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Benefits of replacing pressure decay testing with tracer gas testing

GLOBAL MARKETS ARE INCREASINGLY ASKING COMPANIES FOR MORE COST-EFFECTIVE PRODUCTION PROCESSES WHILE SIMULTANEOUSLY DEMANDING HIGHER PRODUCT QUALITY. THIS CHALLENGE REQUIRES INTEGRATED QUALITY TESTING METHODS THAT REDUCE UNIT COSTS AND, AT THE SAME TIME, IMPROVE PRODUCT QUALITY.

Production managers are faced with special challenges in the industrial leak testing sector. On the one hand, requirements regarding the leak-tightness of a component are often not available or not clearly specified. On the other hand, the variety of test methods and their levels of performance are frequently unknown. INFICON’s innovative leak testing technology, based on the tracer gas principle, has technical measuring advantages compared to pressure-dependent test methods. Every required quality class has a cost-optimized test method.

 

Starting points for selecting a suitable leak testing method include the requirements for leak-tightness of the component as well as the stability of ambient conditions in the testing location.
 
The leakage rate is the specification for the leak-tightness of a component. This must not exceed the maximum permitted loss
of content (operating medium) of a component over the course of its lifetime. As the operating medium does not usually correspond with the necessary tracer gas used for leak testing, conversion to the corresponding gas leakage rate must take place. Empirically determined values are available for components which were filled with fluid.
     Leak testing methods which are not particularly dependent on ambient conditions, especially the temperature, are advantageous. Within industrial leak testing, indirect test methods are particularly common; this is where the results are expressed as a leakage rate based on a change of pressure within a component, whereas with direct test methods, the actual gas leakage is measured based on a tracer gas.
 
GOOD REASONS FOR YOUR CHANGE
 
1 SAFER AND FASTER TESTING PROCEDURES –DESPITE TEMPERATURE FLUCTUATIONS
Differential pressure tests need stable temperatures. Temperature effects due to air-conditioning systems, drafts andsun, heat radiation from production facilities or fluctuating test part temperatures can be compensated for only to a limited extent and lead to faults in the testing process.
 
Here the INFICON trace gas method provides a remedy: it measures the leaking gas flow directly so that the temperature effect becomes negligible. Even very hot or cold test parts can be tested without a problem and without delay. A strong case for more efficiency in your testing process.
 
2 EVIDENCE OF THE SMALLEST LEAKS –EVEN WITH LARGE-VOLUME COMPONENTS
The differential pressure test measures the pressure change in the test part caused by the leak and not the amount of outflowing gas. Drawback: a very small leak in a large-volume component produces hardy any change in pressure and thus is not detected.
Contrast this with the INFICON trace gas method: here the outflowing gas is measured directly. Even the smallest leaks in very large-volume components are detected.
 
3 REDUCE UNIT COSTS –WITH RECOVERY UNITS
The trace gas testing entails costs for trace gases that, however, you can offset by using a simple recovery unit. In addition, the INFICON measuring technology allows the most minute test gas concentrations, which saves up to 95% of the costs depending on the application.
Last but not least: the differential pressure test also creates costs - for keeping the air clean, drying and compressing the test air.
 
4 MORE SAFETY – DUE TO THE LOW TEST PRESSURE
Conventional test methods require high test pressures to generate a detectable leak rate despite their low measurement sensitivity. Drawback: faulty and incorrectly attached high pressure lines and defective test parts pose serious risks under high pressure.
The INFICON solution: leak detection devices with low-pressure testing options. This increases the operating safety and lowers your outlays for protective mechanisms and test gas filling.
 
5 ELIMINATE LEAKS – THROUGH EFFECTIVE LOCALIZATION
With the INFICON trace gas method you locate leaks quickly and precisely - also in connection with pressure-dependent testing or integrated into manual or automated leak testing according to the sniffer method. You can then eliminate the leak, check the success of the repair and return the component to the valueadded chain.
 
6 TESTING OF SENSITIVE OR FLEXIBLE COMPONENTS – WITH TRACE GAS ONLY
Each pressure-related change in the component’s volume follows a change in pressure. This makes the pressure drop testing of flexible or unstable components impossible.
For the purposes of this application, INFICON offers you accumulation leak detection products that detect even the smallest leaks at minimum fill pressures. A special bonus: The very simple testing methodology guarantees you low investment costs.
 

A New STAR On Its Way To The Market BAG402

INFICON is the leading manufacturer of Hot Ionization Vacuum Gauges and delivers this gauge
technology into several major and minor applications.
If we talk on Hot Ionization gauges, then some customers aren’t allowed to combine the Hot
Ionization gauge with any complementary technology (e.g. isolation valve). In these cases we
couldn’t offer that option.
Now, we will complete our Hot Ionization gauge offering with a dual filament Bayard-Alpert gauge
by SEMI West. Basically, we just took out the Pirani from the BPG402-S. It’s called BAG402 and it
comes in three different electronics and two flange versions.
 

Type

Setpoint

connector

interface

     
       
       
       
       
 
The BAG402 with DSUB9 is interface compatible (GP Signal output and pin compatible) to our
competition. It directly compete with the Granville-Phillips Micro-Ion Module 354/347, Edwards AIXS
and the Instrutech Hornet 401. With this gauge OEM-customers can switch to our BAG402
without tool-redesign and we also can attack existing enduser’ market of GP, Instrutech, and
Edwards. This version will be available in July 2014.e
 
The BAG402-S with DSUB15 focuses on the OEM-market for new tools. That means in order to
save the future’s replacement market, the offered gauge type must have a different connector than
the market competitors. This version is also as EtherCAT version available and it will be available
by the end of this year.
Additionally, the BAG402-S with DSUB15 addresses the replacement market of the BAG100 and
ITR100 and offers the mantissa and exponent output of the BAG100. This version will be available
by the end of this year.
If any customer is interested in our DSUB15 version of the BAG402-S earlier, then we offer the
BPG402-S for the same price until the BAG402-S becomes available.
INFICON is the leading manufacturer of Hot Ionization Vacuum Gauges and delivers this gauge
technology into several major and minor applications.
If we talk on Hot Ionization gauges, then some customers aren’t allowed to combine the Hot
Ionization gauge with any complementary technology (e.g. isolation valve). In these cases we
couldn’t offer that option.
Now, we will complete our Hot Ionization gauge offering with a dual filament Bayard-Alpert gauge
by SEMI West. Basically, we just took out the Pirani from the BPG402-S. It’s called BAG402 and it
comes in three different electronics and two flange versions.

 

Leak Testing of Engines

Today's engines are very sophisticated technical products which consist of many different components and their performance depends on a complex and interdependent operation of many different processes. therefore the manufacturing of such devices is complicated and challenging. many, if not all, vechicle manufacturers consider the engine as their core product. however, due to the complexity and variety of engine components, vehicle manufacturers produce ony certain key components ( cylinder head, camshaft, crankcase, crankshaft, connecting rod, the so-called five - C's) and buy most other components from outside suppliers. it is at the manufacturing facility that the whole engine is assembled and tested. among the many tests performed, the engines are tested for leakage. This is especially important as any leakage can damage and may eventually destroy the entire engine. This application report will provide a general overview of the testing requirements, typical testing procedures and test methods for engine manufacturing testing.  more details please contact our team

 

If you interested to know more about 'LEAK TESTING OF ENGINES',

please call us (+6221) 55960019 or send email to contact@sucira.com