Leak Testing for Hardware Die-Casting Parts

Prevent air and liquid leaks: For products such as valve bodies, pump bodies, oil circuit components, water circuit components, liquid cooling plates, and sensor housings, even minor leaks can lead to functional failure.

Verify laser welding quality: Laser welding may result in defects that are difficult to detect visually, such as pores, cracks, and incomplete penetration.

Identify defective products early: Detect leaking parts before shipment to avoid rework, complaints, or recalls after products reach the customer.

Enable data traceability: Air leak testers can record test pressure, pressure drop or leak rate, test time, and pass/fail results, facilitating quality management and problem analysis.

Deliver on product promises: Airtightness testing is the key method to verify whether the enclosure truly meets its protection rating.

Protect internal precision components: Even tiny leakage points can become channels for water vapor, dust, salt spray, and other contaminants to enter.

Ensure stable communication performance: Corrosion or damage to internal components may eventually lead to signal attenuation, connection interruptions, and other issues.

Reduce after-sales costs: Airtightness testing before shipment helps identify and remove defective products.

Complies with environmental standards: Excessive refrigerant leakage violates the Kigali Amendment and local environmental regulations, resulting in heavy fines.

Ensures cooling performance: Every 10% refrigerant loss reduces cooling efficiency by 15%–20%, leading to poor cooling performance.

Prevents air and moisture ingress: Moisture can freeze at the expansion valve, causing blockages and frequent system shutdowns.

Maintains stable system pressure: Even tiny gaps or micro-leaks can cause high-pressure side leakage, reducing discharge pressure and condensation performance.

Process-related defects: During high-temperature and high-speed filling, internal defects such as porosity, shrinkage cavities, and micro-cracks may occur.

High sealing requirements: As molds in real applications, these parts often operate under pressure media and alternating vacuum/positive pressure environments.

Ensures service life: Sealing issues may not appear immediately but worsen over time, eventually causing mold failure or production downtime.

Ensures forming accuracy: Leakage affects pressure distribution in the mold cavity, leading to product defects.

Key structural component: Critical metal structure at the stern, made of aluminum or magnesium alloy die casting.

Multiple functions: Protects propellers, rudders, and shafts, providing flow guidance, corrosion resistance, and vibration reduction.

High sealing requirement: Long-term underwater operation requires excellent airtightness; leakage may cause water ingress and failure.

Impact on vessel safety: Leakage can lead to water entering motors, transmission systems, and bearings, posing safety risks.

1. Test area: Sealing performance of the entire cavity of the die casting part.

2. Function: Prevent engine abnormalities caused by poor sealing, reduce complaints and rework, and improve customer satisfaction.

3. High sealing requirement: High-pressure working environment requires excellent airtightness; even slight leakage reduces performance.

4. Safety impact: Leakage may cause oil/gas leakage in the engine compartment, reduced performance, increased fuel consumption, and potential safety hazards.

1. Test area: Sealing performance of the entire die casting part.

2. Function: Prevent reduced waterproof performance of LED lights caused by poor sealing, avoiding moisture ingress.

3. High sealing requirement: Outdoor environments require proper sealing to prevent water ingress, oxidation, and corrosion.

4. Safety impact: Water ingress may cause circuit dampness, leading to leakage, short circuits, or even fire hazards.