1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS5902 AEROSPACESTANDARDAS5902 Issued 2002-05 Reaffirmed 2015-07 Installation of
5、Externally Swaged Fittings RATIONALE AS5902 has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE:This document describes engineering requirements for installation of externally swaged fittings used inaerospace fluid systems.2. REFERENCES:2.1 Applicable Documents:The following
6、 publications form a part of this specification to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and
7、references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.2.1.1 SAE Publications: Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.AS4215 Fittin
8、g, Adapter, Beam Seal, External Thread, External Swage Tube End, Hydraulic, 3000 psiAS4217 Fitting, Adapter, Beam Seal, Bulkhead, External Swage Tube End, Hydraulic, 3000 psiAS4218 Fitting, Elbow, 45 deg., Beam Seal, External Thread, External Swage Tube End, Hydraulic, 3000 psiAS4219 Fitting, Elbow,
9、 45 deg., Beam Seal, Bulkhead, External Swage Tube End, Hydraulic, 3000 psiAS4225 Fitting, Elbow, 90 deg., Beam Seal, External Thread, External Swage Tube End, Hydraulic, 3000 psiAS4226 Fitting, Elbow, 90 deg., Beam Seal, Bulkhead, External Swage Tube End, Hydraulic, 3000 psiSAE INTERNATIONAL AS5902
10、 Page 2 of 10 2.1.1 (Continued):AS4234 Fitting, Adapter, Beam Seal, Swivel Nut, External Swage Tube End, Hydraulic, 3000 psiAS4459 Fittings, Tube, Fluid System, 3,000 psig Maximum, Permanently Attached, Specification forAS5266 Fitting, Adapter, Straight, Flared, External Swage, HydraulicAS5267 Fitti
11、ng, Adapter, Straight, Flareless, External Swage, Hydraulic2.2 Definitions:SWAGED DIAMETER: A permanently deformed diameter on the fitting caused by crimping with the swage dies designed with predetermined after swaged diameter governed by the go-no gage.SWAGED LENGTH: A permanently deformed length
12、on the fitting caused by crimping with the swage dies designed with predetermined after swaged length governed by the go-no gage.TUBE INSERTION: Predetermined distance of tube entry inside the fitting beyond the silicone grooves governed by the witness marking tool.WITNESS MARK: Ink or electroetched
13、 mark put on tube end with the aid of witness marking tool to assure proper tube insertion.3. ASSEMBLY AND INSTALLATION OF EXTERNALLY SWAGED FITTING:In order to achieve anticipated hardware performance per AS4459, the criteria for assembly and installation of externally swaged fittings shall be as f
14、ollows:All personnel assigned to the installation of tube fittings shall be a qualified installer trained and certified (as required) by the applicable department(s) of the organization or the approved fitting and/or tooling manufacturer(s).SAE INTERNATIONAL AS5902 Page 3 of 10 3.1 Assembly of Fitti
15、ng and Tubing Material Combinations and Tube Wall Requirements:The fitting materials are available in 21-6-9 Cres, commercially pure (CP) Titanium and 6061-T6 overaged Aluminum Alloy for use on different tubing materials per allowable fitting and turbine material combinations as shown in Table 1:The
16、 selection of tubing wall up to 3000 psi system operating pressure shall be in accordance with AS4444 and/or AS4459 recommendations.3.2 Fitting Installation:The recommended steps of installing externally swaged fittings onto tubing are as follows:1. TUBE PREPARATION:Tube end may be cut by any conven
17、tional cutting methods such as saw cutting or grinding. It shall be cut square within 0.5 degree and remove burrs and slivers on inside and outside of tube.Hand cutter and deburring tools are available for manual tube end preparation as needed (refer to 3.3.1 for further tooling reference).Determina
18、tion of optimum tube lengths shall include compensation of material growth factor from swaging and tooling clearance as follows (see Figures 1 through 2 and Table 2):TABLE 1Fitting Material Tubing MaterialCres 3AL-2.5V Titanium AlloyCres 21-6-9 CresCres 304 1/8 Hard CresCres 6061-T6 Aluminum AlloyCP
19、 Titanium 3Al-2.5V Titanium AlloyAluminum Alloy 6061-T6 Aluminum AlloySAE INTERNATIONAL AS5902 Page 4 of 10 FIGURE 1 - Determination of Material Growth Factor Per Fittingand Tubing Material Combinations, Tube Wall and SizeFIGURE 2 - Optimum Fitting Location and Distance Between Tube BendSAE INTERNAT
20、IONAL AS5902 Page 5 of 10 3.2 (Continued):2. WITNESS MARK:Each tube end shall be ink marked or electroetched with witness mark for proper tube insertion inside the fitting prior to swaging. Apply witness mark that is compatible to the fitting and tubing materials to avoid undesired contamination.The
21、 witness marking tool may be used for easy and accurate method of marking. It is optional to have multiple or one continuous circumferential witness mark for visibility control purpose.An illustration is shown below for the distance of tube insertion requirements (see Figure 3 and Table 3):TABLE 2 -
