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Swaging

Swaging is a forging process in which the dimensions of a metal workpiece, such as a rod, tube, or wire, are altered by forcing it into a die or dies using compressive forces, thereby changing its cross-section without removing material.^[1] Typically performed as a cold-working operation, it reduces the diameter, tapers ends, or forms specific profiles, enhancing the material's strength through work hardening.^[2] The process is commonly applied to ductile metals including steel, aluminum, copper, and titanium.^[3]

History

Origins and Etymology

The term "swage" originates from the Old French word souage, referring to a decorative groove or ornamental molding, which evolved into the Middle English "swage" by the 14th century to describe tools and techniques for shaping metal with similar grooved forms.^[4] The earliest recorded use of "swage" in English appears in 1374, in the accounts of John de Sleford, denoting grooved or molded features on metal objects such as basins, candlesticks, and salt cellars.^[5] This linguistic root reflects the technique's initial association with aesthetic and functional shaping in metalwork, where tools impressed patterns or contours into heated or cold metal. Although the specific terminology emerged in medieval Europe, the underlying principles of swaging—compressive deformation using specialized tools or hammers to form grooves, tapers, and contours—trace back to ancient metalworking civilizations during the Bronze Age, around 2000 BCE. In this era, artisans shaped copper and bronze tools and weapons through cold hammering after smelting to remove impurities, achieving precise forms without melting the metal entirely.^[6] Archaeological evidence from sites across the Near East and Europe indicates that such hammering techniques were essential for creating decorative elements and functional edges on early bronze artifacts. By the Iron Age, around 1200 BCE, swaging-like methods became integral to blacksmithing, where smiths employed swages and related tools to forge grooves, tapers, and decorative motifs on iron and steel items such as horseshoes, tools, and hardware.^[7] These tools, often paired with anvils and hammers, allowed for efficient shaping of wrought iron, marking the technique's adaptation to harder metals and its foundational role in pre-industrial craftsmanship. This early manual application laid the groundwork for later mechanized developments in the 19th century.

Evolution of Techniques

During the 19th century, swaging techniques became integral to industrialized blacksmithing, transitioning from artisanal methods to more standardized processes for mass production. Blacksmiths utilized hammers and anvil-mounted swages to taper and shape heated metal rods, particularly for manufacturing nails by forging four-sided points and heads in dies while the material was white-hot.^[8] This approach extended to rivets, where swaged forms were cut from preformed rods to ensure uniformity in construction elements like iron columns in structures from the mid-1800s onward.^[9] These developments supported the expanding demands of the Industrial Revolution, enabling higher output of hardware essential for infrastructure and machinery. In the early 20th century, mechanization advanced swaging through the adoption of hydraulic presses, which provided consistent and powerful compression for more complex operations like tube reduction. Patents from the 1920s, such as US Patent 1,430,974 describing rotary swaging machines for shaping metal rods, laid the groundwork for efficient diameter reduction in tubular components.^[10] These innovations allowed for precise control over pressure, surpassing manual limitations and facilitating applications in emerging manufacturing sectors. A pivotal development occurred in the 1960s with key theoretical contributions to rotary swaging by Richard L. Kegg, whose work on die-workpiece mechanics enabled high-precision forming with minimal material waste and improved surface finishes.^[11] Post-World War II, swaging proliferated in the aerospace and automotive industries amid rapid technological expansion and the need for lightweight, durable parts. The era's focus on high-performance materials drove innovations in swaging for components requiring tight tolerances, such as drive shafts and linkages.^[12] Notably, Master Swaging, Inc., formed around 1960 and incorporated in 1970, emerged as a key player, specializing in swaged helicopter elements like torque tubes, pitch links, control rods, and rotor bolts using processes including hot and cold swaging on materials such as titanium and aluminum alloys.^[13] This growth reflected broader industry shifts toward precision fabrication to meet demands for reliable aircraft and vehicle systems. As of 2025, swaging techniques have evolved with computer-controlled systems, integrating CNC automation for enhanced repeatability and adaptability in processing lightweight alloys critical to electric vehicle production. These advancements enable precise forming of components like connecting rods and structural tubes from aluminum and magnesium alloys, reducing engine weight by 15-20% while maintaining structural integrity to extend range and efficiency.^[14] Such integration supports the automotive sector's push toward sustainable mobility, with swaging contributing to optimized designs in EV frames and powertrain elements.

