MHICA Axial Swage

Axial swage
© 2017 MHI Canada Aerospace, Inc. All Rights Reserved. Proprietary and Confidential
Basic permalite fitting part number
structure
“Permalite end” standard dimensions
description of equipment
• The equipment used to install PermaLite fittings consists of a hydraulic pump and tool
kit containing DAT tooling along with other accessories. The makeup of the kit may
vary based upon the fitting sizes being swaged and the special needs of the user. See
Appendix Ill for typical tool kit content and part numbers.
• PermaLite fitting configurations, dimensions and part numbers are provided in the
PermaLite product catalog or from a series of tabulated drawings, all of which are
available from Permaswage or its representative.
Safety precautions
• Before operating the pump, all hose connections must be tightened with the proper tools. Do not over
tighten. Connections need only be tightened securely and leak-free. Over tightening may cause premature
thread failure or high pressure fittings to split at pressures lower than their rated capacities. Note that hose
is pre-charged with hydraulic fluid and to operate swage components properly, they must be free of air. Do
not damage or puncture hose; doing so can cause loss of internal pressure and cause personal injury.
• Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately release all pressure.
Never attempt to grasp a leaking hose under pressure with your hands. The force of escaping hydraulic fluid
could cause serious injury.
• Do not use the hose to move attached equipment. Stress may damage the hose and cause personal injury.
• To prevent hose and swivel damage - hold the swage tool and not the hose when transporting swage tools.
• Do not subject the hose to any potential hazard such as fire, extreme heat or cold, sharp surfaces, or heavy
impact. Do not allow the hose to kink, twist, curl, or bend so tightly that the fluid flow within the hose is
blocked or reduced. Periodically inspect the hose for wear. Above-mentioned conditions can damage the hose
and result in personal injury.
• Hose material and coupler seals must be compatible with the pump hydraulic fluid. Hoses also must not come
in contact with corrosive materials, such as creosote-impregnated objects and some paints. Consult the
manufacturer before painting a hose. Never paint the couplers. Hose deterioration due to corrosive materials
may result in personal injury.
• All components in the hydraulic system must match the 10,400 psi maximum pressure rating of the pump
Installation of permalite fittings
The recommended length of straight tube for insertion into PermaLite fittings is length D as
shown on the Positioning mark in Figure 2 This allows for the full use of the 0.300" I tube position
tolerance designed into PermaLite fittings. For unions, a 0.300" fitting position tolerance is
shared by both tubes, so a straight tube length of (C + D)/2 is acceptable 2 If a tube/fitting
position tolerance of zero is acceptable to the installer, then length C (see Fiqure 2) is the
minimum straiqht lenqth of tubing that can be inserted into PermaLite fittings. Bent tubing 5
should take into consideration the minimum straight tube length to be inserted into a PermaLite
fitting
conditions
• The tube seal area shall be free of cracks, splits, seams, folds, scratches, handling
damage or any other imperfection that is detrimental to the performance of the
swaged joint. In addition, this area shall be clean and free of paint, glue or any
other substance that is not specified in this manual or by Permaswage in writing.
• Tube ends, ID and OD, shall be de-burred.

