Developing a Leak Test - Housing part for an automotive customer

M

mboteo

#1
Developing a Leak Test

We are molding a housing part for an automotive customer. The housing gets filled with 300degrF Epoxy at the customer, and should, of course, not leak thru the housing.

We inherited a leak tester from the previous molder, but no information on what settings we need to use to test the part on leaks (the tester was set to 3seconds at 5 psi, but we found many rejecxts that shouldn't be rejects.

Does anyone have any advise on where I can find information of how to determine the leak tester settings (in seconds at a certain PSI or kPa). The tester is only using air pressure. How can we re-create the condition of hot epoxy by using airpressure.

Also looking if I can add an additional confirmation test. By filling the part with some other liquuid. Any ideas where I can find table that translate certain epoxy viscosities into oil types.

Any help, please!

S.
 
Elsmar Forum Sponsor

CarolX

Super Moderator
Super Moderator
#2
leak testing

Does the equipment bear the name of the manufacture? Contact them and see what product literature is available. Perhaps they have a technical rep that could give you some guidance.

You might want to try a search on Google. I have pretty good results with this search engine.

Ragrds,
CarolX
 
J

Jim Biz

#3
I agree Carol ---

mboeto - I might add - would the customer have any information on what their "expected" specifications are for this leak test??
 
E

energy

#4
Re: Developing a Leak Test

Originally posted by mboteo

We inherited a leak tester from the previous molder, but no information on what settings we need to use to test the part on leaks (the tester was set to 3 seconds at 5 psi, but we found many rejects that shouldn't be rejects.
S.
How did you determine that they weren't leakers? Visual, magnification? Did the machine indicate leaking? Is the part capable of being static leak tested? :smokin:
 
H

HFowler

#5
Energy,

You might consider a hydrostatic test for leak determination. This involves pressurizing the cavity with water instead of air. It's a lot safer and more forgiving than air which sounds like what you're looking for. I've used both, and you're right about air rejecting potentially good parts.

Hope this helps.
Hank Fowler
 
U

Unregistered

#6
The customer's only requirement in this case is that the housing won't have voids that can cause leaking. The houses are filled with epoxy and cured at 140degrC (don't know yet what type of epoxy yet). The leak testing is part of a test dial (5 other test in following station are done on the parts).

I guess the leak test was the previous molder's choice of test to ensure 100% testing on the parts as part of their process controls (read detection method) in their PFMEA.

So pressures and times have never been set by the customer; we just try to get a comparable test towards what the conditions are at the customer.

We found that rubber pad that seals of the part during the test is prone to wear, and might cause false leakers. Also found when decreasing the pressure and time, leakers might pass (applying a more severe Water leak test on one part).

The goal is to find out how I should translate the customers conditions into the pressure and time variables of my test station. The supplier of the test station has only been able to supply me the specifics of how to set, maintain and calibrate the test station.

I might want to dig into my old schoolbooks of "Fluidomechanica" to calculate the correct formulas, etc. But maybe somebody has some lists of websites to refer to me to make things easier.

Thanks anyway,
S.
 
B

Bob Stevens

#8
We perform a Pressurized Air test on a Vacuum Motor used on 4-wheel drive vehicles. The test machine was designed and develop by by J. C. Boudreau of Colony Hill Electronics and measures leaks in Pascals. If interested, you can contact J. C. at (800) 421-8903 and he may be able to help you resolve some of your problems.

