A Key Step in Ensuring Reliable AI Server Liquid Cooling Systems

As AI computing grows in power and density, liquid cooling has become a key solution for heat management in server racks.

With higher power density, both pressure and thermal stress inside the system increase. This requires stronger pipes, connectors, and key components, directly affecting overall system stability and safety.
If a leak or structural failure occurs, it can lead to system downtime, costly repairs, and operational risks.

That is why burst testing is implemented early in development, to make sure the system stays safe and reliable over time.
 

Why is Burst Testing Important?

Burst testing helps us understand how much pressure key components can handle under extreme conditions. We can design safer and more reliable products by identifying their limits. It also helps to
  • Define the maximum pressure a component can withstand before failure.
  • Establish a safe operating range (Maximum Allowable Working Pressure, MAWP).
  • Identify potential weak points in the design.
  • Improve safety marginsy and overall reliability.
Using real test data to guide the design process, companies can lower the risk of failure, shorten development time, and launch products faster.
 

Application Scope: Key Components in the Secondary Loop of Liquid Cooling Systems

Burst testing is mainly used in the secondary loop of AI server liquid cooling systems. Each component reacts differently under high pressure due to differences in design, material, and usage conditions. Typical components tested include:
  • Cold plates
  • Manifolds
  • Quick disconnects (UQD / UQDB)
  • Hose kit
 

Following International Standards for Reliable Results

To ensure consistent and trustworthy results, burst testing follows international standards:

  • IEC 62368-1 – Safety requirements for liquid cooling components.
  • OCP (Open Compute Project) – Requires burst pressure to be at least 3× MAWP.
  • ASTM D1599 – Test method for pressure resistance of plastic pipes and tubing.
  • ISO 18869 – Performance and leakage standards for quick disconnects.
 

What Happens When Pressure Goes Beyond the Limit?

Burst testing also shows how components behave under extreme pressure. For example:
  • Cold plates: Cracking, deformation, leakage and flatness over tolerance
  • Manifolds: Weld failure or leakage
  • Quick disconnects: Thread damage, O-ring deformation or leakage during disconnection
  • Hose kit: Hose rupture or connector failure
Understanding failure modes is the key to optimizing design and improving liquid cooling system reliability.

【Burst Test Procedure】
 (Generated with Gemini AI)

Step 1 – Preparation:
Evaluate the type of water connection on the test sample (e.g., insert core fittings, QD fittings, threaded fittings...etc.) and design adapters to securely connect the sample to the testing equipment.

Step 2 – Removing Air and Pressurizing:
During the test, deionized water, coolant (PG25), or other fluids are used. All air must be removed from the pipes to prevent a sudden burst caused by trapped air. Pressure should only be applied after the system is fully purged.

Step 3 – Stepwise Pressurization and Holding Until Burst:
Pressure is applied in stages, checking for leaks at each step, until rupture or the standard’s maximum pressure is reached. This approach is commonly used for OCP and large-pipe testing.
 
【Burst Test–Pressure Data Chart】
 

DEKRA iST–Professional Validation Services

With the rapid growth of AI servers and high-power liquid cooling applications, DEKRA iST provides comprehensive burst testing and pressure validation services for liquid cooling systems. We assist companies ensure product reliability from R&D to mass production.

Our advantages include:
  • Testing procedures in compliance with international standards.
  • Precise pressure control and measurement capabilities.
  • Support for a wide range of critical liquid cooling components.
  • Customized test conditions and validation solutions.
Through systematic validation and professional testing expertise, we help customers reduce risks, improve product quality, and accelerate time-to-market.
Stay tuned for DEKRA iST’s upcoming “Liquid Cooling Tech Series,” which covers both component-level and system-level testing. This series provides practical insights and a complete perspective to help the industry enhance the safety and stability of liquid cooling systems.


Liquid Cooling Tech Series | Coming Soon:
#2 Water Hammer & Pressure Cycling Tests for Liquid Cooling Components
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