The aerospace and defense industry has extremely stringent requirements for product sealing performance—any tiny leak could affect mission success or even endanger lives. With its high-precision detection capability, automation control technology, and non-standard customization strength, the AMT air tightness tester provides reliable leak testing solutions for the aerospace and defense sector.
I. Aerospace Field
Aerospace products involve multiple critical systems such as fuel, environmental control, oxygen, and hydraulics. Air tightness directly affects flight safety and mission reliability.
1. Comprehensive Testing of Aircraft Air Tightness Systems
Modern aircraft contain several systems that require strict sealing. Traditional methods use a separate set of testing equipment for each system, resulting in many models with single functions. AMT offers an integrated air tightness testing solution that can simultaneously cover:
| Test System | Testing Requirements | AMT Solution |
|---|
| Fuel System | Test pressure 0.030–0.032 MPa | Multi-channel synchronous testing, simultaneous testing of multiple systems |
| Environmental Control System | Engine bleed air duct: 0.38–0.392 MPa, leakage 165–170 L/min | Flow testing mode, real-time leak rate monitoring |
| Cabin Air Tightness System | Test pressure 0.030–0.032 MPa | Positive pressure decay method, high-precision differential pressure sensor |
| Oxygen System | High-pressure test 13–15 MPa | High-pressure testing mode, up to 25 MPa or more |
| Hydraulic System | High-pressure line sealing | Automatic switching of multiple ranges, covering different pressure requirements |
Application of an integrated air tightness testing device for a certain aircraft type shows that integrated design significantly reduces maintenance preparation time and improves aircraft maintenance support efficiency.
2. Testing of Engine and Pipeline Components
| Test Object | Testing Requirements | AMT Solution |
|---|
| Exhaust flanges and diaphragms | Critical process in aerospace products; low efficiency of manual testing | Automated testing device; reuse rate increased by 200%, testing efficiency improved approximately 17 times |
| Engine oxygen supply system | High-pressure air tightness testing | Custom sealing fixtures adaptable to various interfaces |
| Turbine outlet duct | 0.09–0.098 MPa, leakage 25–30 L/min | Small-volume high-precision testing, identifies micro-leaks |
To meet the special needs of aerospace assembly and manufacturing, AMT provides flexible, modular testing equipment, effectively solving the problems of low equipment reuse rate and high customization costs in multi-specification, small-batch production.
3. Integral Fuel Tank and Cockpit Sealing
Integral fuel tanks are important components of aircraft structures, and their sealing directly affects flight safety. AMT solutions include:
Integral fuel tank testing: Uses helium mass spectrometer leak detection equipment for micro-level leak identification
Cockpit sealing test: Simulates in-flight pressure differential to verify cabin pressure retention capability
Wing fuel tank: Large-volume testing mode adapted to wing box structure characteristics
Requirements for aircraft air tightness integrated test systems indicate that integral fuel tank testing requires automatic gas distribution equipment, helium mass spectrometer leak detectors, etc., with test pressures up to 25 MPa or more.
II. Defense Field
Defense products cover missiles, rockets, ammunition, military electronics, and other categories, with extremely strict sealing performance requirements.
1. Solid Rocket Motors
Air tightness testing of solid rocket motors is an important method for judging motor sealing performance.
| Test Object | Testing Requirements | AMT Solution |
|---|
| Motor casing | High-pressure sealing test | Multi-channel automated test system, single or multi-channel optional |
| Nozzle assembly | High-temperature gas path sealing | Custom fixtures adaptable to irregular shapes |
| Ignition device | Micro-leak identification | High-precision differential pressure sensor, resolution 0.01 Pa |
Compared with traditional single-motor testing using manually adjusted pneumatic test benches, the multi-channel automated test process enables engineering application of automated air tightness testing technology, greatly improving solid rocket motor assembly efficiency and air tightness test quality.
2. Air-to-Ground Guided Munitions
The sealing of missile fuel tanks directly affects combat effectiveness and safety. AMT offers a dual-channel testing solution:
Two-channel synchronous testing: Two test channels connect to the engine compartment and fuel tank respectively, completing multi-location testing with one clamping
Single-channel testing mode: One channel connects to the fuel tank under test, the other connects to a constant pressure chamber or ambient atmosphere for high-precision differential comparison
Portable benchtop design: Facilitates on-site deployment and transport, adaptable to different operational scenarios
3. Military Electronics and Special Equipment
| Test Object | Testing Requirements | AMT Solution |
|---|
| Military communication equipment | Environmental protection (waterproof, dustproof, moisture-proof) | IP rating testing, positive/negative pressure dual modes |
| Sights / aiming devices | Optical component sealing | Localized pressurization testing to avoid leakage through transparent areas |
| Underwater alarm | Deep water environment sealing | High-pressure testing mode simulating underwater pressure |
| Ammunition packaging | Moisture-proof for long-term storage | Micro-leak identification ensuring storage life |
4. Astronaut Life Support Systems
Air tightness testing technology has extended to the field of astronaut life support. Products from domestic leak testing companies have been applied in spacesuit and related product testing, "flying into space."
