The overview combines values from 3 independent manufacturer compendia and one technical publication[1], [2], [4], [19]. Some values differ by one decade. This scatter is a result in itself. If a source gives a theoretical limit and a limit achieved in practice, the figure shows both values.
The figure shows 3 ranges in which the sources agree. These values are suitable for a customer specification:
- Pressure decay with air: theoretically approximately 10⁻⁴ mbar·l/s, realistic in industry 10⁻³ to 10⁻² mbar·l/s[4].
- Helium sniffer test: 10⁻⁷ to 10⁻⁶ mbar·l/s.
- Helium integral test in the vacuum chamber: approximately 10⁻¹² mbar·l/s, the same in all 3 compendia[1], [2], [4].
Properties of the methods
Pressure decay. The method needs little effort, is fast and has a low cost. It reacts strongly to temperature changes, up to the point where it is not usable (see section 04). Other documented limits: water condensation causes incorrect measurements. In vacuum technology, the method has almost no importance[1].
Pressure rise in vacuum. The manufacturer states that the method prevents the temperature effects[4]. But outgassing of the wall has an effect. One criterion separates the 2 effects and must be part of each test specification. If the time for a specified pressure rise stays constant, there is a leak. If the time increases, the cause was outgassing[1].
Bubble test. The method is visual and standards cover it, but it has 2 disadvantages. The wet test part must dry after the test[4]. In cycle-based production, this costs time. With foam spray, the result depends on the attention of the inspector[4]. Thus foam spray is not a capable process.
Acoustic emission. ISO 18081 gives a fundamental physical limit: turbulent flow causes detectable emissions, laminar flow usually does not[15]. Gas leaks give stronger signals than liquid leaks. In two-phase flow, cavitation causes signal peaks. These peaks are at least one order of magnitude above the turbulence signals[15].
Forming gas instead of helium. A mixture of 95 % nitrogen and 5 % hydrogen detects leaks of 5 · 10⁻⁷ mbar·l/s. The tracer gas is the hydrogen in the mixture. Hydrogen has 3 advantages over helium[19]:
- The atmospheric background of hydrogen is 0.5 ppm, of helium 5 ppm. This gives a 10 times better basis for the signal-to-noise ratio.
- The dynamic viscosity of hydrogen is 8.7 µPa·s, of helium 19.4 µPa·s. Thus, in laminar flow, pure hydrogen flows through a leak more easily. This advantage applies only to pure hydrogen. Forming gas with 95 % nitrogen flows approximately like nitrogen.
- The gas does not adhere to surfaces, and a purge removes it significantly faster. This decreases carry-over and purge times.
To ISO 10156, the mixture is not flammable. Its cost is a fraction of the cost of helium[19].
Dye penetrant test. Systematically, this method is not part of this overview. ISO 3452-1 describes a test method for surface cracks[20]. The method gives no quantitative leak rate. It finds the location of a leak, but it does not measure the leak rate.