Process

Fundamental Principles

Swaging is a forging process that utilizes compressive forces applied through dies to reduce the diameter of a rod or tube, create tapers, or form internal and external shapes on a workpiece.^[15]^[16] The process deforms the material without removing it, relying on the dies to confine and shape the workpiece under high pressure.^[17] The fundamental physics of swaging involves plastic deformation induced by radial impacts or sustained pressure from the dies, causing the material to flow outward or conform to the die geometry.^[15]^[16] This deformation is governed by the material's yield strength, which determines the onset of permanent shape change, and its ductility, which allows for elongation without fracture.^[15] The extent of size reduction is quantified by the reduction ratio r = \frac{D_i - D_f}{D_i} \times 100\%, where D_i represents the initial diameter and D_f the final diameter of the workpiece.^[18] Swaging can be performed as a cold process at room temperature or below 0.3 times the material's absolute melting temperature (T_m), which enhances precision and surface finish through strain hardening but limits reductions to avoid cracking.^[19]^[20] In contrast, hot swaging occurs at elevated temperatures to improve formability and enable larger reductions by lowering flow stress and increasing ductility, though it may require recrystallization annealing to restore properties.^[19]^[15] Key factors influencing the swaging outcome include die design, which determines the deformation path and final geometry; lubrication, which minimizes friction and heat buildup to prevent surface defects; and workpiece feed speed, which controls strain rate and helps avoid issues like cracking or uneven deformation.^[16]^[15] Proper management of these elements ensures consistent material flow and high-quality results.^[17]

Equipment and Methods

Swaging equipment encompasses a range of manual and industrial tools designed to deform metal workpieces through compressive forces applied via dies. In traditional blacksmithing, manual tools such as swage blocks, hammers, and anvils form the core setup. A swage block is a heavy cast iron or steel tool featuring multiple grooves and holes for shaping, typically used in conjunction with a hammer to strike the heated workpiece placed within or against the block's contours.^[21] The process begins by heating the metal to a malleable state, often in a forge, followed by positioning it in the swage block and repeatedly striking it with a hammer to gradually conform the material to the desired shape, such as rounding or tapering edges.^[22] Industrial swaging relies on powered machinery for higher precision and volume production, including hydraulic swaging presses and pneumatic hammers. Hydraulic presses generate forces ranging from 25 tons for tube forming to over 1,000 tons for heavy-duty applications, utilizing fluid pressure to drive a ram that closes dies around the workpiece.^[23] Pneumatic hammers, powered by compressed air, deliver rapid impacts suitable for lighter swaging tasks like tapering rods or cables, often incorporating rotating mechanisms to simulate hammering actions.^[24] These machines enable both hot and cold working, though cold swaging predominates in modern settings to enhance material strength without heating equipment. The operational method for swaging follows a standardized sequence to ensure uniform deformation. The workpiece is first inserted into the open dies, which are aligned precisely to prevent eccentricity or misalignment during compression. Dies then close around the material via press activation or hammer strikes, applying force to reduce diameter or form shapes incrementally; for longer pieces, the workpiece is fed progressively through the dies to achieve consistent results along its length. Upon completion, the formed part is ejected from the dies, often aided by release mechanisms in hydraulic systems.^[25] In cold swaging processes, lubricants or coolants are applied to minimize friction, control heat buildup, and improve surface finish.^[26] Safety protocols and setup procedures are critical to mitigate risks like die slippage or workpiece defects. Dies must be firmly secured and verified for straightness, parallelism, and perpendicularity before operation to avoid uneven forces that could cause equipment failure or injury.^[27] For complex geometries, multi-stage dies are employed, where the workpiece passes through sequential die sets to progressively refine the shape while maintaining alignment. These measures draw on the underlying deformation physics of plastic flow under compression, ensuring controlled material reduction without cracking.^[28] Quality control in swaging emphasizes post-process inspection to verify dimensional accuracy, particularly for precision components. Tolerances as tight as ±0.01 mm on diameters up to 25 mm are achievable, especially with mandrel-supported internal forming, allowing for high-precision parts in industries requiring exact fits.^[29] Measurements using calipers, micrometers, or coordinate measuring machines confirm adherence to specifications, with any deviations corrected through die adjustments in subsequent runs.^[25]

