Heat Exchanger, Coil & Radiator Manufacturing calculator

Leak Test Capacity Calculator

Use this calculator to check whether leak testing can clear the production schedule. It combines fixtures per cycle, available test cycles, station uptime, and first-pass yield so quality and operations can see the true shipment-ready capacity.

What this calculator does

  • Estimate good leak-tested heat exchanger assemblies per shift from test fixtures, cycles, station uptime, and first-pass leak test yield.
  • Use it when helium, air decay, pressure decay, dunk, or mass spectrometer leak testing limits coil, radiator, condenser, or oil cooler shipments.
  • Converts leak test fixture loading, test cycles, station uptime, and first-pass yield into good assemblies per shift.

Formula used

  • Gross leak test capacity = assemblies tested per cycle × usable leak test cycles
  • Good leak-tested output = gross capacity × station uptime × first-pass leak test yield

Inputs explained

  • Assemblies tested per cycle: undefined
  • Usable leak test cycles: undefined
  • Leak test station uptime: undefined
  • First-pass leak test yield: undefined

How to use the result

  • Use it for line balancing, test stand staffing, leak test equipment justification, and shipment commit reviews.
  • It does not model different hold times, pressure levels, tracer gas recovery, rework retest loops, or customer-specific acceptance limits.

Common questions

  • What should I enter for usable leak test cycles? Use the cycles that can actually run in the shift after loading, pressurizing, stabilization, hold time, venting, unloading, calibration checks, and planned downtime.
  • Does first-pass yield include reworked units? No. Enter the percent that passes on the first test. Reworked units should be treated as additional demand on the leak test station.
  • How can this result guide a production decision? Compare good leak-tested output with the assembly schedule. If the result is short, add test hours, improve fixture loading, split product mix, or attack leak defects.
  • When is a detailed test plan still needed? A detailed plan is needed when different products have different pressures, volumes, stabilization times, leak limits, tracer gases, or regulatory test requirements.

Last reviewed 2026-05-12.