Leak detectors Manufacturers online

Leak detectors or leak testers are used to identify and quantify leaks in closed systems.

Such devices are essential in a variety of industries, e.g. in the automotive industry, in the production of medical technology, in gas and water supply, as well as in the aerospace industry. The devices check whether a component or system is gas or liquid-tight to ensure safe operation and compliance with legal requirements.

Below you will find how leak testers work and how they are used, their advantages and disadvantages, as well as trends and developments:

How leak testers work:

Leak testers can be based on different physical principles that vary in their accuracy, sensitivity and applicability. The most common test methods include:

• Pressure decay method: this method is based on measuring the pressure decay in a system after it has been pressurized with air or a gas. If a leak is present, a pressure drop will occur over time.
  How it works: The component is first pressurized with a gas to a defined pressure. A sensor measures the pressure curve over a defined period of time. Any deviation from the standard value indicates a leak.
  Application: This method is suitable for smaller components and systems where even small leaks are significant.
• Differential pressure method: The pressure difference between a test specimen and a reference volume is monitored.
  How it works: Two chambers - one with the component and one reference chamber - are pressurized to the same pressure. A sensor measures the pressure difference. A drop in pressure in the test specimen indicates a leak.
  Application: This method is often used for series testing and offers high precision.
• Helium leak test: Helium is an ideal gas for leak testing as it has a very small molecule and can therefore escape through even the smallest cracks.
  How it works: The test specimen is placed in a chamber and filled with helium. A mass spectrometer detects the escaped helium, even in the case of very small leaks.
  Application: This method is used in high-precision applications such as aerospace or medical technology.
• Underwater testing (bubble testers): This method is used to visualize leaks.
  How it works: The test specimen is immersed under water and pressurized. Gas bubbles emerge at leak points.
  Application: This method is often used in quality control for simple components.
• Ultrasonic leak detectors: These devices are portable and enable leaks to be located quickly.
  How it works: By detecting ultrasonic noises produced by the movement of gases in leaks.
  Use: They are versatile and suitable for testing compressed air systems, vacuum systems and large systems.

Use of leak detectors:

Leak detectors are important in various stages of the production process or maintenance of a system:

1. Quality control in manufacturing:
In many industries, 100% leak testing is an integral part of the final inspection. Components, such as pressure vessels, valves or housings of electronic components, are leak tested after manufacturing to ensure that they meet specifications and have no leaks.

2. Testing of supply lines:
In the gas and water supply industry, lines and pipes must be regularly tested for leaks to prevent leaks, which can lead to high environmental and safety risks.

3. Maintenance of machines and systems:
During maintenance work on machines and systems (e.g. in the chemical or food industry), the tightness of containers, pipes and pumps is checked regularly to prevent interruptions to operations or safety risks.

4. Safety checks:
In safety-critical applications, such as in aviation or medical technology, leak tests are essential. They ensure that the components meet the high requirements and that there is no risk of uncontrolled leakage of gases or liquids.

Advantages and disadvantages of the methods:

• The pressure decay method is inexpensive and easy to implement but has the disadvantage of low sensitivity for very small leaks.
• The differential pressure method is very precise and also suitable for series testing. The disadvantage is its sensitivity to temperature or pressure fluctuations.
• The helium leak test has the highest accuracy for the smallest leaks, but is very cost-intensive and requires complex equipment.
• The underwater test makes leaks visually recognizable and is easy to use, but is not suitable for precise measurements.
• Ultrasonic leak detectors: These devices are small and lightweight, but cannot provide reliable results in noisy environments.

Trends and developments:

• Modern leak detectors are often integrated into automated manufacturing processes to make testing faster and more efficient.
• By using improved sensor technology, such as optical or acoustic leak detectors, smaller leaks can be detected more quickly.
• The integration of leak testing systems into data analysis tools enables more precise monitoring of testing processes and better error prevention in production.

Leak detectors are an indispensable tool in quality assurance and safety monitoring. The choice of the right method depends heavily on the application and the accuracy requirements needed. Careful selection and regular maintenance of these devices are crucial to ensure operational safety and compliance with regulations.

