Leak Test Technology Development (LTTD) & Prove-out

NCMS Project #: 173003

Problem:

A method to detect and locate leaks of liquids or pressurized gases that may be combustible, hazardous, or functionally detrimental to the end product if a leak occurs is a critical manufacturing and repair process leading to safer and more reliable military systems, and safer industrial or military workplaces.
Five candidate technologies were evaluated for location capability and sensitivity: Photoacoustics, Surface Acoustic Wave, Millimeter Wave, Time-of-Flight Mass Spectrometry, and Speed of Sound (SoS).
Primary objectives were: cycle-time reduction, sensitivity, and simultaneous location. Secondary objectives were: robustness, cost effectiveness, and ease of use.

Benefit:

Availability: Increased MTBF increased F-14 system availability.
Cost: At $5K a sensor ($45K w/charge station), payback was realized in one test with leak found in engine nacelle not found via Fleet Readiness Center Southeast standard test methods.
Cycle Time: Individual leaks detected in under one second with immediate recovery. Reduced or eliminated failures at the wet fuel check stage.
Reliability: Detected leaks 10x smaller than the leak testing methods used at Fleet Readiness Center Southeast leading to increased MTBF and fuel savings in decreased leak volume during service life.

Solution/Approach:

The SoS sensor system was developed for leak checking in repair and refurbishment of fuel systems of the F-14 at Fleet Readiness Center Southeast.
Its simplicity results in a robust and economical method for detecting and locating leaks of helium, hydrogen, sulfur hexafluoride and other gases having molecular weights lighter or heavier than ambient air.

DOD Participation:

Industry/Academia Participation:

Benefit Area(s):