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 reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication m
3、ay 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: +1 724-776-4970 (outside U
4、SA) 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/AS6116AEROSPACESTANDARDAS6116 Issued 2011-11 Aluminum Fittings, Axially Swaged Tube with Flar
5、eless Separable, Fluid System Up to 1500 psi (10 340 kPa) Maximum, Specification for RATIONALE This specification is being prepared to provide the performance requirements for aluminum axially swaged, field attachable, 1500 psi, tube fittings. 1. SCOPE This SAE Aerospace Standard (AS) establishes th
6、e requirements for externally swaged aluminum tube fittings on aluminum tubing with flareless separable fitting ends for use in hydraulic supply and return aerospace fluid systems including pneumatic, coolants, and fire extinguishers up to a maximum operating pressure of 1500 psig (10 340 kPa) and a
7、 maximum operating temperature range of 65 to +225 F (-54 to +107 C). This specification covers a common aluminum fitting that may be used for a range of operating pressures up to 1500 psi with different tubing materials and tubing wall thicknesses, and is assembled with the same tooling in accordan
8、ce with AS6124. Table 12 shows applicable aerospace fitting part number standard and tubing materials and operating pressures. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applica
9、ble 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 references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regula
10、tions unless a specific exemption has been obtained. 2.1 SAE Publications Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AMS2700 Passivation of Corrosion Resistant Steels AMS-QQ-A-225/8 Alumi
11、num Alloy 6061 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished AMS-QQ-A-225/9 Aluminum Alloy 7075 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished AMS-QQ-A-225/6 Aluminum Alloy, 2024, Bar, Rod, and Wire; Rolled, Drawn, or Cold Finished AMS4083 Aluminum Alloy Tu
12、bing, Hydraulic, Seamless, Drawn, Round 1.0MG 0.6, .20CR (6061-T6) Solution and Precipitation Heat Treated Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS6116 Page 2 of 39 AMS4081 Aluminum All
13、oy, Tubing, Hydraulic, Seamless, Drawn, Round, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T4) Solution Heat Treated and Naturally Aged AMS4071 Aluminum Alloy, Drawn, Round, Seamless Hydraulic Tubing, 2.5Mg - 0.25Cr (5052-O), Annealed AMS4070 Aluminum Alloy, Drawn, Round Seamless Tubing, 2.5Mg - 0.25Cr (
14、5052-O), Annealed AMS2477 Conversion Coating for Aluminum Alloys Low Electrical Resistance Coating AS478 Identification Marking Methods AS603 Impulse Testing of Hydraulic Hose, Tubing, and Fitting Assemblies ARP1185 Flexure Testing of Hydraulic Tubing Joints and Fittings AS1241 Fire Resistant Phosph
15、ate Ester Hydraulic Fluid for Aircraft AS1376 Alternate Dimensions, Center Body Section, Shape Fluid Fittings, Design Standard ARP4784 Definitions and Limits, Metal Material Defects and Surface and Edge Features, Fluid Couplings, Fittings and Hose Ends ARP5412 Aircraft Lightning Environment and Rela
16、ted Test Waveforms AS33514 Fitting End, Standard Dimensions for Flareless Tube Connection and Gasket Seal AS5863 Fitting End, 24 Cone, Flareless, Fluid Connection, Design Standard AS6115 Fitting Assembly, Straight, Male Flareless, Axially Swaged, Hydraulic, Up To 1500 psi AS6117 Fitting Assembly, Un
17、ion, Axially Swaged, Hydraulic, Up To 1500 psi AS6118 Fitting Assembly, Straight, Female Flareless, Axially Swaged, Hydraulic, Up To 1500 psi AS6119 Fitting Assembly, Elbow, 90, Axially Swaged, Hydraulic, Up To 1500 psi AS6120 Fitting Assembly, Elbow, 45, Axially Swaged, Hydraulic, Up To 1500 psi AS
18、6121 Fitting Assembly, Tee, Axially Swaged, Hydraulic, Up To 1500 psi AS6122 Fitting Assembly, Straight, Bulkhead, Flareless, Axially Swaged, Hydraulic, Up To 1500 psi AS6123 Fitting Assembly, Tee, Axially Swaged On The Run, Male Flareless On The Side, Hydraulic, Up To 1500 psi AS6124 Aluminum Axial
19、ly Swaged Fittings, Installation and Inspection Procedure AS6158 Fitting Assembly, Tee, Axially Swaged On The Run, Female Flareless On The Side, Hydraulic, Up To 1500 psi AS6159 Fitting Assembly, Tee, Axially Swaged To Female Flareless On The Run, Male Flareless On The Side, Hydraulic, Up To 1500 ps