| Application | Testing Requirements | AMT Solution |
|---|
| Spacesuit | Absolute sealing to ensure astronaut safety | Ultra-high precision testing, leak rate down to 10⁻⁶ mbar·L/s |
| Spacecraft cabin sections | Mating surface sealing | Large-volume testing mode adapted to cabin structure |
| Extravehicular equipment | Space environment adaptability | Sealing verification under alternating high/low temperatures |
III. Testing Methods and Selection Guide
The aerospace and defense field has diverse testing requirements. AMT offers multiple testing methods:
| Testing Method | Applicable Scenarios | Accuracy Level | AMT Recommended Configuration |
|---|
| Direct pressure method | Large-volume products (integral fuel tanks, cabin sections) | 10–100 Pa | AMT series standard direct pressure mode, max pressure up to 25 MPa |
| Differential pressure method | Small to medium precision components (valve bodies, sensors) | 0.01 Pa resolution | AMT series high-precision differential pressure sensor, eliminates environmental interference |
| Flow method | Quantitative leak rate analysis (pipeline systems) | ml/min level | AMT series flow sensor (5–5000 ml/min optional) |
| Helium mass spectrometry | Ultra-high precision micro-leak detection | 10⁻⁶ mbar·L/s | Custom helium leak detection system adapted to defense requirements |
| Multi-channel testing | Simultaneous or staggered testing of multiple products | System reliability | PLC control, automatic parameter acquisition |
IV. Core Advantages of the AMT Air Tightness Tester
1. High Precision and High Stability
The AMT series uses high-quality sensors and valve groups, equipped with a high-performance pneumatic system and embedded computer technology. Differential pressure sensor resolution reaches 0.01 Pa, meeting aerospace micro-leak detection requirements. The control/detection module uses a PLC as the system control core, enabling automatic solenoid valve control and real-time pressure signal acquisition.
2. Automation and Intelligence
Fully automatic control: Automates the entire process of pressurization, holding, testing, and venting
Real-time parameter acquisition: Real-time monitoring of pressure, flow, leak rate, and other data
SPC quality analysis: Statistical analysis of total tests, pass rate, average of qualified products, and more
3. Modularity and Flexibility
To address the multi-specification, small-batch characteristics of aerospace products, AMT adopts a modular design approach:
Control/detection module: The fixed part of the equipment, automatically performs air tightness pressure-holding tests
Positioning/sealing module: The variable part, quickly adapts to different product specifications by changing tooling
Rapid reconfiguration: Supports quick changeover of multiple flange and interface specifications
4. Flexible System Integration
Rich I/O interfaces for easy connection to PLCs and other external control devices
Multiple communication methods: RS232, Ethernet, optional Profinet/Profibus
Can connect to MES systems for real-time traceability of test data
Supports single-channel/multi-channel test mode switching
V. Advantages of AMT Solutions
1. Full Process Coverage
From component-level testing to complete machine air tightness re-inspection, from R&D validation to production line inspection, AMT provides air tightness testing equipment for the entire lifecycle of aerospace and defense products.
2. Non-Standard Customization Capability
For special conditions such as irregularly shaped products, high-pressure testing, multi-station requirements, and automated line integration, custom fixtures and testing solutions are available. AMT has successfully applied these to air tightness testing of defense products including exhaust flanges, solid rocket motors, and air-to-ground guided munitions.
3. Rapid Local Service
Adhering to the service philosophy of "rapid response, mission accomplished," AMT provides 7×24 hour technical support to customers.
VI. Conclusion
In the aerospace and defense field, air tightness testing has evolved from a traditional "quality control" step into a core pillar of "safety assurance + mission success." Whether it is aircraft fuel, environmental control, and oxygen systems, or missile and rocket motors, or astronaut life support equipment, the AMT air tightness tester, with its professional spirit of "leading technology and continuous improvement," provides reliable, accurate, and efficient air tightness testing solutions for the defense technology industry, helping realize the vision of "making manufacturing smarter."
If you have air tightness testing needs for aerospace or defense products, please contact our engineers for a customized solution.
