Metered Volume (IP67 Leak Testing)

Metered volume leak testing (also known as volumetric fill leak testing) is a non-destructive leak testing method used to detect leaks in a wide range of products, from automotive parts, medical devices, or electronic components. It is specifically used for leak testing sealed products or products that do not have a means of allowing air to be introduced to the inside of the product. This technology involves placing a sealed part into a chamber, then monitoring the change in pressure (or vacuum) over time that occurs inside of the chamber. If the pressure inside of the chamber drops, it indicates air leaking into the product being tested. This type of testing is commonly used for IP67 (ingress protection) leak testing to ensure a product cannot ingress water or dust.
 

How It Works

1. Loading the Component into a Chamber: The part being tested is loaded into a leak free chamber.  The chamber is closed and sealed shut.
2. Pressurization: The chamber is pressurized with a gas (usually air or nitrogen). LeakMaster utilizes a specialized pneumatic circuit and chamber to deliver an exact amount of gas volume into the chamber. A precision pressure regulator and air tank is set to determine the setpoint pressure delivered to the chamber.
3. Stabilization:  After reaching the target pressure an isolation valve closes to trap the pressurized gas in the chamber.  The test pressure is allowed to stabilize which allows for stretching/cooling of the chamber and the device under test.
4. Decay Monitoring: After stabilization, the chamber pressure is monitored over a specified time period. The key to this method is the assumption that a sealed chamber, loaded with a device being tested without any leaks, will maintain its pressure.
5. Leak Detection: If a leak exists in the device under test, air escapes from the chamber into the device under test, causing a detectable drop in pressure.
6. Analysis and Reporting: The chamber’s pressure drop is analyzed. If the pressure decays at a rate above a predefined threshold, the tested component is deemed defective. A pass or fail determination is then made based on the test results.

 

Key Benefits Metered Volume Leak Testing (IP67 Leak Testing)

• Non-Destructive: Metered volume decay 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 sensitive enough to detect small leaks, which is crucial in applications where even tiny leaks can compromise performance or safety.
• Versatile: Metered volume leak testing can be performed with a pressure decay, vacuum decay, or differential pressure decay leak test circuit. This method is widely used across industries such as consumer electronics such as phones or watches. It is also used in applications such as optics (scopes), electronics enclosures, sealed lighting assemblies, and pharmaceutical/ food packaging.
• Quantitative Results: The test provides numerical data, making it easy to determine the severity of leaks and to make precise decisions about part integrity.

 

Applications

• Automotive Industry: Engine control modules (ECM) sealed electronic sensors, cameras, and switches.
• Medical Devices: Verifying the integrity of drug delivery systems, surgical instruments, catheters, and other medical equipment.
• Consumer Goods: Leak testing for electronics, phones, smart watches, vacuum-sealed packages, or any components requiring an IP (ingress protection) rating.
• Military and Defense: Optics and scopes, GPS modules, sealed explosives and storage containers.

 

Limitations

While metered volume leak decay testing is highly effective, there are certain limitations to consider:

• Leak Location: The method can indicate the presence of a leak but cannot pinpoint the exact location of the leak.
• Environmental Factors: Changes in ambient temperature can sometimes influence pressure readings, requiring careful control of test conditions and testing environment.
• Volume Dependent:  Metered volume decay leak testing is volume dependent.  This means that if the part volume of the device being tested is not consistent (part to part), then the results can be inconsistent.  It is typically used on products that have a consistent/repeatable external dimension.

 

Metered volume decay leak testing is a reliable, accurate, cost-effective, and efficient method for detecting leaks in sealed products. Its non-destructive nature, coupled with its ability to provide quick, 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, metered volume decay testing offers an important level of precision and sensitivity that contributes significantly to product quality and safety.

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