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 theref
2、rom, 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 2011 SAE International All rights reserved. No part of this pub
3、lication 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: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS6124AEROSPACESTANDARDAS6124 Issued 2011-12Aluminum Axially Swaged Fittings, Instal
5、lation and Inspection Procedure RATIONALEProcedure for assembling and inspection AS6116 type aluminum axially swaged fittings. 1. SCOPE 1.1 Purpose This procedure establishes the instructions to prepare tube ends, install and inspect axially swaged permanent tube fittings qualified to AS6116. This p
6、rocedure is applicable when specified on the engineering drawing or in the procurement document.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 applicable issue of other publications
7、 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 regulations unless a specific exempti
8、on has been obtained. 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.orgAS6116 Aluminum Fittings, Axially Swaged Tube With Flareless Separable, Fluid System Up
9、to 1500 psi(10340 kPa) Maximum, Specification for 3. TOOLING AND GAGING VERIFICATION REQUIREMENTS 3.1 Tooling and Gaging Verification Prior to the listing of new gaging and tooling numbers in this procedure, the fitting/tooling system supplier shall demonstrate the interchangeability/capability by a
10、ssembling and gaging two sample fittings of each size of each manufacturer listed in the PRI-QPL-AS6116. The assembled fittings shall be tested to and pass the AS6116 impulse test requirements. Potential suppliers shall submit a plan to demonstrate interchangeability/capability to the Performance Re
11、view Institute(PRI), G-3 Fluid Distribution, Qualified Products Group (QPG), at PRI, 161 Thorn Hill Rd, Warrendale, PA 15086-7527. The QPG will grant approval for the suppliers numbers and name be added for the applicable tools or gages after demonstrating interchangeability/capability. SAE AS6124 P
12、age 2 of 12 4. GENERAL 4.1 Dimensions All dimensions in this specification are in inches. 4.2 Tube End Preparation The tube ends shall be cut square as defined in Figure 1. The tube ends , I.D. and O.D., shall be free of burrs. 4.3 Tube Condition - Sealing Area The tube sealing area shall be in acco
13、rdance with the tubing specification finish requirement. There shall be no scratches or other handling damage marks. This area shall be clean and free of paint, glue or any other foreign substance. 4.4 Tube Marking 4.4.1 Pre-Applied Tube End Marking At least one pair of marks, (positioning marks and
14、 inspection marks) as shown in Figure 1, shall be pre-applied with the given dimensions from Table 1 to each prepared tube end prior to fitting installation. A suitable permanent method such as ink stamp or electro-etch, etc. may be used. Should the tube ends be unmarked, the appropriate marks shall
15、 be applied using a tube marking gage as shown in Figures 2A and 2B, and using a suitable TEC (Trace Element Certified) permanent ink felt tipped pen. NOTE 1: Due to the possibility of ink contaminating tubing, inks which contain lead, 25 ppm maximum, or free halogens, 225 ppm combined maximum, shal
16、l not be used for marking. NOTE 2: See Table 2 for suppliers of marking gages. FIGURE 1 - POSITIONING AND INSPECTION TUBE MARKING SAE AS6124 Page 3 of 12 TABLE 1 - DIMENSIONS FOR INK STAMP OR ELECTRO-ETCH (IN) TABLE 2 APPROVED MARKING GAGES Dash Size Gage Number Supplier -04 DAT09AEMG1004 Cage Code
17、14798 -05 DAT09AEMG1005 Cage Code 14798 -06 DAT09AEMG1006 Cage Code 14798 -08 DAT09AEMG1008 Cage Code 14798 -10 DAT09AEMG1010 Cage Code 14798 -12 DAT09AEMG1012 Cage Code 14798 -16 DAT09AEMG1016 Cage Code 14798 -20 DAT09AEMG1020 Cage Code 14798 -24 DAT09AEMG1024 Cage Code 14798 NOTE: Approved Supplie
18、rs Cage Code 14798 Designed Metal Connections, dba Permaswage 14800 S. Figueroa, Gardena, California, 902484.4.2 Marking Gage Positioning The marking gage shall be bottomed on the end of the tube. FIGURE 2A - APPLICATION OF TUBE POSITIONING & INSPECTION MARKS USING APPROVED MARKING GAGES DashSize Di
19、a “A” Max.Inspection Mark Length(L1)PositioningMark Length (L2)D0.010E0.010Max. Out of Square “X”-04 .253 .350 .300 .320 .513 .003 -05 .3155 .350 .300 .455 .643 .003 -06 .378 .350 .300 .525 .792 .003 -08 .503 .350 .300 .695 .995 .005 -10 .629 .350 .300 .710 1.000 .005 -12 .754 .350 .300 .810 1.140 .