Types of Swaging

Rotary Swaging

Rotary swaging is a high-speed incremental forging process that utilizes rotating dies to impart rapid radial blows to a workpiece, such as tubes or rods, while it advances axially through the swaging head.^[26] The dies, typically arranged in two or four segments and backed by hammer blocks, revolve around the workpiece, with centrifugal force driving their radial oscillation to deliver impacts at frequencies ranging from 1,500 to 10,000 strokes per minute.^[30] This continuous operation enables precise diameter reduction for long workpieces without requiring intermediate annealing, distinguishing it as an efficient method for net-shape forming.^[31] In the mechanism, the swaging head's spindle rotates the hammer blocks and dies synchronously with the axial feed of the workpiece, ensuring uniform compressive forces across the cross-section.^[32] The oscillating dies conform the material to the desired profile, achieving up to 50% cross-sectional area reduction per pass, particularly suited for elongating and tapering tubes or rods.^[33] The axial feed rate is controlled independently to ensure production speed and deformation uniformity.^[30] Key advantages of rotary swaging include its ability to produce uniform deformation with minimal heat generation, as the process operates at ambient temperatures and avoids excessive friction through high-speed impacts.^[12] This results in enhanced material properties, such as increased hardness and refined microstructure, while maintaining tight tolerances on the order of ±0.02 mm.^[30] As of 2025, modern implementations feature CNC-controlled rotary swagers, which enable automated precision forming of aerospace tubing, supporting complex geometries in lightweight components for aircraft structures.^[12]

Static and Incremental Swaging

Static swaging, also known as stationary or hydraulic swaging, is a non-rotary metal forming process that employs fixed dies within a press to achieve compressive deformation of a workpiece in a single stroke. In this method, a hydraulic or mechanical ram applies direct axial force to push the workpiece into the stationary dies, reducing its cross-section perpendicular to the axis of deformation without rotation. This technique is particularly suited for short workpieces or those with thick walls, where high localized force is required to shape robust components.^[17]^[34] The mechanism relies on plane strain conditions due to the extended contact length between the dies and workpiece, resulting in minimal axial elongation compared to other forming methods. Typical press forces range from 200 to 2000 tons, enabling deformation of materials like steel pipes or cables under controlled hydrostatic tension to prevent centerline fracture. Unlike rotary processes, static swaging delivers higher force per stroke at lower speeds, prioritizing strength over precision for heavy-duty applications.^[17]^[35] Incremental swaging extends the static approach through a multi-pass sequence using progressive dies, where each pass achieves a gradual reduction of 12-20% in cross-sectional area to form elongated or complex profiles.^[36] This step-by-step method is essential for processing long tubes exceeding 5 meters, as it minimizes material springback and buckling by distributing deformation over multiple insertions. Hydraulic presses with capacities up to 4200 tons facilitate these passes, often incorporating intermediate annealing for work-hardened alloys.^[37]^[35] In heavy industry, static and incremental swaging are applied to form large-diameter pipes and high-strength cables, such as those used in oil and gas pipelines or structural rigging, where the processes ensure uniform wall thickness and enhanced mechanical integrity.^[35]^[34]

Materials

Metals and Alloys

Swaging is highly suitable for ductile metallic materials that can endure substantial plastic deformation, including copper, aluminum, low-carbon steels, and brass, which facilitate cold working without excessive cracking. These metals exhibit favorable formability due to their ability to undergo reductions in cross-sectional area of 20-50% per pass in rotary or static swaging processes, depending on the initial temper and die design. Stainless steels, such as AISI 304 and 316, are particularly valued in swaging for their inherent corrosion resistance, making them ideal for components exposed to harsh environments like marine or chemical processing equipment.^[38]^[39]^[40] For high-strength alloys like titanium and nickel-based superalloys used in aerospace applications, swaging typically requires elevated temperatures to overcome their limited room-temperature ductility and high yield strengths. Hot swaging of beta titanium alloys, for instance, at temperatures around 800°C followed by aging, refines the microstructure to achieve a balance of strength and toughness, with ultimate tensile strengths exceeding 1000 MPa. Similarly, Inconel 718 superalloy undergoes rotary swaging at hot deformation conditions to form precision components, where processing temperatures mitigate cracking risks associated with its gamma-prime precipitates.^[41] Work hardening during swaging increases dislocation density, enhancing strength but necessitating intermediate annealing cycles—often at 400-600°C—to recrystallize the structure and restore ductility for multi-pass operations.^[42] Key processing parameters for successful swaging of metals include sufficient ductility to ensure uniform deformation and minimize surface defects. In high-strength steels, such as advanced high-strength variants, insufficient lubrication or excessive die pressure can lead to galling—a form of adhesive wear where material transfers between the workpiece and tool, compromising surface finish and dimensional accuracy. Advancements have extended swaging to high-entropy alloys, like tungsten-based compositions swaged at 1300°C, enabling the production of ultra-high-strength materials with improved thermal stability for next-generation manufacturing in extreme environments.^[43]

