Leak Testing Course

Lesson 1 • Leak Rate Units and Measurement

Introduces standard leak rate units, conversion factors, and detection thresholds. Enables students to interpret and compare specifications across industries.

Lesson 2 • Physical Principles of Leakage

Covers fluid dynamics, pressure differentials, and molecular flow regimes that govern leak behaviour. Provides the physics foundation required for method selection.

Lesson 3 • Overview of Leak Testing Methods

Surveys all major leak testing categories and their typical applications. Sets the roadmap for the methods covered in subsequent chapters.

Lesson 4 • Regulatory and Standards Framework

Outlines international standards bodies, industry-specific leak testing requirements, and documentation obligations. Connects technical practice to compliance expectations.

Lesson 1 • Pressure Decay Testing

Details the pressure decay method, instrumentation requirements, and data interpretation. Connects measurement precision to reliable pass/fail decisions.

Lesson 2 • Vacuum Decay Testing

Covers vacuum-based leak detection for sealed packages and components. Demonstrates how vacuum decay complements pressure decay for low-pressure applications.

Lesson 3 • Pressure Testing Fundamentals

Explains pressurisation principles, test media selection, and safety precautions. Establishes the baseline knowledge needed before operating pressure test equipment.

Lesson 4 • Flow-Based Leak Testing

Introduces mass flow and differential pressure flow methods for quantifying leak rates. Bridges qualitative detection to quantitative measurement.

Lesson 1 • Immersion Bubble Testing Procedure

Covers step-by-step immersion testing, tank setup, and observation techniques. Ensures consistent, repeatable results across different operators.

Lesson 2 • Liquid Tracer and Dye Methods

Introduces fluorescent dye and coloured liquid tracers for enhanced leak visualisation. Expands detection capability for fine leaks not visible by standard immersion.

Lesson 3 • Bubble Emission Testing Principles

Explains how pressurised gas escaping through a leak produces detectable bubbles. Establishes sensitivity limits and conditions that affect bubble visibility.

Lesson 1 • Accumulation Testing Method

Describes enclosing a part to accumulate tracer gas and measuring total leak rate. Demonstrates how accumulation improves sensitivity for very small leaks.

Lesson 2 • Detection Physics and Sensitivity

Explains how tracer gas detectors sense molecular concentration and convert it to a leak rate signal. Links detector physics to achievable sensitivity levels.

Lesson 3 • Sniffer Probe Testing Technique

Covers handheld sniffer probe operation, scanning patterns, and response time considerations. Provides practical skills for locating leaks on large or complex parts.

Lesson 4 • Safety Protocols for Tracer Gas Use

Addresses ventilation, gas storage, handling procedures, and emergency response for tracer gas operations. Ensures a safe working environment before hands-on practice.

Lesson 1 • Calibration and Verification

Establishes calibration procedures using certified reference leaks and verification intervals. Ensures measurement traceability and instrument reliability.

Lesson 2 • Vacuum Method Testing

Details the inside-out vacuum method where helium is sprayed externally on an evacuated part. Covers connection, pump-down, and systematic spray technique.

Lesson 3 • Mass Spectrometer Leak Detector Principles

Explains the magnetic sector mass spectrometer operating principle and vacuum system design. Provides the theoretical basis for understanding MSLD performance specifications.

Lesson 4 • Pressure Method Testing

Covers the outside-in pressure method using a sniffer probe connected to the MSLD. Extends MSLD capability to parts that cannot be evacuated.

Lesson 1 • Scanning Techniques and Procedures

Covers systematic scanning patterns, probe positioning, and distance effects for leak location. Develops consistent field technique for reliable detection.

Lesson 2 • Signal Interpretation and Reporting

Teaches signal amplitude analysis, false-call reduction, and structured reporting formats. Translates raw acoustic data into actionable maintenance decisions.

Lesson 3 • Ultrasonic Detector Equipment

Surveys contact and airborne ultrasonic detectors, transducer types, and signal processing features. Guides equipment selection for different test environments.

Lesson 4 • Acoustic Emission Principles

Explains how turbulent flow through a leak generates ultrasonic acoustic emission. Connects signal frequency and amplitude to leak size and pressure differential.

Lesson 1 • System Validation and Qualification

Defines installation qualification, operational qualification, and performance qualification protocols. Ensures the system meets specifications before production use.

Lesson 2 • System Architecture and Components

Maps the functional blocks of an automated leak test system from part interface to data output. Provides a design framework for subsequent specification decisions.

Lesson 3 • Instrumentation Selection and Specification

Guides selection of transducers, flow meters, and detectors based on required sensitivity and cycle time. Links instrument specifications to test requirement compliance.

Lesson 4 • Statistical Process Control Integration

Introduces SPC charting, control limits, and trend monitoring for leak test data. Connects test results to continuous process improvement.

Lesson 1 • Root Cause Analysis of Leak Failures

Applies failure analysis tools to identify manufacturing, design, and material causes of leaks. Closes the loop between detection and corrective action.

Lesson 2 • Leak Testing in Extreme Environments

Covers cryogenic, high-temperature, and high-pressure leak testing challenges and adaptations. Prepares students for demanding industrial and aerospace applications.

Lesson 3 • Continuous Improvement of Leak Test Programs

Uses data-driven methods to reduce false rejects, improve sensitivity, and lower test costs. Positions students to lead ongoing program optimisation.

Lesson 4 • Complex Geometry and Multi-Port Testing

Addresses leak testing of assemblies with multiple cavities, ports, and internal passages. Develops problem-solving skills for non-standard test configurations.