20、005 -16 1.004 .350 .300 1.080 1.510 .012 -20 1.255 .350 .300 1.305 1.785 .015-24 1.505 .350 .300 1.585 2.145 .015SAE AS6124 Page 4 of 12 FIGURE 2B - TUBE POSITIONING & INSPECTION MARKS AFTER REMOVING MARKING GAGE 4.4.3 Minimum Straight Tube Length to Bend In the case of swaging a fitting on bent tub
21、ing, the installation marks shall be within the minimum straight tube length to bend based on the orientation of the tube bend with respect to the swage tool. Figure 3 shows the two different orientations for a typical 90 degree bent tube. Minimum straight tube lengths to bend are shown in Table 3 f
22、or each orientation (configuration). FIGURE 3 INSTALLATION OF BENT TUBEPositioning Mark Inspection Mark SAE AS6124 Page 5 of 12 TABLE 3 MINIMUM STRAIGHT TUBE LENGTH (L) TO BEND Dash Size Configuration I Configuration II -04 2.64 .94 -05 2.57 1.07 -06 2.82 1.23 -08 2.92 1.46 -10 2.85 1.58 -12 3.56 1.
23、65 -16 3.65 2.05 -20 3.99 2.30 -24 4.37 2.71 4.4.4 Minimum Port Separation Distance In the case of swaging fittings on parallel tubing, it is recommended to maintain the minimum port separation distance to engage the swage tool on two parallel fittings without interference for proper swaging. Figure
24、 4 shows the configuration of two fittings in parallel. Table 4 shows the recommended minimum port separation distance M for various size combinations of Aluminum Axially Swaged Fitting series (i.e. a 04 fitting next to a 10 fitting). FIGURE 4 MINIMUM PORT SEPARATION DURING INSTALLATION OF PARALLEL
25、TUBING TABLE 4 MINIMUM PORT SEPARATION DISTANCE (M) COMBINATIONS Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -04 .750 -05 .785 .785 -06 .870 .905 .942 -08 .985 1.020 1.057 1.145 -10 1.125 1.160 1.197 1.285 1.372 -12 1.225 1.260 1.297 1.385 1.482 1.582 -16 1.460 1.495 1.532 1.620 1.707 1.817 1.979
26、-20 1.700 1.735 1.772 1.860 1.947 2.057 2.219 2.366 -24 1.803 1.838 1.875 1.963 2.050 2.160 2.322 2.517 2.620SAE AS6124 Page 6 of 12 5. FITTING INSTALLATION AND ASSEMBLY 5.1 Fitting Installation 5.1.1 Positioning Mark Locate the edge of the unswaged fitting “ring” over the positioning mark as shown
27、in Figure 5. The length of the positioning mark is the amount of positioning tolerance allowed. The edge of the fitting “ring” may be anywhere along the length of the positioning mark as illustrated in Figure 5. NOTE: Can ONLY be used with fittings that have a TUBE STOP. FIGURE 5 - POSITIONING MARK
28、AT DIFFERENT TUBE INSERTION DEPTHS 5.1.2 Axially Swaged End Fittings with Tube Stops In general, elbows, tees, crosses and straight adapter fitting ends have a tube stop. The tube stop allows for the proper tube insertion making sure that the tube is not inserted too deep to adjoining or adjacent po
29、rt (see Figure 6) especially in the case of reducer configurations. Even for these type of fitting ends, the tube end shall be marked for inspection purposes to verify that the tube was inserted to at least the minimum insertion depth. SAE AS6124 Page 7 of 12 FIGURE 6 FITTING END WITH A TUBE STOP5.1
30、.3 Shared Insertion In the case of AS6117 unions, the tube insertion allowance is shared by each leg of the union. If one tube end is inserted to maximum depth, then the opposite tube end can only be inserted to a minimum depth as shown in Figure 7. This shared insertion condition is only applicable
31、 to unions, which have a through bore to allow placement onto cut lines during repair.NOTE: Under maximum insertion conditions, it will not be possible to see the Inspection mark until after swaging. FIGURE 7 - EXAMPLES OF ACCEPTABLE SHARED TUBE INSERTION CONDITIONS FOR AS6117 UNIONS BEFORE SWAGING
32、5.2 Fitting Assembly 5.2.1 Swage Tool Selection Select the correct assembly tool based on fitting size. Figure 8 shows a typical axial swage tool. Table 5 lists available assembly tooling by fitting size. NOTE: In all cases, the green color code of the fitting shall match the color code of the tool.