Non-Metallic Materials

Swaging processes for non-metallic materials, such as thermoplastics and composites, differ significantly from those applied to metals due to the materials' heat sensitivity, lower ductility, and anisotropic properties. For thermoplastics like PVC and nylon, swaging is commonly performed using ultrasonic or heat-assisted methods to soften and reform the material, enabling the creation of ridges, collars, or tube ends for assembly purposes.^[44]^[45] These techniques involve applying vibratory energy or controlled heat to generate frictional melting, allowing plastic flow into a desired shape while capturing adjacent components, such as in medical device assemblies or hose fittings.^[46] Low-force dies or tooling are employed to minimize deformation stress, preventing cracking in the relatively brittle cold state of these materials.^[44] In fiber-reinforced polymer composites, swaging adaptations focus on joining rather than direct bulk deformation to maintain structural integrity and fiber alignment. Incremental approaches, such as using swaged metal couplers to splice glass fiber-reinforced polymer (GFRP) bars, apply compressive forces to secure connections without significantly disrupting the embedded fibers, which is critical for lightweight applications like reinforcement in construction.^[47] Similarly, swage anchorages for carbon fiber-reinforced polymer (CFRP) tendons preserve fiber orientation by limiting deformation to the metallic components interfacing with the composite.^[48] These methods ensure up to 92% retention of the composite's tensile strength post-joining.^[48] Key challenges in non-metallic swaging include precise temperature control to avoid overheating, which can cause melting or degradation in thermoplastics, or excessive cooling leading to brittleness and reduced flexibility.^[45]^[46] Ultrasonic processes monitor force drops (typically 5-10% of initial trigger force) to indicate melting onset, allowing real-time adjustments.^[44] Compared to metal swaging, non-metallic variants require substantially lower applied forces—often in the range of controlled pneumatic or servo pressures rather than the hundreds of tons used for ductile metals—and heightened attention to lubrication to reduce friction during reformation.^[44]

Applications

Traditional Crafts and Toolmaking

In traditional blacksmithing, manual swaging techniques involved heating metal bars and using swage blocks or fullers inserted into the anvil's swage hole to taper and shape them, allowing artisans to create precise forms without excessive material loss.^[49] These methods were essential for forging horseshoes, where blacksmiths swaged the ends of heated iron blanks to fit the curved contours of a horse's hoof, ensuring proper traction and durability during the 18th century when guild-regulated practices emphasized hand-forged precision for agricultural and equestrian needs.^[50] For decorative ironwork, swaging enabled the creation of ornamental scrolls, balusters, and gates by gradually reducing and curving heated stock in grooved swages, a technique passed down through European guilds that highlighted the blacksmith's skill in blending utility with aesthetic appeal.^[49] In toolmaking, swaging played a key role in shaping chisels, files, and anvils by compressing and forming hardened steel blanks into desired profiles, often using specialized swage tools fitted to the anvil for controlled deformation.^[50] A prominent application was in saw blade maintenance, where 19th-century machines and hand tools swaged individual teeth to set them alternately left and right, expanding the kerf width to prevent binding during cuts and improve saw efficiency in woodworking.^[51] For instance, early mechanical swages, such as those patented in the 1880s, clamped the blade and hammered the tooth edges to flare them precisely, a process that evolved from manual methods to semi-automated devices by the late 1800s, revolutionizing tool production in mills and workshops.^[52] Swaging also found use in the repair of musical instruments, particularly for restoring brass components like trumpet bells or flute joints without soldering, by inserting mandrels or swaging dies to gently expand or reshape deformed sections while preserving the instrument's acoustic integrity.^[53] This technique, rooted in 19th-century repair practices, allowed luthiers and band instrument specialists to correct dents or misalignments in brass tubing through controlled compression, maintaining seamless joints and tonal quality essential for performance.^[54] Culturally, swaging held significant importance in medieval armor and weaponry production, where blacksmiths used swage blocks and stakes to form plate components like breastplates, helmets, and sword guards from wrought iron, contributing to the knightly class's protective gear and symbolizing craftsmanship in feudal societies.^[55] These techniques, documented in guild records from the 14th to 16th centuries, underscored swaging's role in enabling mass production of articulated armor during conflicts like the Hundred Years' War, blending metallurgical innovation with the era's martial heritage.^[56]

