Pressure decay leak testing: principle, process and applications
Learn how pressure decay leak testing works, when to use it, and why it is widely used in medical, pharma and industrial manufacturing.
What is pressure decay testing?
Pressure decay testing is a leak detection method that identifies leaks by measuring the loss of pressure in a sealed product over time.
How pressure decay testing works
The process follows four steps:
- The product is sealed
- It is filled with air or gas to a defined pressure
- The system stabilizes
- Pressure is monitored over time
A pressure drop beyond a defined threshold indicates a leak.
Why pressure decay testing is widely used
Pressure decay is popular because it:
- Is non-destructive
- Requires no consumables
- Works on a wide range of products
- Provides fast cycle times
- Is easy to automate in production lines
Applications
Common applications include:
- Syringes and medical devices
- Packaging seals
- Automotive components
- Plastic housings and enclosures
Advantages and limitations
Advantages
- High repeatability
- Low operating cost
- Suitable for inline testing
Limitations
- Sensitive to temperature variation
- Requires stable fixturing
- Limited detection for ultra-micro leaks