33、 SAE AS6124 Page 8 of 12 FIGURE 8 TYPICAL AXIAL SWAGE TOOL TABLE 5 APPROVED AXIAL SWAGE TOOLS DashSize RecommendedTool Tool Direction Supplier -04 DAT09AETA1004 Universal* Cage Code 14798 -05 DAT09AETA1005 Universal* Cage Code 14798 -06 DAT09AETA1006 Universal* Cage Code 14798 -08 DAT09AETA1008 Univ
34、ersal* Cage Code 14798 -10 DAT09AETA1010 Universal* Cage Code 14798 -12 DAT09AETA1012 Universal* Cage Code 14798 -16 DAT09AETA1016 Universal* Cage Code 14798 -20 DAT09AETA1020 Universal* Cage Code 14798 -24 DAT09AETA1024 Universal* Cage Code 14798 * Universal Capable of both push and pull positions
35、as shown in Figure 9 5.3 Fitting Installation With the fitting positioned onto the tube as described in 5.1, select the proper tool for the application. The ring “forward/push“ position is the preferred tool position for most applications, however, a ring “reverse/pull“ position is required for some
36、 applications where there is a lack of tooling space. For the forward/push position, align the swage tool to one leg of the fitting so that the “ring“ is fully nested into the movable jaw of the tool and the front opening of the tool is bottomed into the “fitting body“ as shown in Figure 9. For the
37、reverse/pull position, align the swage tool to one leg of the fitting so that the “fitting body“ is bottomed in the movable jaw and the “ring“ is nested into the tooling body as shown in Figure 9. However, not all fittings can be swaged in the reverse/pull position. See Figure 10 for an example. SAE
38、 AS6124 Page 9 of 12 FIGURE 9 AXIAL SWAGE TOOL POSITION BEFORE ACTIVATION Reverse/Pull Position Forward/Push Position FIGURE 10 An Exception to Using Swage Tooling in the Reverse/Pull Position SAE AS6124 Page 10 of 12 5.3.1 Tool Pressurization The hydraulic pressure sources are available from the su
39、ppliers listed in Table 6. Apply hydraulic pressure up to 10 000 psi to the tool to advance the fitting ring or fitting body to complete the assembly process as shown in Figure 11. The swage is complete when the ring has advanced enough to meet the inspection gage length as listed in Table 7. Releas
40、e the pressure and inspect the tube-fitting joint after removing the tool. WARNING: Assembly tools operate under high-pressure hydraulic loads. The tools have moveable jaw and extreme loads can be applied to close the jaw relative to the tool body. Operate with care to avoid “pinch points” that coul
41、d result in injury to the hand or fingers. CAUTION: Fitting must always be fully nested into the tool to maximize tool life. Failure to seat the fitting into the bottom of the tool jaw will cause excessive loading of the tool flanges and could result in damaging the fitting and/or premature failure
42、of the tooling jaw as well as personal injury. TABLE 6 - PRESSURE SUPPLY SUPPLIERS Pressure Supply Description Part Number Supplier Hand Operated Pump DLT05MAPM1000 Cage Code 14798 Pneumatic Pump DLT02MAPP1000 Cage Code 14798 Foot-Operated Air/Hydraulic Intensifier DLT03MAPP1000 Cage Code 14798 Batt
43、ery Operated Pump DLT06MAPE3000 Cage Code 14798 5.3.2 Re-Engagement of Tooling (if necessary) If it is determined that the Ring has not been fully advanced in the initial swage process, the fitting can be reinserted into the tool jaw and the swage process can be repeated. The fitting shall be fully
44、nested into the tool jaw, and if possible, it isrecommended that the tool be rotated at least 90 degrees or preferred to the opposite side of the initial tool placement, then input the pump pressure of 10 000 psi, to fully advance the ring. This will help to distribute the tool pressure about the co
45、ntact surfaces on the fitting. 6. ASSEMBLED FITTING INSPECTION 6.1 Ring Advancement Inspection After fitting installation, ring advancement must be verified using a style C inspection gage at least one location on the swaged fitting. Inspection gage style C is shown in Figure 12. If an inspection ga
46、ge is not available, dimension Z, Table 7 must be verified at a minimum of three different locations on the swaged fittings. In the event of incomplete ring advancement see section 5.3.2 Re-engagement of Tooling. FIGURE 11 - COMPLETE AND INCOMPLETE RING ADVANCEMENT SAE AS6124 Page 11 of 12 TABLE 7 -
47、 MAXIMUM INSPECTION GAGE LENGTHS DashSize Length“Z“ inches max. -04 .434 -05 .512 -06 .638 -08 .800 -10 .812 -12 .899 -16 1.168 -20 1.385 -24 1.659 6.1.1 Inspection Gage Availability A typical inspection gage style C is shown in Figure 12. Suppliers for the inspection gages are listed in Table 8. FI
48、GURE 12 - INSPECTION GAGE STYLE C TABLE 8 APPROVED INSPECTION GAGE SUPPLIERS Size Style Gage Number Supplier -04 C DAT09AECG1004 Cage Code 14798 -05 C DAT09AECG1005 Cage Code 14798 -06 C DAT09AECG1006 Cage Code 14798 -08 C DAT09AECG1008 Cage Code 14798 -10 C DAT09AECG1010 Cage Code 14798 -12 C DAT09
49、AECG1012 Cage Code 14798 -16 C DAT09AECG1016 Cage Code 14798 -20 C DAT09AECG1020 Cage Code 14798 -24 C DAT09AECG1024 Cage Code 14798 6.2 Inspection of Tube Insertion After assembly, to ensure that the tube was inserted to the required depth, the position of the inspection mark relative to the swaged fitting-ring edge can be visually verified as shown in Figure 13. The