Pipe, Tube, and Cable Forming

Swaging plays a critical role in tube reduction processes, where the diameter of pipes and tubes is precisely sized to meet requirements for plumbing and exhaust systems. This involves applying radial compressive forces to deform the tube material, typically reducing its outer diameter while maintaining wall thickness integrity for leak-proof connections. In low-pressure applications, such as fluid transfer lines, swaging serves as an alternative to welding or soldering by mechanically squeezing fittings onto tubes, achieving leak rates as low as 10⁻⁸ cc/sec under helium testing at 3,000 psi.^[57] For instance, a thin layer of soft metal like tin (0.0025 mm thick) can be applied between the fitting and tube to fill interstitial spaces during deformation, enhancing sealing without altering standard tolerances.^[57] Expanding tube ends for fittings is commonly achieved through rotary swaging, where dies rotate around the tube to gradually flare or bead the end, facilitating secure joints in plumbing assemblies. This method allows for the creation of swedge joints by expanding the bore of one tube end to mate with another fitting, ensuring a tight, vibration-resistant connection without additional adhesives.^[58] In exhaust systems, rotary swaging reduces tube diameters to fit standardized components, improving flow efficiency and structural alignment in industrial piping.^[59] Cable swaging involves compressing ferrules—metallic sleeves—around wire ropes to form secure, permanent terminations that withstand high tensile loads in applications like cranes and elevators. The process uses hydraulic or mechanical tools to deform the ferrule, gripping the rope strands uniformly and preventing slippage under dynamic stresses, in compliance with standards such as EN 13411-3, which specifies ferrule-securing requirements for safety-critical terminations.^[60] This compression ensures the assembly achieves full rope breaking strength, with the ferrule's deformation creating a cold-welded bond that resists corrosion and fatigue in overhead lifting systems.^[60] For lockbolts and fasteners, swaging forms the collar around the bolt pin to provide structural integrity, particularly in aluminum tube assemblies used in construction. The process begins by inserting the pin through aligned holes in the components, followed by positioning the collar on the pin; a tool then pulls the pin while an anvil swages the collar into the pin's lockgrooves, elongating both to eliminate gaps and develop consistent clamp force.^[61] This results in high shear and tensile strengths, such as 3,050–6,825 lbf for common sizes, making it suitable for frameworks and scaffolding where vibration resistance is essential.^[61] Swaged aluminum tubes in construction benefit from this method, as it enhances load distribution in support structures like handrails and trusses without heat-affected zones.^[39] Compliance with standards like ASTM B306 ensures the quality of seamless copper tubes used in swaged applications for plumbing and drainage systems. These tubes, made from UNS No. C12200 copper, are specified for drain, waste, and vent (DWV) piping with nominal sizes from 1¼ to 8 inches in straight lengths up to 20 feet, allowing swaged ends to mate seamlessly with fittings for corrosion-resistant joints.^[62] The standard mandates tolerances for wall thickness and diameter to support deformation processes like swaging, ensuring dimensional stability and pressure integrity in sanitary drainage installations.^[59]

Electronics and Electrical Components

Swaging is widely utilized in the electronics industry for forming wires and connectors, particularly through cold swaging processes that reduce the diameter of copper wires to fit terminals or enable crimping on circuit boards. This technique deforms the wire under compressive force using dies, creating secure, gas-tight connections without removing material or generating heat, which is ideal for preserving electrical conductivity and avoiding damage to insulation. For example, swage assembly fastens pin terminals—often made from ductile alloys like brass or copper—to printed circuit boards by flaring and compressing the shank with a punch and anvil, requiring a board hole diameter no more than 0.004 inches greater than the shank for reliable retention; this is commonly paired with soldering for applications involving heavy-gauge wires from cables.^[63]^[64]^[65] In housing assembly, swaging excels at shaping aluminum cases for batteries and sensors, delivering the tight tolerances (<0.05 mm) necessary for compact, high-performance devices. Rotary swaging machines, for instance, precisely form the external cans of cylindrical lithium-ion batteries like the 18650 type by incrementally deforming the aluminum, ensuring uniform wall thickness and seamless integration without welds. Similarly, this process embeds optical sensors into metallic tubes during fabrication, using a mandrel to position components and achieve diameter tolerances as fine as ±0.001 inches, which supports the mechanical stability and signal integrity required in sensor housings. These applications leverage the ductility of aluminum alloys to avoid cracking while maintaining structural integrity under operational stresses.^[66]^[25]^[67] The advantages of swaging in electronics stem from its high precision and minimal material waste, facilitating miniaturization in small-scale manufacturing where space constraints demand components with consistent geometries. This cold-forming method produces dimensionally accurate tubular parts at high speeds, reducing costs for intricate assemblies compared to machining. Historically, swaging's role expanded post-1950s alongside the semiconductor boom, as growing demand for reliable, precision-formed metal elements in circuit boards and devices drove innovations in cold-working techniques.^[68]^[69]