Here are the key aspects to look out for when buying leak testers:

When purchasing leak testers, there are many aspects that should be considered to ensure that the device is suitable for the specific application.

• Choosing the right test method depends heavily on the type of system to be tested for leaks:
• Is the system to be tested gas-tight or liquid-tight? Some methods are more suitable for gases, others for liquids.
• Pressure decay method: Suitable for low-cost, simple tests. Ideal for airtight systems where the pressure drop is measured over time.
• Differential pressure method: High accuracy, ideal for serial testing and systems with high quality requirements. Measures the pressure difference between a test specimen and a reference volume.
• Helium leak test: Very sensitive and accurate. Often used in aerospace or medical technology where the smallest leaks need to be detected.
• Underwater testing: Suitable for visual detection of leaks (by rising bubbles) in simpler applications.
• Ultrasonic leak detectors: These devices are portable and enable the rapid detection of leaks by locating the flow noise of gases.
• How small can the leaks to be detected be? More precise methods such as the helium leak test are more expensive but offer extremely high accuracy.
• Make sure that the device is designed for the required pressure range. When testing high pressure systems, robust devices that meet the specific pressure requirements are necessary.
• Pay attention to the device's ability to detect very small leaks if the application requires it (e.g. in aviation or medical devices).
• Is the device suitable for the materials of the parts to be tested (e.g. metal, plastic)? Some test gases or test pressures can damage certain materials.
• Will the device be used in a clean environment, e.g. in medical technology or food production, or in a harsh industrial environment? The robustness and protection class of the device must be tailored to this.
• Automation is an important factor for industrial applications:
• The leak tester should be able to be integrated into automated production lines. Pay attention to interfaces (e.g. industrial bus systems such as Profinet or Ethernet/IP).
• If the device is used in series production, it should work quickly and be able to perform a large number of tests in succession.
• The device should be user-friendly and offer intuitive operation:
• Look for a display with clear, understandable user guidance on which the measurement results are easy to read.
• Modern leak testers are often equipped with software that facilitates data evaluation and storage. Good software integration makes it possible to monitor and document test processes.
• There should be training on how to operate and maintain the device. Simple, clear user manuals are also important.
• A leak tester should be durable and low-maintenance:
• Pay attention to the reliability of the device, especially in applications where downtime is costly. Reputable brands often offer higher quality and more reliable devices.
• Regular calibration is required to maintain measurement accuracy. Find out about the effort and cost of calibration.
• Devices with automated calibration functions and self-diagnostic systems increase efficiency and reduce downtime.
• How often does the device need to be serviced? Less maintenance-intensive devices offer advantages during operation.
• In addition to the purchase price, the running costs should also be taken into account:
• Higher quality devices may cost more, but generally offer better accuracy and reliability.
• Take into account the costs of consumables (e.g. test gases such as helium), calibration and maintenance.
• A more expensive but more accurate device may be worthwhile if it can prevent errors or production downtime.
• Make sure that the device complies with the relevant industry standards, especially in regulated areas such as medical technology, the automotive industry or aviation.
• Check whether the device is certified to meet the requirements of the desired application. This is particularly important in the pharmaceutical, medical or food industries.
• Make sure that spare parts are easily and quickly available to minimize downtime.
• Some manufacturers offer maintenance contracts that cover regular maintenance and calibration of the device.
• Find out whether the manufacturer offers training on commissioning and operating the appliance.
• Good technical support is particularly important if problems need to be resolved quickly during operation.
• Is the device capable of receiving software updates to keep pace with future requirements?
• If your production processes are growing, it is an advantage if the device is modularly expandable.

When purchasing a leak tester, the specific requirements of the application, such as the test method, sensitivity, ability to integrate into existing systems and cost-effectiveness, should be thoroughly considered. Factors such as user-friendliness, reliability, maintenance and support from the manufacturer also play a decisive role. Careful consideration of these points will help you to select the optimum device for your needs and save costs in the long term.

Leak testers can be purchased from various suppliers. You will find comprehensive information on manufacturers and suppliers of Leak testers around the world on Exportpages.