Leak testing technology, as a key method for ensuring product sealing performance, has long surpassed its traditional applications in industries such as automotive, new energy, and consumer electronics, and is continuously extending into more specialized fields. With its high-precision detection capability, flexible customization options, and modular design philosophy, the AMT air tightness tester provides reliable leak testing solutions for a variety of special application scenarios.

I. Rail Transportation

In the manufacturing of rail transit vehicles, the main air supply pipeline system is the power lifeline for core systems such as braking and pneumatic control. Any tiny leak or potential defect may evolve into a serious safety hazard during subsequent high-intensity operation.

Testing challenges: Traditional testing relies on manually applying soapy water and observing bubbles, which suffers from low efficiency, blind spots, significant human factors, and inability to quantify results.

AMT solution: Drawing on advanced acoustic imaging detection concepts, AMT offers a non-contact, visual intelligent gas leak detection solution. Using microphone array beamforming technology, it precisely captures ultrasonic signals generated by gas leaks, making leak points "visible, audible, and accurately locatable."

Application scenarios:

• Air tightness testing of train main air supply pipelines

• Sealing verification of brake system pipes and valves

• Leak detection of air conditioning system pipes

• Sealing testing of door pneumatic systems

II. Petrochemical & Energy Sector

The petrochemical industry involves a large number of flammable and explosive media, so leak testing directly affects production safety and environmental protection.

1. Tank truck safety inspection
The hand-held gas leak detector innovatively developed by Jingzhou Oil Depot of Hubei Petroleum uses a telescopic aluminum rod as the main body, equipped with a PID combustible gas detector, a suction copper tube at the top, a wireless high-definition explosion-proof endoscope camera, and explosion-proof lighting. It displays real-time images and combustible gas detection data.

Results: Testing time is reduced from at least 30 minutes to 7–8 minutes, eliminating the risk of working at heights and solving the problem of missed detection of concealed parts such as the bottom emergency valve of tank trucks.

2. Process pipelines and pressure vessels
In the manufacturing of offshore oil and gas equipment, high-pressure leak testing is a critical step to ensure the quality of pressure-bearing equipment such as process pipelines and pressure vessels after installation, focusing on welds, flange interfaces, and other connection points.

AMT solution: Provides high-pressure testing modes, with pressure sensor ranges covering -1 bar to 20 bar, and customizable for higher pressure requirements. For key parts such as flange interfaces, a multi-channel synchronous testing system can be configured to achieve comprehensive testing of complex pipelines.

III. Special Environments & Extreme Conditions

With the development of Industry 4.0, leak testing equipment faces increasingly complex environmental challenges.

1. High/low temperature environment testing
Some applications require leak testing under extreme temperatures:

• High-temperature conditions: engine components, heat exchangers (above 80°C)

• Low-temperature conditions: refrigeration equipment, LNG storage/transport (below -20°C)

• High-humidity environments: outdoor equipment, marine equipment (above 90% RH)

Technical goal: Through material and structural innovation, ensure stable operation of test tooling in environments from -40°C to 120°C and high humidity, with temperature/humidity fluctuation effects reduced to within ±2%.

2. High pressure / vacuum environment

• High-pressure testing: Some manufacturers already support high-pressure helium testing up to 75 MPa, reaching a global leading level. AMT can customize high-pressure testing solutions to meet special field requirements such as nuclear power and deep-sea equipment.

• Vacuum testing: Negative pressure testing mode is suitable for indirect testing of products without an inflation port and is widely used in vacuum packaging, spacecraft components, and more.

IV. Aerospace Special Components

In aerospace product manufacturing, the bonding of exhaust flanges and diaphragms and their leak testing are critical process steps. Exhaust flanges come in many specifications with small batch sizes, and traditional manual testing is inefficient.

1. Automatic flange leak testing
Innovative solution: A modular design approach splits the testing device into a control/detection module and a positioning/sealing module:

• Control/detection module: The fixed part of the equipment, automatically performs flange leak pressure-holding tests with positioning tooling.

• Positioning/sealing module: The variable part, quickly adapts to multiple product specifications by changing the flange mounting plate.

Results: The reuse rate of the device increased by 200%, and testing efficiency improved approximately 17 times compared to traditional manual methods.

2. Spacecraft cabin segment testing
Key components such as spacecraft cabin mating surfaces and life support systems have extremely high sealing requirements. AMT provides high-precision testing solutions with leak rates reaching 10⁻⁶ mbar·L/s, ensuring reliability of aerospace products in extreme environments.

V. Other Emerging Application Fields

1. Nuclear power
Critical components such as fuel rods, control rod drive mechanisms, and cooling systems in nuclear power plants have extremely high sealing requirements. Leak testing equipment has broad application prospects in the nuclear power field, ensuring safe operation of nuclear facilities.

2. Deep-sea equipment
Underwater robots, deep-sea detectors, diving equipment, etc., have strict waterproof sealing requirements. High-pressure testing mode can simulate deep-water environmental pressure to verify equipment sealing performance.

3. Special equipment testing
For general industrial scenarios such as steel drums, refrigeration equipment, and special containers, AMT air tightness testers provide customized testing solutions, offering domestic alternatives.

VI. 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 air power system and embedded computer technology. Differential pressure sensor resolution reaches 0.01 Pa. High-performance dedicated CPU, ARM CORTEX-A8 core, frequency 800 MHz, dual CPU configuration, with 4000V electrostatic discharge protection.

2. Multiple test methods
Supports positive pressure testing, negative pressure testing, pressure decay testing, differential pressure testing, flow testing, and other methods. Users can flexibly choose according to different product requirements.

3. Modular and flexible design
Drawing on modular design concepts from aerospace assembly manufacturing, the control/detection module is separated from the positioning/sealing module. By changing tooling, the device quickly adapts to multiple product specifications, effectively solving the problems of low equipment reuse rate and high customization costs in multi-specification, small-batch production.

4. Intelligent data management

• Storage for 100 test programs, multi-level password protection

• Storage for up to 1 million test results, USB automatic export to Excel format

• Real-time SPC quality analysis: total tests, pass rate, average of qualified products, and other statistical analysis

• Real-time test curve display, real-time monitoring of pressure and time status at each stage

5. Flexible custom tooling
For special-shaped products, special interfaces, high temperature, high pressure, and other special conditions, custom fixtures and testing solutions are available. For products without an inflation port, custom profile tooling can be designed for indirect testing.

VII. Conclusion

As a fundamental support for high-end manufacturing, the application boundaries of leak testing technology are continuously expanding. From rail transportation to petrochemicals, from aerospace to deep-sea equipment, from nuclear power facilities to special equipment, the AMT air tightness tester, with its professional spirit of "leading technology and continuous improvement," provides reliable, accurate, and efficient leak testing solutions for various special fields, helping customers realize the vision of "making manufacturing smarter."

Whether it is batch testing of standard products or non-standard customization for special conditions, AMT offers professional solutions. If you have leak testing needs in special fields, please contact our engineers for customized solutions.

For leak testing requirements in rail transportation, petrochemicals, aerospace, or other special fields, please contact our engineers to obtain a customized solution.