Only Permaswage products shall be used in the installation of PermaLite fittings and DAT
tooling shall only be used for the installation of PermaLite fittings.
Preparation of dat tooling
THIS TOOLING IS SUBJECT TO HIGH PRESSURE AND FORCES DURING ITS OPERATION. KEEP FINGERS AWAY
FROM MOVING PARTS (THE TOOL JAWS AND THE PERMALITE FITTING IF PRESENT) WHEN PRESSURIZING THE
DAT TOOL. ALWAYS ENSURE THAT THE PERMALITE FITTING IS PROPERLY POSITIONED WITHIN THE TOOL
BEFORE AND DURING THE SWAGING PROCESS. IMPROPER USE MAY RESULT IN TOOL FAILURE, FITTING
DAMAGE, AND/OR PERSONAL INJURY. EYE PROTECTION IS RECOMMENDED. USE ONLY THE HOSES, QUICK
DISCONNECTS (QD), AND SWIVELS SUPPLIED IN PERMASWAGE /DMC KITS - DO NOT SUBSTITUTE. DO NOT
HOLD TOOL BY THE QD OR HOSE - DAMAGE TO THE SWIVEL MAY RESULT. DO NOT EXPOSE THE TOOLING
OR ITS COMPONENTS TO TEMPERATURES IN EXCESS OF 150 0 F (65 0 C). NEVER DISASSEMBLE THE TOOL FOR
ANY REASON - CONTACT A PERMASWAGE /DMC REPRESENTATIVE FOR SERVICE.
1 . Select the proper DAT tool per Table A2, T2, 5T2, S2 or S4
2. Inspect the tooling to ensure that it is in good working condition. The following items/areas should be checked
• Check the area between and around the jaws to ensure that there is no dirt or other debris lodged in the tool. Pay particularly
close attention to the slot that guides the moveable jaw.
• Check the jaws and surrounding areas to ensure that there are no cracks, nicks or dings.
NOTE: IF THERE ARE NICKS AND/OR DINGS IN THE JAW AREA CONTACT PERMSWAGE OR ITS REPRESENTATIVE.
Preparation of dat tooling
3. Attach Permaswage/DMC 10,000 psi hydraulic hose to DAT tool and
Permaswage /DMC hydraulic pump. (Note Section 4.1 Safety
Precautions).
4. Actuate the pump (see pump manual), and allow the tool to cycle
one or two times without a PermaLite fitting. Inspect for the following:
•The ability of the pump to move the pressure gage needle into the
"green" (9,800 to 10,400 psi; 676 - 717 BAR) range.
•The operation of the pressure relief valve. This is established by:
 For electric and pneumatic powered pumps: The unit stops cycling.
 For hand pumps: "Snapping noise" as the relief valve opens.
• That the moveable jaw moves smoothly and retracts completely.
• For any leakage from any of the components.
5. If necessary, release the pressure.
6. All DAT tools provided for your applications are color coded to prevent mixing of tools during installation
(see Table 2 for color code identification). In general, the tool color code matches the PermaLite fitting ring's
color code.
Permalite tooling color codes
Tube marking and insertion
ALWAYS APPLY TUBE INSERTION (INSPECTION, POSITIONING AND VERIFICATION) MARKS. IF A COLOR CODED
MARKING TEMPLATE IS NOT AVAILABLE, SEE FIGURE 2 AND TABLE Al, T 1, 5T1 OR S1 FOR LOCATION OF TUBE
INSERTION MARKS, AND DEPENDING ON THE APPLICATION.
1. Select the proper color coded marking template and snap it into position onto the end of the
tube. Use the sight hole to ensure that the marking template fits flush against the tube end.
Using the provided marking pen (Permaswage /DMC part number DLT5301000-01 or equivalent),
make a mark in each slot by running the pen along the sides of each slot. Ensure that the
marking is clearly visible in order to verify the position of the fitting before and after the
swaging. Marking at multiple locations around the tube is recommended
2. Repeat for each tube end to be swaged.
3. For all PermaLite fittings slide the fitting onto the tube locating it on the positioning mark.
Note that the positioning mark is located in the middle of the three insertion marks
4. Alternatively, for PermaLite fittings with a tube stop, slide the fitting onto the tube until it
stops
TUBING SHALL BE PROPERLY ALIGNED SO THAT AT NO POINT IN THE INSTALLATION OF PERMALITE FITTINGS
SHALL TUBING BE FORCED INTO THE FITTING
Tube marking template and insertion
marks
• Elbows, tees, crosses and straight adapter fittings have a tube stop as shown in FIGURE
6. A tube stop is a mechanical stop machined inside the fitting that prevents tube
insertion too deep into the fitting causing interference or blockage of fluid flow to the
adjacent port.
• In the case of unions, the tube insertion allowance is shared by each tube inserted into the
union. If one tube end is inserted to the maximum insertion depth then the opposite tube
end can only be inserted to the minimum insertion depth, or, both tube ends can be
inserted to nominal tube insertion depths as shown in FIGURE 7. This shared tube insertion
condition is only applicable to unions with a bore thru, to allow placement onto cut lines
during installation or repair
Swaging operations
1. DAT tooling must be allowed access such that its location is not restricted by any adjacent
structure to the fitting being swaged.
2. Every DAT tool is capable of swaging a fitting in either the push or pull position (see Figure 8).
HOWEVER, not all fittings can be swaged in the pull position, see Figure 9 for an example.
3. Using the DAT tool in the pull position requires special attention to ensure that the fitting does
not move during the swaging process. For this reason, it is recommended that at least one end
of a PermaLite fitting be swaged in the push position or, for the case of a separable fitting,
fasten before attempting a swage in the pull position.
4. DAT Universal tools are identified with black, silver and blue color bands. For sizes —10, -12
and —16 (only) tools, use corresponding color-coded inserts as specified in Appendix ll. Insert
snaps on the tool's fixed jaw (cylinder) prior to positioning tool onto the fitting.
Swaging operations
After the fitting has been positioned on the tube, it shall be swaged into place using the
following procedure:
1. Position the DAT tool onto the fitting so that the fitting groove is bottomed against the swage
tool and the ring is fully nested within its jaws. IT IS IMPERATIVE THAT THE FITTING GROOVE
IS FULLY NESTED ONTO THE DAT TOOL The longitudinal axis of tool and fitting shall be
parallel. In no circumstances shall the tool be forced into position or cocked.
2. While holding the tool in place, actuate the pump until the pressure gage needle is in the
"green" (9,800 to 10,400 PSI• 676 - 717 BAR) and the pressure relief valve has functioned.
Note that as the pump pressure builds, the tool jaw advances the fitting ring until it is flush
with the fitting flange
3. Release the pump pressure. The DAT tool jaws will retract allowing the tool to be easily
removed from the swaged joint.
4. Repeat steps 1 - 3 for each end to be swaged.
Swaging operations
Swaging operations
Swaging operations
Inspection of swaged connection
Visually inspect the position of the swaged fitting on the tube. At least two (2) marks should be
visible in whole or in part, see Figure Il. If not, the tube was inserted too far into the fitting. The
verification mark should always be completely exposed. The positioning mark will either be
completely exposed or partly covered. The inspection mark should always be partly/completely
covered or just touching the swaged fitting.
NOTE: IN NO EVENT SHOULD THERE BE A VISIBLE GAP BETWEEN THE INSPECTION MARK AND THE
SWAGED FITTING. THIS WOULD INDICATE INSUFFICIENT TUBE INSERTION; SEE SECTION 7,
"TROUBLESHOOTING".
NOTE: IF AN INSPECTION GAGE IS NOT AVAILABLE, USE LENGTH F