Firearms and Precision Machining

Swaging plays a critical role in firearms manufacturing, particularly through incremental swaging techniques used to form rifling in gun barrels. This process involves displacing metal rather than removing it, creating helical grooves that impart spin to bullets for improved accuracy and stability. Button swaging, a common incremental method, employs a carbide button—a hardened tool shaped as the negative image of the desired rifling pattern—pulled or pushed through the pre-drilled barrel bore under high pressure. As the button advances, it swages the grooves into the barrel's interior surface, typically achieving twist rates of 1:7 to 1:12 for rifle calibers like 5.56mm or 7.62mm. This cold-forming approach enhances barrel strength by work-hardening the steel, reducing the risk of defects compared to traditional cut rifling.^[70]^[71]^[72] In precision firearm components, swaging is applied to shape parts from steel alloys via cold processes, avoiding heat to maintain material integrity and tight tolerances. For instance, rotary swaging tapers suppressor tubes by progressively reducing diameter along the length, forming conical sections that optimize gas flow and alignment with the firearm muzzle. This method uses dies that hammer the workpiece over a mandrel, creating smooth transitions essential for suppressor performance and balance. Similarly, swaging forms end fittings or housings for recoil spring assemblies, coiling or reshaping steel wire into precise diameters for consistent tension and durability in high-stress environments. These cold processes, often on chromium-molybdenum-vanadium (Cr-Mo-V) alloys, improve fatigue resistance and surface finish without introducing thermal distortions.^[73]^[25] Swaging mandrels enable custom tooling in precision machining for firearms, allowing the production of specialized components with exceptional accuracy. These mandrels, inserted into the workpiece during swaging, guide deformation to achieve internal features like threaded bores or profiled chambers, supporting applications in bolt carriers or magazine followers. Tolerances as fine as ±0.001 inches (0.025 mm) are routinely maintained, ensuring compatibility with mating parts under extreme pressures up to 60,000 psi. In military-grade production, such as 7.62mm rifle barrels, swaging adheres to standards like those outlined in U.S. Army Materiel Command specifications, optimizing variables like die pressure and heat treatment for enhanced ballistic performance and longevity. Post-swaging finishes may comply with MIL-STD-171 for corrosion resistance in service environments.^[25]^[73]^[74]

Medical Devices

Swaging plays a pivotal role in the fabrication of stents and catheters, particularly through the rotary swaging of Nitinol tubes to produce expandable vascular stents. This cold-working process reduces the diameter of annealed Nitinol wire or tubing while maintaining the alloy's superelasticity and shape memory properties, allowing stents to be compressed for delivery via catheter and then expand to their programmed shape upon heating to body temperature.^[75] Shape memory alloys like Nitinol, with their ability to undergo large deformations and recover without permanent strain, are ideal for these applications due to their biocompatibility and fatigue resistance, as detailed in materials processing studies.^[75] In surgical tool manufacturing, swaging is essential for tapering hypodermic needles from stainless steel tubing, achieving precise outer diameters as small as tens of microns for accurate drug delivery and minimally invasive injections.^[76] Similarly, swaging forms stainless steel components for endoscopes, such as flexible tubing sections that require reduced diameters and custom tapers to navigate anatomical pathways while maintaining structural integrity under repeated flexing.^[77] To ensure biocompatibility and prevent contamination in life-critical devices, swaging processes for medical applications are performed in controlled cleanroom environments, such as ISO-7 facilities compliant with ISO 13485 standards.^[76] These sterile conditions minimize particulate introduction, preserving the material's surface integrity and enabling diameter reductions up to 40%—as demonstrated in cold swaging of biomedical alloys—without inducing defects that could compromise implant safety or elicit adverse tissue responses.^[78]

Automotive and Aerospace

Swaging plays a pivotal role in the automotive sector by enabling the precise forming of exhaust tubes, which direct combustion byproducts away from the engine while maintaining structural integrity under thermal stress.^[79] This cold-forming process reduces tube diameters and shapes ends without weakening the material, allowing for seamless integration into exhaust systems that comply with emissions standards.^[80] Similarly, swaged tubes are integral to fuel lines, where they withstand high pressures and corrosive fuels, ensuring reliable delivery from the tank to the engine in both conventional and hybrid vehicles.^[81] Brake lines and power steering components also benefit from swaging, as the process creates leak-proof connections that endure vibrational and hydraulic loads.^[82] In electric vehicle (EV) applications, swaging facilitates the fabrication of lightweight tubular components integrated into battery housings, supporting thermal management systems and structural reinforcement while minimizing overall vehicle mass for improved range.^[83] Roll cage components in performance and racing automobiles rely on swaged tubing for tapered joints and fittings, enhancing crash protection through precise diameter reductions that maintain high strength-to-weight ratios.^[84] Within aerospace, precision tube swaging is essential for hydraulic lines that power flight controls, landing gear, and actuators, where materials like titanium provide corrosion resistance and reduced weight critical for fuel efficiency.^[12] For instance, in the Boeing 787 Dreamliner, swaged titanium fittings ensure secure, lightweight assemblies in high-stakes hydraulic systems, approved for use by major manufacturers including Boeing.^[85] These components undergo hydrostatic and pneumatic proof pressure testing to verify tolerance up to operational limits, often exceeding 3,000 psi, preventing failures in extreme environments.^[86] Rotary swaging, in particular, allows for radial compression of tubes without heat, preserving material properties for aerospace-grade performance.^[12] For automotive styling, incremental swaging methods enable the customization of exhaust tips by gradually tapering and flaring stainless steel tubing, achieving aesthetic angles and finishes that enhance vehicle appearance without compromising flow dynamics.^[84] Suspension parts, such as control arm tubes, are similarly formed using this technique to fit bespoke designs in aftermarket upgrades, balancing rigidity with reduced weight for improved handling.^[80]

