Mass Flow Leak Testing

Mass Flow leak testing is a non-destructive testing leak method used to detect leaks in a wide range of products, from automotive parts, medical devices, to military and defense components. This technology involves pressurizing a sealed part or system and then measuring the air flow required to maintain the setpoint delivery pressure.  If the mass flow sensor detects flow after the part is sufficiently pressurized, it indicates the presence of a leak. This method of leak detection measures the amount of replacement air that is required to keep a device being tested up to a specific setpoint pressure.
 

How Mass Flow Testing Works

1. Sealing the Component: The part being tested must be sealed so that air can be delivered to the inside of the device under test (DUT).
2. Pressurization: The component or system 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, an isolation valve closes to trap the pressurized gas in the device under test.  The test pressure is allowed to stabilize which allows for stretching/cooling of the device under test.
4. Leak Detection: After stabilization, a test valve opens to introduce the Mass Flow sensor into the test circuit.  Air pressure is continuously supplied to the part through the Mass Flow sensor.  The Mass Flow sensor measures the amount of replacement air required to maintain the setpoint test pressure.
5. Analysis and Reporting: The mass flow sensor is analyzed. If the flow rate is 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 Mass Flow Testing

• Non-Destructive: Mass Flow 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.
• Versatile:  Mass Flow leak testing is widely used across industries such as automotive, consumer products, ammunition devices, and more. It is suitable for testing a wide variety of shapes and sizes, from small individual components to large assemblies.

• Volume Independent:  Mass Flow leak testing is not volume dependent. This means if the internal volume of the device being tested does not have to be consistent.  It is typically used on products that have a high stretch rate.
• Quantitative Results: The test provides numerical leak rate 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.

LeakMaster has been crafting the finest mass flow leak testers for decades. We are one of the largest manufacturers of mass flow leak testers in the world. Our patented B-Stable technology allows us to test products up to 50% faster than our competitors with outstanding accuracy over a wide part and environmental range.
 
We’ve successfully tested large parts like exhaust systems, EV battery packs and headlights to small, delicate medical devices with our Guardian and UltraFlow V3 mass flow instruments. Bringing a wealth of instrumentation, practical knowledge and expertise to every application we tackle including:
 
Guardian – Modern, refined and highly sensitive. The Guardian is LeakMaster’s most configurable mass flow leak tester, with multiple sensor options and unique features you can only find on the Guardian. For long term value and peace of mind.

UltraFlow V3 - The patented UltraFlow V3 is the world’s best performing pressure decay - mass-flow combination leak test instrument. Offering blazing performance and high-performance flow monitoring up to 200 LPM. When your mass flow application requires the absolute fastest cycle time, there is only one UltraFlow.

The world's largest automotive, medical device, and die casting manufacturers count on LeakMaster’s mass flow technology to provide fast stable results, and we are the specified leak tester for many military and defense programs as well.
 
LeakMaster, setting the bar for production ready mass-flow leak testers.

Contact Us

For more information on our  Mass Flow Leak Testing Instruments, please see our Contact Us page.