20、i AS6445 Fitting Assembly, Tee, Axially Swaged On The Run, Bulkhead Flareless On The Side, Hydraulic, Up To 1500 psi AS6446 Fitting Assembly, Tee, Axially Swaged On The Run, Internal Port End On The Side, Hydraulic, Up To 1500 psi Copyright SAE International Provided by IHS under license with SAENot
21、 for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS6116 Page 3 of 39 AS6457 Fitting Assembly, Tee, Axially Swaged To Male Flareless On The Run, Male Flareless On The Side, Hydraulic, Up To 1500 psi AS6458 Fitting Assembly, Tee, Axially Swaged To Female Flareless On
22、 The Run, Female Flareless On The Side, Hydraulic, Up To 1500 psi AS6192 Fitting Assembly, Elbow, 90, Axially Swaged, Female Flareless, Hydraulic, Up To 1500 psi AS6193 Fitting Assembly, Elbow, 45, Axially Swaged, Female Flareless, Hydraulic, Up To 1500 psi AS6194 Fitting Assembly, Tee, Axially Swag
23、ed, Female Flareless On The Run, Axially Swaged On The Side, Hydraulic, Up To 1500 psi AS6195 Fitting Assembly, Tee, Male Flareless, Bulkhead Flareless On The Run, Axially Swaged On The Side, Hydraulic, Up To 1500 psi AS7003 NADCAP Program Requirements AS7112 National Aerospace and Defense Contracto
24、rs Accreditation Program (NADCAP) Requirements for Fluid System Components AS85449/2 Clamp Assembly, Saddle Type, Cushioned, Phosphate Ester Fluid ResistantAS85449/3 Clamp Assembly, Saddle Type, Cushioned, High TemperatureARP5416 Aircraft Lightning Test Methods ARP5412 Aircraft Lightning Environment
25、 and Related Test Waveforms 2.2 ASME Publications Available from American Society of Mechanical Engineers, 22 Law Drive, P.O. Box 2900, Fairfield, NJ 07007-2900, Tel: 973-882-1170. www.asme.org.ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay) 2.3 ASTM Publications Available from AST
26、M International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM A 580 Standard Specification for Stainless Steel Wire ASTM E 8 Tension Testing for Metallic Materials ASTM E 499 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in
27、 the Detector Probe Mode ASTM D1193 Standard Specification for Reagent Water ASTM D1655 Standard Specification for Aviation Turbine Fuels 2.4 ISO Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ISO 7137
28、Environmental Conditions and Test Procedures for Airborne Equipment Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS6116 Page 4 of 39 2.5 PRI Publications Available from Performance Review Inst
29、itute, 161 Thornhill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616, www.pri-network.org.PD2001 Qualified Product Management Council Procedures for Qualified Products Group PD2101 Aerospace Quality Assurance, Product Standard, Qualification Procedures, Fluid Systems 2.6 RTCA Publications Availab
30、le from Radio Technical Commission for Aeronautics Inc., 1828 L Street, NW, Suite 805, Washington, DC 20036, Tel: 202-833-9339, www.rtca.org.RTCA/DO-160 Environmental Conditions and Test Procedures for Airborne Equipment 2.7 U.S. Government Publications Available from the Document Automation and Pro
31、duction Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, https:/assist.daps.dla.mil/quicksearch . MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8 +
32、100 MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance (Inactive for New Design as of 29 March 1996) MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircra
33、ft and Missile MIL-A-8625 Anodic Coatings For Aluminum and Aluminum Alloys MIL-DTL-5541 Chemical Conversion Coating on Aluminum and Aluminum Alloys MIL-PRF-16173 Corrosion Preventive Compound, Solvent Cutback, Cold-Application MIL-PRF-23377 Primer Coatings: Epoxy, High-Solids MIL-HDBK-831 Preparatio
34、n of Test Reports 3. TECHNICAL REQUIREMENTS 3.1 Qualification Fittings supplied in accordance with this document shall be representative of products which have been subjected to and which have successfully passed the qualification tests specified in this standard. 3.1.1 Manufacturer Qualification A
35、manufacturer producing a product in conformance to this procurement specification shall be accredited in accordance with the requirements of PD2101, AS7003, and AS7112, and shall be listed in a Performance Review Institute (PRI) Qualified Manufacturers List (QML). Copyright SAE International Provide
