly features

The Stealth leak test module is the newest member of the Differential Pressure family. Modular, compact and lightning-fast describes the Stealth. Its compact design and low cost per channel make it a great value and ideal for multi-channel applications.

Differential Pressure leak testing is a reliable, cost-effective, and extremely sensitive method for detecting leaks in various industries. Its non-destructive nature, coupled with its ability to provide quick, accurate, quantitative results, makes it a popular choice for quality control and assurance in manufacturing. Whether it is ensuring the integrity of an automotive part or verifying the airtightness of a medical device, differential pressure decay testing offers an elevated level of precision and sensitivity that contributes significantly to product quality and safety.

The world's largest manufacturers count on LeakMaster’s Differential Pressure technology to provide stable and reliable results. When the leak rate is low, trust the experts at LeakMaster.
 

Contact Us

For more information on our Differential Pressure Leak Testing Instruments, please see our Contact Us page.