Castings/Die Cast Components

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Trust is built and maintained by many small actions over time. As a leading provider of casting and die-cast leak testing solutions for over 20 years, we’ve helped numerous manufacturers maintain leak-free production of castings.

Air leak testing is a crucial quality control process in the casting industry to ensure the integrity and reliability of cast parts. Since the inception of die-casting and machining production, manufacturers have tried numerous ways to detect ever smaller leaks in their aluminum castings. Die cast parts present special challenges for leak testing due to potential defects such as pinholes/blowholes, shrinkage porosity/cavities, machining imperfections, and hot tears or cracks. As casting manufacturing has progressed, air leak testing has proven itself to be a reliable, measurable indicator of the quality and leak-tightness of countless aluminum die-castings.

When selecting the correct leak test method for die castings, factors such as part size, required reject leak rate, cycle time, and specific application requirements must be considered. 
 

Pressure Decay

Pressure decay is the most common leak testing method for testing a casting, such as this V-Twin motorcycle housing. Pressure decay testing fills the part to a target pressure, isolates it, and measures pressure loss over time. The pressure can then be converted to a volumetric leak rate (standard cubic centimeters per minute). If the casting leaks more than the maximum volumetric leak rate or pressure loss value, then the part is deemed failed. This method is easily automated and integrated into production processes.
 

Vacuum Decay

Like pressure decay, only a vacuum is applied to the part. Fast and repeatable. Seal tooling also benefits from vacuum decay testing, as the seals are sucked to the part openings rather than fighting pressure applied to the inside of the part.
 

Mass Flow

Ideal for larger volume or elastic parts, the mass flow testing method measures the makeup air flow required to maintain constant pressure, compensating for air loss through leaks.
 

Differential Pressure

Best for small leaks due to its ability to measure microscopic leaks down to a few microns or sub 1 sccm leak rates. Differential Pressure testing method measures the difference between a reference volume and the production part.

By detecting and addressing casting leaks promptly, manufacturers can avoid costly repairs, downtime, warranty claims and potential damage to their reputation.
 

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For more information on LeakMaster’s die-casting leak testing expertise and cutting-edge leak testing products, Contact Us today.