GIVEN IN TABLE A3, T3, 5T3, OR S3. MAXIMUM LENGTH 'F' SHALL APPLY ALL AROUND THE FITTING
RING/FLANGE.
Place the inspection gage onto the completed swage. The flat gage shall fit all around the fitting
ring/flange without forcing it. The cylindrical gage shall fit around the fitting ring/flange
without forcing it in at least one location. If the gage does not fit, see Section 7,
"Troubleshooting"
Due to tolerance stack up and other variables apparent in tools, fittings, tubes and the installer's
experience, it is possible to identify:
• A gap between the fitting flange and the ring leading edge
• Tool marks/Deformations on the Fitting Flange and Ring
• A fitting flange/ring deformation of a maximum 0.030"
• Damage to the ring composite overlay (if applicable) not to exceed the hatched areas
Dat universal axial swage tools
DAT universal tools (with two adapters) are designed to swage three types of fittings of a same size It swages 4
ksi & 5 ksi Titanium fittings and also 3 ksi & 5 ksi Stainless Steel Repair fittings. See Table ZI for DAT Universal
tool Kit information
Dat universal axial swage tools
Tool Preparation for Swaqinq Operation:

1. Install appropriate adapter for sizes —
10, -12 and -16 (Black for DPL4000T
fittings, Blue for DPL5000T, and
DL3000- & DL5000- Stainless Steel
Repair Fittings), which will snap onto
cylinder flange
2. Follow installation procedures outlined