Other Industrial Uses

Swaging finds application in general manufacturing for shaping shafts and fasteners, where rotary swaging machines deliver rapid compressive forces to deform metal rods, tubes, or wire into precise forms without material removal.^[2] For instance, point forming via swaging reduces the diameter of rod ends to create tapered sections, facilitating automated feeding and assembly in production lines.^[87] This process enhances component strength through work hardening while maintaining material integrity. In structural engineering, swaging integrates with roll forming to fabricate cold-formed steel frames for buildings, allowing controlled deformation of sections to improve joint connections and load transfer efficiency.^[88] The technique offsets profiles at specific points, enabling seamless assembly of framing members that support architectural demands for durability and precision.^[89] Within the defense sector, rotary swaging produces reliable components for military vehicles, such as structural elements requiring high strength and tight tolerances under extreme conditions.^[12] Portable swaging devices further support field repairs by efficiently securing fittings and hoses, reducing downtime in operational environments.^[90] Swaging also enables the creation of specialized fasteners like swage nuts and sleeves, which deform to provide permanent, high-strength anchors in assemblies across industrial settings.^[91]^[92] These components embed securely into parent materials, offering vibration resistance superior to traditional threaded fasteners.^[93]

Advantages and Limitations

Benefits Over Alternative Processes

Swaging provides exceptional material efficiency over subtractive methods such as machining, which generates substantial scrap through material removal; in contrast, swaging deforms the workpiece without waste, achieving material cost savings of 40-80%.^[94] This near-zero-waste approach not only reduces raw material consumption but also enhances the material's properties via cold working, refining the grain structure and improving fatigue resistance through strain hardening.^[95] For instance, rotary swaging of alloys like Cu-Cr-Zr has been shown to increase fatigue strength by promoting ultrafine grains that resist crack propagation under cyclic loading.^[95] The process demonstrates superior versatility for forming intricate geometries from continuous stock material, producing seamless components without the joints or heat-affected zones inherent in welding, which can introduce vulnerabilities.^[96] This capability is particularly advantageous for medium-volume production runs, where swaging's tooling efficiency lowers per-part costs compared to CNC machining due to minimized setup and waste handling.^[94] Unlike welding, which requires separate assembly steps, swaging maintains material integrity across complex profiles, such as tapered tubes or pointed rods, in a single operation.^[20] Swaging delivers high precision and rapid throughput, attaining surface finishes below 1.6 μm Ra—routinely as low as 0.1 μm in recess swaging setups—while rotary variants can operate at feed rates up to 40 m/min, exceeding the pace of many alternatives.^[97]^[98] This combination ensures consistent dimensional accuracy and small surface roughness without secondary finishing, boosting overall production efficiency.^[96] From an environmental perspective, cold swaging requires significantly lower energy than thermal-intensive processes like extrusion, which demand heating to achieve deformation, thereby reducing overall consumption and emissions in manufacturing.^[99] This efficiency aligns with sustainable practices by optimizing resource use and minimizing the carbon footprint associated with high-heat forming methods.^[100]

Challenges and Considerations

Swaging is primarily applicable to ductile materials, as the process relies on extensive plastic deformation that can lead to cracking or fracture in brittle substances.^[101] The maximum area reduction per pass typically ranges from 10% to 30%, depending on the material and setup, often requiring multiple passes or intermediate annealing steps to achieve substantial overall diameter changes without exceeding the material's workability limits.^[36]^[102] Common defects in swaging include wrinkling or collapse in thin-walled tubes due to compressive instability during deformation, particularly without internal support.^[103] This can be mitigated by employing a mandrel to provide internal reinforcement and maintain tube integrity. Springback, arising from elastic recovery in high-strength alloys, may also distort final dimensions and is often addressed through controlled heat treatment to relieve residual stresses.^[104]^[105] Economically, custom swaging dies for specialized shapes can exceed $500 in cost, driven by precision machining and material requirements, rendering the process less viable for very low-volume production where amortization is challenging.^[106] Safety considerations in manual swaging highlight risks of repetitive strain injuries from prolonged hammering or handling, with OSHA's General Duty Clause requiring employers to address ergonomic hazards through measures like automation integration to reduce injury risks in manufacturing as of 2025.^[107]^[108]