Bob
 
Thread starter Similar threads Forum Replies Date
Q Storing and developing SAMD (Software as a Medical Device) in the Cloud IEC 62304 - Medical Device Software Life Cycle Processes 2
T Ideas for developing a Supplier Quality Management System, non automotive ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
J Quality Assurance in China - Developing a quality management system for a California company Misc. Quality Assurance and Business Systems Related Topics 7
D Co-developing a new medical device ISO 13485:2016 - Medical Device Quality Management Systems 2
S Root cause analysis - The system of developing a work instruction is not effective Problem Solving, Root Cause Fault and Failure Analysis 1
L Problems while documenting the SOUPs used for the software we are developing IEC 62304 - Medical Device Software Life Cycle Processes 4
A Developing a ISO 9001:2015 Internal Audit Plan and Schedule ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 40
D Developing an Umbrella Management System Quality Management System (QMS) Manuals 2
R Developing procedure for Determining Company's Context And Interested Parties ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 53
Richard Regalado Sample Plan for Developing an ISO 22301 Business Continuity Management System (BCMS) Business Continuity & Resiliency Planning (BCRP) 3
D Developing a Supplier Risk Matrix Supplier Quality Assurance and other Supplier Issues 4
M Developing a new Plating Vendor - What software to track certifications Software Quality Assurance 2
T Need help developing an ECO (Engineering Change order) procedure Document Control Systems, Procedures, Forms and Templates 3
T Developing an AS9100 Internal Auditor Training Program AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
AnaMariaVR2 Developing Innovative Ideas for New Companies: free course Training - Internal, External, Online and Distance Learning 0
F Developing a Robust MSA Program - over 35,000 gages in 1 million square ft. facility Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 6
T Developing Reward Programs for Employees Quality Manager and Management Related Issues 4
H Identifying Potential Automotive Suppliers before Developing New Products Supplier Quality Assurance and other Supplier Issues 2
S Developing Documentation and Defining Processes as Subcontractor IATF 16949 - Automotive Quality Systems Standard 6
A Developing Technology and Equipment to Manufacture Clients Product - Can exclude 7.3? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
B Developing a Segment-Based Customer Service Benchmarking 6
B Developing a Queue Management Procedure - Need some help writing a Proposal Quality Manager and Management Related Issues 2
Sidney Vianna ISO 9001 - Its Relevance and Impact in Asian Developing Economies ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 0
R Developing a c = 0 Sampling Plan Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
AnaMariaVR2 Preparing for the RAC Examination -- Developing an RAC Study Plan Professional Certifications and Degrees 1
P Developing a Counterfeit Parts Prevention Program AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 8
L Developing a QMS Manual for AS9100 and ISO 9001 AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 20
Q Developing a Sampling Plan for a New Product Inspection, Prints (Drawings), Testing, Sampling and Related Topics 14
L Developing an Access ECO Tracking Database - Need help Document Control Systems, Procedures, Forms and Templates 8
P Developing Performance Standards - ISO 14630:2008? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
P Developing a SOW for Entire Site Calibration Requirements General Measurement Device and Calibration Topics 3
J Developing Plans for Corrective Actions for Audit Non-Conformities ISO 13485:2016 - Medical Device Quality Management Systems 5
M Developing a Career Plan Career and Occupation Discussions 5
A Policy for Suppliers - Developing a Supplier Policy Document ISO 13485:2016 - Medical Device Quality Management Systems 3
M Developing your own personal "Body of Knowledge" document. Professional Certifications and Degrees 3
K Developing an TL 9000 Audit Checklist - Help required TL 9000 Telecommunications Standard and QuEST 2
E Developing the Essential Requirements Checklist - Identifying Requirements Other US Medical Device Regulations 3
N ISO 9001 and the HR Function - Developing a Total Quality Management System for HR ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 16
B ISO Clause Reference for Developing Common Customer Service Standards ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 3
M Developing a CPI for First Pass Yield Final Inspection - Need help Quality Tools, Improvement and Analysis 7
M Developing a Medical Device Audit Checklist 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 5
A Developing HR (Human Resources) Policies ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 1
A Developing a Position Grade for Employee Suggestions ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
B Developing In-House Calibration Capacities General Measurement Device and Calibration Topics 5
S Developing Petrochemical Company Processes - Help needed Process Maps, Process Mapping and Turtle Diagrams 1
S I need help in developing a Center of Excellence Misc. Quality Assurance and Business Systems Related Topics 5
D Input Requirement Document for developing Product Presentation by Multimedia Solution Document Control Systems, Procedures, Forms and Templates 2
T Developing the Risk Management Plan - Risk Management Policy and Objectives ISO 14971 - Medical Device Risk Management 25
O Developing a QMS for biomedical start up company which only does R&D? ISO 13485:2016 - Medical Device Quality Management Systems 5
Z Developing an ISO 13485 System - New Small Medical Device Company ISO 13485:2016 - Medical Device Quality Management Systems 11

Similar threads

Top Bottom