in Section 5.0 of this manual
Deburr Hand pump
Tubing repair techniques
Four basic types of tubing system failures lend themselves to permanent repair using PermaLite techniques.
The failure types and recommended repair procedures are as follows:
A. TYPE 1--SmaII Hole or Short Crack in Tube (One Union Repair)
DAMAGED TUBE SECTION
1. Make cuts only after checking to assure enough space in which to operate swage tool
2. Make one or two cuts as necessary to allow removal of damaged tube section. 300" is the maximum allowable
tube gap for most PermaLite unions (If two cuts are required, and the distance between cuts exceeds O. 300" or
the PermaLite union's maximum Allowable Tube Gap
3. Deburr tube ends, mark tube ends with appropriate marking template and replace removed section of tube with
a compatible PermaLite union fitting. Completed repair
TYPE 2- Lengthwise damage or crack in tube
Damaged section
1. Make cuts only after checking to assure enough space in which to operate swage tool. Make two cuts to allow removal of damaged section of
tube
2. Use a tube splice and two compatible PermaLite union fittings to recreate the section of tubing which was removed, or use a PermaLite
Extended Union. Minimum tube splice length should be 2x “D”. Assemble these parts into the line being repaired before you swage the
fittings
3. Deburr the tube ends, mark tube ends with appropriate marking template and swage each of the fittings
Completed repair- 2 unions and tube section
Completed repair- extended union
TYPE C- Leaking elbow, tee, or cross
Damaged section Completed repair
1. Cut out defective elbow, tee, or cross. Make cuts only after checking to assure enough space in which to operate
swage tool
2. Swage tube splices to a compatible PermaLite elbow, tee, or cross fitting. Do this to re-create section of tubing
system that was removed
3. Swage each leg (tube) of this assembly to the tubing being repaired. Use PermaLite union fittings
TYPE 4a- damaged female flare end fitting
1. Cut off the flared end of the tube. Use of cut off
lengths permits repair of the line without splicing
new tubing into the line.
2. Replace the removed fitting with a compatible
PermaLite flare fitting.
TYPE 4b- damaged MS sleeve, female flareless end fitting
1. Cut off the flared end of the tube. Using cut-off

lengths permits repair of the line without splicing new
tubing into the line.
PermaLite flareless fitting
TYPE 4c- damaged beam seal end fitting- sizes 03-20
1. Cut off the damaged fitting at a distance from

the sealing surface.
PermaLite fitting
TYPE 4d- damaged end fitting repair with tube splice and union
Replacing MR54040 and MR44000P, internally swaged, and R44275PT butt-welded, female beam seal assemblies in
sizes -20 and -24. also applies to externally swaged and AS4203 internally swaged female beam seal assemblies in all
sizes
1. Cut off damaged fitting at a point where there is enough space in which to operate the swage tool
2. Prepare a tube splice to replace cutout section of tube. Cut, deburr, and mark tube ends. Make sure tube splice meets
tube insertions into end fitting and union before swaging. Minimum tube splice should be 2x “D”
3. Swage a compatible PermaLite union fitting to one end of a tube splice. Swage PermaLite beam seal or other type of
adapter fitting to the other end of the same tube splicing.
4. Connect the end of this assembly with a union fitting to the end of the tube being repaired.
Completed repair
Minimum straight tube length – bent
tube
• The recommended minimum straight length of a bent tube varies based upon the
orientation of the tube bend angle with respect to the DAT tool. FIGURE 18 shows
two different configurations of 90 0 bent tube insertions. Recommended minimum
straight tube lengths for all PermaLite series are shown in Tables Xl-X4. In
configuration l, the swivel of the DAT tool is oriented toward the bent tube. In
configuration Il, the swivel of the DAT tool is oriented away from of the bent tube.
The recommended straight tube length is determined for nominal tube insertion for
both configurations.
• Tube bending operations may deform tube wall and tube diameters to values
outside of specification requirements. All tube ends to be swaged upon must
conform to dimensional requirements within the tube specification. System design
should take this into consideration when establishing straight tube length after a
bend.
Minimum straight tube length – bent
tube

MHICA Axial Swage

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Axial swage

• Tube ends, ID and OD, shall be de-burred.

5. If necessary, release the pressure.

4. Repeat steps 1 - 3 for each end to be swaged.

NOTE: IF AN INSPECTION GAGE IS NOT AVAILABLE, USE LENGTH F

Tool Preparation for Swaqinq Operation:

2. Follow installation procedures outlined

DAMAGED TUBE SECTION

Completed repair- extended union

Damaged section Completed repair

1. Cut off the flared end of the tube. Using cut-off

1. Cut off the damaged fitting at a distance from

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