As the automotive industry evolves toward electrification, intelligence, and lightweight design, the sealing performance requirements for components are becoming increasingly stringent. As a key testing device ensuring product quality and safety, the air tightness tester plays an irreplaceable role throughout the entire automotive manufacturing process. AMT Leak Testing Technology (Chongqing) Co., Ltd. has deep expertise in the field of air tightness testing and provides customized leak testing solutions for the automotive industry.

I. Powertrain System

The powertrain of conventional fuel vehicles and hybrid vehicles contains many components that require rigorous sealing.

AMT Solution: For complex engine cavity structures, AMT adopts modular fixture design combined with switchable differential and direct pressure modes. A single device can cover multiple models on a mixed production line.

II. New Energy Three‑Electronics Systems (Core Growth Area)

New energy vehicles have much stricter sealing requirements than conventional vehicles. Battery safety, in particular, directly affects the safety of drivers and passengers. Currently, over 70% of leak tester orders come from the new energy industry chain.

1. Traction Batteries

The sealing of battery packs and cells is critical for safety and requires multiple tests during manufacturing.

IP67/IP68 protection verification: Battery packs must meet the requirement of no water ingress after 30‑minute immersion at 1 meter depth. AMT provides an ambient pressure accumulation test solution with a pressure difference of only about 3 kPa between the inside and outside of the pack to avoid housing damage, while maintaining a fast test cycle to meet production line requirements.

2. Electric Motors and Electronic Controls

• Motor housing: Water channel sealing test to ensure no leakage in the cooling system

• Motor controller: Verification of electronic component protection rating

• High‑voltage connectors: Sealing test for charging sockets and high‑voltage wiring harnesses

3. Final Assembly Re‑test

To address the challenge of limited space when re‑testing the battery pack after vehicle assembly, compact quick‑connect fittings can be used to rapidly inflate through the explosion‑proof valve, allowing a single operator to complete the test.

III. Thermal Management System

The complexity of thermal management in new energy vehicles has increased, driving a surge in leak testing demand.

• Air conditioning lines: Refrigerant leak detection using helium or hydrogen‑nitrogen mixed gas (cost only 1/20 of helium testing)

• Cooling plates / radiators: Water circuit sealing test for battery cooling plates and motor radiators

• Electronic expansion valves: High‑precision small‑volume testing requiring micro‑leak identification

• Water pumps / water valves: Dynamic sealing performance verification

IV. Body and Chassis Components

• Headlamps: Anti‑fog and waterproof testing to ensure no fogging in adverse weather

• Fuel tanks: Fuel evaporation leak control to meet China‑6 emission standards

• Shock absorbers: Gas damping seal test

• Braking system: Sealing of brake lines and vacuum booster

• Transmission housing: Leak detection at oil seals and mating surfaces

V. Automotive Electronics and Sensors

As the electronic content of vehicles increases, the waterproof and dustproof requirements for ECUs, sensors and other components have reached the IP6K9K level.

• Electronic control unit (ECU): Core components such as transmission control units require high‑pressure testing (up to 1.7 MPa), sometimes combined with water immersion testing to increase sensitivity for micro‑leak detection

• Pressure sensors: Sealing test of the pressure sensing cavity

• Cameras / radar: Waterproof testing for ADAS sensors

VI. Comparison of Testing Methods and Selection Recommendations

VII. Advantages of AMT Solutions

1. Full Process Coverage
From component‑level testing to complete pack re‑test, AMT provides equipment covering the entire process from R&D validation to production line inspection.

2. Intelligent Data Management
The equipment supports storage of over 1 million test data records and can connect to MES systems for real‑time monitoring and traceability of test data.

3. Non‑Standard Customization Capability
For special conditions such as irregular workpieces, confined spaces, and high‑pressure testing, custom fixtures and testing solutions are available.

4. Rapid Local Service
Adhering to the service philosophy of "rapid response, mission accomplished," AMT provides 7×24 hour technical support to customers.

VIII. Conclusion

Leak testing has evolved from a traditional "quality control" step into a core pillar of "safety assurance + efficiency improvement." Whether for conventional automotive components or the three‑electronics systems of new energy vehicles, AMT Leak Testing Technology (Chongqing) Co., Ltd., with its professional spirit of "leading technology and continuous improvement," provides reliable, accurate, and efficient leak testing solutions for the automotive industry, helping customers realize the vision of "making manufacturing smarter."

If you have leak testing needs for automotive components or new energy batteries, please contact our engineers for a customized solution.