22、 Union Cutout and Interconnect TubeSizeMinimumTooling ClearanceRecommended UnionCut Off Length03 0.92 2.2504 1.07 2.5405 1.11 2.6206 1.15 2.6908 1.65 3.7010 1.70 3.7812 1.66 3.9216 1.80 4.2020 1.91 4.4124 2.04 4.66SAE INTERNATIONAL AS5902 Page 6 of 10 FIGURE 3 - Witness Mark LocationTABLE 4Size Tube
23、 ODTube Insertion LengthMinimumTube Insertion LengthMaximum03 0.187 0.473 0.77304 0.250 0.615 0.91505 0.312 0.655 0.95506 0.375 0.690 0.99008 0.500 1.193 1.49310 0.625 1.233 1.53312 0.750 1.303 1.60316 1.000 1.448 1.74820 1.250 1.550 1.85024 1.500 1.675 1.975SAE INTERNATIONAL AS5902 Page 7 of 10 3.2
24、 (Continued):3. POSITIONING FITTING AND TOOLING:Two options may apply to positioning the fitting and tooling depending on whether swaging is conducted on production bench or out in the field.First option is to set up the tooling on the bench while the fitting is inserted into the swage dies until it
25、 stops against the stop plate of the tool. The fitting shall then be backed off to a distance that will accommodate the material growth from the result of swaging. Thus, it prevents damaging the stop plate from the pushing force of the material growth. The tube shall be inserted into the fitting pri
26、or to swaging.The second option is to position around the fitting/tubing joint with the tooling head separating from the main tooling body. Assemble the main tooling body to the head with the back off distance between the fitting and the stop plate prior to swaging.The configuration of the typical t
27、ooling is in Figure 4 for reference.4. SWAGING THE FITTING:The swaging tool is connected to the electric pump or hydraulic pump pneumatically operated from a 60 to 100 psi shop air to reach the required output pressure through the swaging tool for swaging. Hand pump is also available for manual oper
28、ation.Swaging of each fitting requires a few seconds of time. Design features are built in the pump and the tool to provide adequate swage as required preventing from over swaging. Double or triple swaging would be helpful on thicker than recommended tube wall or less desirable fitting/tubing materi
29、al combinations, such as 21-6-9 Cres fitting on 304 1/8 Hard Cres tubing.It is important to use serialized matching swage dies (two die halves) for every swaging operation to obtain an optimum swage.SAE INTERNATIONAL AS5902 Page 8 of 10 FIGURE 4 - Tool Assembly for SwagingSAE INTERNATIONAL AS5902 Pa
30、ge 9 of 10 3.2 (Continued):5. INSPECTION OF SWAGED FITTING/TUBING JOINT:The use of certified go-no go gage is recommended for inspecting swaged diameter and swaged length on the fittings. Simply put the gage around the swaged joint on any two or three locations at approximately 90 or 120 degrees apa
31、rt, respectively.If the swaged joint does not fit the certified gage, the joint may have been under swaged and it shall be re-swaged. The requirements for the after swaged diameter and swaged length are listed below for reference purpose (see Figure 5 and Table 4):FIGURE 5 - Swage InspectionTABLE 4
32、- Swaged DimensionsSize Maximum Swage Diameter Minimum Swaged Length03 0.247 0.34004 0.315 0.46005 0.381 0.50006 0.447 0.53008 0.606 1.02010 0.735 1.02012 0.863 1.02016 1.144 1.16020 1.390 1.40624 1.680 1.420SAE INTERNATIONAL AS5902 Page 10 of 10 4. TOOLING MAINTENANCE:All tooling shipped from the m
33、anufacturer shall include operation manual.Tooling shall be cleaned after each production use to remove particles and contaminants. Inspect swage dies to ensure cleanliness and free of dirt and particles entrapped in die segments.Swage tool shall be periodically certified by Quality Control based on
34、 penetrant inspection and swage samples.5. QUALITY CONTROL:Monitoring of the process and examination of the end-items shall be in compliance with those Quality Assurance provisions that ensure that the requirements of this specification are met. Verification tasks are outlined as follows:a. All tool
35、ing shipped from the manufacturer shall include certification of inspection.b. Verify that only certified and appropriately maintained tools are used for performing this process.c. Conduct pressure test on swaged tube assembly per AS4459 as required.6. NOTES:6.1 Dimensions:All dimensions are in inch
36、es.6.2 Safety Precautions:Users shall follow instructions for proper use of tooling and safety precautions. Improper use or exceeding tool life may result in tool failure and/or personal injury. Always consult tooling manufacturer(s) when in doubt on tooling conditions for safety.It is recommended t
37、hose swage tool operators shall take further precautions to avoid close alignment between them and the driving force of the swage head and the immediate rear of the power unit.6.3 Tooling Design Change:Any changes in tooling design affecting product qualification under the control of AS4459 shall require appropriate requalification as required.PREPARED UNDER THE JURISDICTION OFSAE SUBCOMMITTEE G-3B, AEROSPACE FITTINGS OFCOMMITTEE G-3, AEROSPACE COUPLINGS, FITTINGS, HOSE & TUBING ASSEMBLIES
