Automotive & Transportation

Automotive A/C components must remain sealed to ensure efficient operation and prevent refrigerant loss. Leak testing is performed using tracer gas methods to detect leaks in critical parts such as compressors, evaporators, and condensers. Helium Hard Vacuum Systems provide the sensitivity needed to identify even the smallest leaks, supporting reliable cooling performance and cabin comfort.

• Verify A/C component integrity under high-pressure conditions
• Detect leaks in cooling systems to prevent refrigerant loss
• Ensure optimal cooling efficiency and system longevity
• Performed using Helium Hard Vacuum Systems with helium or tracer gases for fast, accurate detection

Leak testing of EV battery cells—including prismatic and cylindrical types—and related components is essential to ensure airtight seals, pressure containment, and protection from contamination. Testing confirms that battery elements are properly sealed and function reliably during regular operation. Tracer gas methods offer fast, highly sensitive detection of even the smallest microleaks that could compromise performance or safety.

• Confirm seal integrity in prismatic and cylindrical battery cells
• Detect microleaks in battery components that affect efficiency and lifespan
• Prevent contamination and pressure loss during operation
• Leak tested using helium hard vacuum, hydrogen or helium sniffing, accumulation, and RGA-based detection systems

Battery pack assemblies must be leak tested to ensure pressure containment and prevent hazardous gas or fluid leakage. In many cases, this includes testing integrated cooling circuits within the battery tray to verify leak-free operation and support long-term system reliability. Tracer gas methods provide high-sensitivity leak detection suitable for in-line production, offline testing, and laboratory validation.

• Verify pack sealing to prevent gas or fluid escape
• Optionally test integrated cooling circuits for leak-free performance
• Detect leaks that could compromise pack safety or system function
• Ensure proper sealing in production and validation environments
• Tested using helium hard vacuum, helium/hydrogen sniffing, accumulation, and RGA-based detection techniques

Fuel system components, including fuel tanks, lines, and valves, undergo rigorous leak testing to ensure they remain sealed and secure. This testing prevents fuel leakage, which could lead to performance issues or safety hazards. Helium Hard Vacuum Systems are used to detect leaks that could compromise system integrity, ensuring the safe operation of fuel systems by preventing leaks.

• Verify sealing of fuel tanks, lines, valves, and related components
• Ensure safe and reliable operation by preventing fuel leaks
• Detect small leaks under pressure using tracer gas methods
• Performed using Helium Hard Vacuum Systems with helium or tracer gases for precise leak detection

Suspension system components are tested for leaks to ensure they can withstand the stresses and pressures they face on the road. Leaks in components like shocks, struts, and air suspension systems could lead to performance failures. Leak testing is performed using helium or tracer gas to detect any leaks and verify component integrity. This ensures safe and reliable performance of shocks, struts, and air systems.

• Verify that suspension system components remain sealed under pressure
• Ensure safe and reliable performance of shocks, struts, and air systems
• Detect small leaks that could lead to performance issues using tracer gas
• Performed using Helium Hard Vacuum Systems with helium or tracer gases for precise leak detection

Braking system components, such as brake lines, cylinders, and master cylinders, undergo leak testing to ensure they function safely under high-pressure conditions. Leak testing is crucial to maintain the integrity of braking systems, preventing failures that could lead to accidents. Helium Hard Vacuum Systems are used for precise detection of leaks, ensuring safe and efficient operation of the braking system.

• Verify sealing and pressure resistance of braking components
• Ensure safe and efficient operation of the braking system
• Detect leaks that could compromise braking performance using tracer gas
• Performed using Helium Hard Vacuum Systems and helium/tracer gases for effective leak detection

High-pressure composite tanks are used to store fuel, air, and other gases in vehicles, including those for hydrogen or compressed natural gas. Leak testing ensures these tanks remain sealed and safe under extreme pressure. Helium Hard Vacuum Systems are used to verify the integrity of these tanks, ensuring that they remain leak-free and safe during operation.

• Verify the sealing of high-pressure composite tanks
• Ensure safe operation of fuel storage systems under pressure
• Detect leaks that could compromise tank integrity or safety using tracer gas
• Conducted using Helium Hard Vacuum Systems

Engine components are subject to leak testing to ensure that oil, coolant, and fuel systems remain sealed and function properly. Testing ensures there are no leaks that could lead to performance issues or safety risks. Helium Hard Vacuum, Sniffing, or pressure decay Systems are used to detect leaks in critical engine components, ensuring long-term reliability and preventing fluid leakage.

• Verify sealing of engine components to prevent fluid leakage
• Ensure the reliability of oil, coolant, and fuel systems
• Detect even small leaks that could affect engine performance using tracer gas
• Performed with Helium Hard Vacuum, Sniffing, or pressure decay Systems

Leak testing of airbag inflators is essential to ensure these safety-critical components perform reliably in the event of a collision. Inflators must remain sealed under high-pressure conditions to guarantee rapid deployment. Helium Hard Vacuum Systems are used to detect even the smallest leaks, preventing failures caused by compromised seals.

• Verify airbag inflators remain sealed for reliable deployment
• Detect leaks in components under high-pressure conditions using tracer gas
• Prevent system failures due to compromised seals
• Performed using Helium Hard Vacuum Systems with helium or tracer gases for accurate leak detection

Temperature stress testing is essential for components like batteries, electronics, and A/C systems in automotive applications. Chillers are used to expose these parts to extreme temperature fluctuations, verifying their performance under both high and low temperatures. This ensures that the components can withstand the thermal stress experienced during regular vehicle operation.

• Verify performance under extreme temperature fluctuations
• Assess the durability of components under both hot and cold conditions
• Ensure electronics, batteries, and A/C systems function optimally
• Conducted using thermal vacuum chambers with integrated chillers for precise control