Porous Parts? No Problem!

Proven Leak Testing for Die Cast Components

Leak Testing for Die Cast Housings, Components and Assemblies 

Leak testing can be performed on pre-assembled die cast components to identify abnormal porosity before additional value is added prior to and after machining. By implementing the test early in the process, manufacturers can reduce the cost impact of defects.

CTS provides simple, cost-effective solutions using pressure decay and mass flow testing techniques to provide repeatable, measurable results. We have helped many manufacturers of die cast parts to reduce their costs, scrap rates and improve quality.

Improve quality assurance and deliver leak-proof aluminum die cast housings

Getting the right leak test can improve your confidence in the quality of die cast parts and assemblies. The porosity of die cast parts can add to the difficulty of setting up a robust leak test process. In addition, many of these components go through washing and drying systems, creating moisture and temperature changes.

CTS helps manufacturers of die cast components address these factors while providing additional benefits:

  • Improved leak test repeatability that decreases the possibility of false accepts and false rejects
  • Reduced test cycle times to fix bottlenecks in machining and assembly
  • Reduced scrap rate of die cast components for better cost management and process efficiency
  • Leak test data to objectively identify which higher leak rate parts can be sent out for impregnation to reduce porosity

Leak Testing Die Castings in Automotive: From ICE to EV

As the automotive industry shifts from internal combustion engines (ICE) to electrically driven systems, Cincinnati Test Systems is using our in-depth experience to help casting and machining companies address the industry-wide changeover to non-water ingress leak testing.

In ICE applications, the castings are designed and tested to hold lubricant and cooling liquids inside the assemblies. Many of the new applications are now requiring isolating water from leaking into them. The challenges that this brings is in relation to leak path and pressure differential changes. In most cases the test methodology remains the same; however, the pressure differential across the part is reversed with acceptable leak rates becoming tighter.

Contact the specialists at CTS to discuss your application and the most effective methods for addressing these new and unique applications.

Cost effective leak test solutions for die casting in manufacturing

With the industry’s largest portfolio of leak test instruments, CTS can recommend the right system for your requirements and budget. Leak testing of die cast components typically utilizes one of three test methods. Contact us to discuss which would work best for you.

Pressure Decay using absolute pressure measurement

This is the most widely used technology to conduct repeatable leak testing on die cast components. It is highly accurate with the implementation of a two-point calibration (zero leak and known reject rate).

Mass Flow Testing

Mass Flow testing enables testing without the need for a calibration sequence, which allows flexibility for testing parts with varying degrees of porosity and multiple part sizes.

Differential Pressure Decay

Provides the same degree of repeatability as Pressure Decay with the added benefit that this leak testing technique offers increased resolution for even greater test accuracy and reduced cycle times.

Turnkey leak test solutions for die cast manufacturers

CTS can simplify the integration of an improved leak test on the production line by providing a turnkey solution, which leverages the capabilities of our leak test instruments and our extensive experience.