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5 Ways to Reduce Cycle Times for Leak Test Applications


  1. Installing a fast fill (FF) circuit can significantly reduce fill times for mass flow and pressure decay applications. The FF circuit has larger fill ports, fill lines, and higher regulated pressure.  We fill with higher regulated pressure and transition to stabilize upon reaching the target pressure.  This is great for large test volume applications.


  1. For high pressure applications with long stabilization times, consider an inside-out test (also called a pressure gain test). This does require a chamber for the part, but offers significantly reduced cycle times because of lower stabilization times and better calibration resolution thanks to a reduced test volume (typically).


  1. Consider testing with a tracer gas for low leak rate, large volume applications and targeted test areas. Examples include a carbon canister or brake line.  Large volumes and flexible parts pose a particularly difficult challenge for traditional leak test methods like pressure decay and mass flow.  Utilizing a tracer gas allows for low leak rates to be detected in a relatively fast cycle time without being affected by the adiabatic temperature effects (for more info on adiabatic temperature effects please refer to our leak training class manual).  Testing utilizing clam shells on brake, fuel, oil, and power steering lines can increase GR&R’s while increasing through-put.  This effort reduces false rejects while testing to more stringent standards.


  1. Test dual cavity parts simultaneously by utilizing pressure decay on one cavity while conducting a vacuum decay test on the second cavity. This allows for testing two cavities at the same time, significantly reducing times.


  1. Ensure that parts are at room temperature prior to testing. We realize this creates a buffer, but traditional leak test methods such as mass flow and pressure decay are significantly impacted by pressure changes in the part during the test.  Heat will expand the air pressure inside the test part causing false rejects or accepts.  This is easy to visualize (think of a milk jug left out after removal from the fridge) and critical to consider when implementing leak test technology.


These are some recommendations and more exist.  Cincinnati Test Systems has over 30 years of experience tackling challenging leak test applications.  Contact us to request more information.


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