36、d by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS6116 Page 5 of 39 3.1.2 Product Qualification All products shall conform to the requirements of this procurement specification and shall be approved in accordance with the requirem
37、ents of PD2001 and PD2101 for listing in a Performance Review Institute (PRI) Qualified Parts List (QPL). 3.2 Materials The fitting materials shall be uniform in quality, free from defects, consistent with good manufacturing practices and shall conform to the applicable specifications and the requir
38、ements specified herein. 3.2.1 Bars and Forgings AMS-QQ-A-225/8 Aluminum Alloy 6061 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished AMS-QQ-A-225/9 Aluminum Alloy 7075 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished 3.2.2 Wire AMS5637 Steel, Corrosion Resistant
39、, Bars and Wire 18Cr - 9.0Ni (SAE 30302) Solution Heat Treated and Cold Drawn 125 ksi (862 MPa) Tensile Strength AMS5685 Steel, Corrosion Resistant, Safety Wire, 18Cr - 11.5Ni (SAE 30305), Solution Heat Treated, Cold Finished AMS-QQ-A-225/6 Aluminum Alloy, 2024, Bar, Rod, and Wire; Rolled, Drawn, or
40、 Cold Finished ASTM A 580 Standard Specification for Stainless Steel Wire 3.2.3 Tube Requirements Aluminum tubing shall meet the requirements of AMS4083, AMS4071, or AMS4070 as defined per Tables 1A and 1B. 3.3 Design and dimensions shall be such that fittings will meet all requirements of this spec
41、ification and the associated aerospace standard part drawings. 3.4 Fabrication 3.4.1 Fluid Passages 3.4.1.1 Drill Offset In the run, tees where the fluid passage is bored from each end, the offset between the bores at the meeting point shall not exceed 0.015 in. A sphere with a 0.020 smaller diamete
42、r shall be capable of traversing the bore intersection. The cross sectional area of the bore junction of angle fittings shall not be less than the cross-sectional area of the smaller passage. The mismatch in straight couplings shall be controlled such that a maximum OD tube (nominal + tolerance) wil
43、l pass through the entire fitting. 3.4.1.2 Maximum Reduction of Cross Section In Swaged Area The cross-sectional area of the swaged fitting/tubing joint shall not be reduced by more than 12% of the minimum tube internal diameter prior to swage. A ball whose diameter is not less than 0.87 times the m
44、inimum tube internal diameter shall pass through the swaged area of the fitting/tubing joint. 3.4.2 Finish 3.4.2.1 Aluminum: As specified in the associated aerospace standard part drawings. CRES: Passivation per AMS2700 Copyright SAE International Provided by IHS under license with SAENot for Resale
45、No reproduction or networking permitted without license from IHS-,-,-SAE AS6116 Page 6 of 39 3.4.2.2 Coating Color The ring shall be anodized (Green) similar to No. 14187, 14193, or 14223 of FED-STD-595. The fitting bore shall be colored green with a pigmented polytetrafluoroethylene (PTFE) or fluid
46、 resistant paint. 3.4.2.3 Dry Lube A lead free solid film lubricant per AS5272 Type I or III, or per AS6449 shall be used to facilitate assembly process. 3.4.2.4 Backup Sealing The fitting bore shall be enforced with heat cured elastomeric Dimethyl siloxane as an additional backup seal. The elastome
47、ric compound shall be cured at a temperature that does not have adverse effect on the fitting material properties, and shall have a Durometer of (54A-60A) and tensile strength of 800-1150 psi (5,516-7,930 kPa). The elastomeric compound shall be filled and completely bonded in the internal grooves of
48、 the fitting ends. The bonded elastomeric seal level shall be determined using the following “Go Gage” values below (e.g. a plug gage with a diameter equals to the maximum tube diameter (Go Gage) shall be possible to pass through the fitting/ring assembly prior to swage with some friction but not causing any damage to the seal). A minimum of two grooves (fitting end sizes -05 and larger) shall be filled with elastomeric Dimethyl siloxane compound. Smaller fitting end sizes shall have a minimum of one groove filled with the sealing compound. Tube Size (in.) Go GageDiameter (in.) 1