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Jun 9, 2020 · Swaging is a forging process that involves the use of compressive forces to deform and manipulate the shape of a workpiece via a die.
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Mar 22, 2023 · Swaging machines essentially shape or forge the metal part through a series of very rapid blows delivered by rotating hammers and forming dies around a piece ...
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Aug 30, 2024 · What is Swaging? Swaging is a fundamental metalworking process that utilizes compressive forces to shape and deform metal parts or components.
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Jun 21, 2025 · Swaging is a metal forming process in which the material is plastically deformed by hammering, pressing, or forcing it into a die to change ...
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... metalwork, from Middle French souage, ornamental border or molding like a torus on a piece of metalwork : Middle French soue, rope, cord (from Old French ...
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[8]
[PDF] h 7 story - National Park Service
Generally speaking, the blacksmith's' tools universally used were flatters,» set hammers, swages, . swage bl'ocks, fullers, hand hammers and1sledges, punches, ...
[9]
The blacksmith at work: making nails by hand - The Victorian Web
Aug 27, 2014 · A blacksmith hammered a four-sided nail on an anvil, tapering the rod, making a point, and hammering the nail head in a die when white hot.
[10]
Nails and Rivets: Pre-Nineteenth Century
The rivet appears to be swaged and cut from a preformed rod shape. It is one of many associated with the Phoenix. Iron Column structures (1850 to 1895). The ...Missing: 19th | Show results with:19th
[11]
POWER SWAGING
Movement is much more precisely limited by controlling the pressure. For bullet swaging, hydraulic power presses offer significant advantage over air presses.
[12]
https://www.fenn-torin.com/blog/rotary-swaging-applications
[13]
Rotary Swaging Applications From Aerospace to Automotive
Nov 26, 2024 · The advantages of rotary swaging are precision, material integrity, and cost-efficiency, with cold-forming leading to faster production and ...
[14]
Background - Master Swaging
Master Swaging, Inc. was formed around 1960 and incorporated in 1970 as a job shop manufacturing facility catering primarily to the helicopter and heavy ...
[15]
Swaged and Broken Connecting Rod Market | Size, share, status ...
MARKET INSIGHTS. Global Swaged and Broken Connecting Rod market was valued at USD 984 million in 2023 and is projected to reach USD 1,368 million by 2030, ...
[16]
None
### Summary of Swaging from the Document
[17]
Rotary Swaging of Bars and Tubes - ASM Digital Library
This article discusses the applicability of swaging and metal flow during swaging. It describes the types of rotary swaging machines, auxiliary tools, and ...Missing: fundamental | Show results with:fundamental
[18]
Swaging - an overview | ScienceDirect Topics
In swaging, a ridge in one part is formed, using a tool to entrap another part, without forming a molecular bond. The forming can be performed using either a ...<|control11|><|separator|>
[19]
Dimensional Characteristics of Products Using Rotary Swaging ...
Apr 24, 2025 · The dimensional precision of swaged product depends on the percentage reduction of outer diameter and forming speed. The work presented in ...
[20]
https://www.engineeringclicks.com/rotary-swaging-extrusion-swaging/
[21]
Swaging: Rotary and Extrusion - Mechanical Engineering Portal
Sep 8, 2017 · Swage manufacturing can be done at room temperature (called cold swaging) and also at the melting or recrystallization temperature of the work ...
[22]
Swage Blocks - Pieh Tool Company
A swage (or swedge) block is a large, heavy block of cast iron or steel used in smithing with various sized shapes in its face and forms on the sides.
[23]
https://www.global.weir/product-catalogue/swaging-machines/
[24]
ESCO® Swaging Machines - Weir Group
The unique mechanical design of the ESCO® Mark 250 swaging machine leverages a relatively low 2000 PSI hydraulic force to deliver up to 1200 ton…
[25]
https://www.microgroup.com/capabilities/forming/swaging/
[26]
Swaging Methods for Component Forming - MicroGroup
Rotary swaging is used to reduce the diameter of tubes and solids or to forge a tube over another tube. Diameters range from .020″ to 1.0″ for tubing. Overall ...
[27]
Swaging Machines | Swager Dies - Fenn Torin
Swaging can be performed hot or cold, although cold is popular because it hardens most materials. The swaging process also improves grain structure, giving the ...
[28]
[PDF] Swager Safety Guide - AWRF
These dies are properly aligned and centered to swage an oval fitting. BOTH dies are firmly fixed in place to prevent any sideways and lengthwise movement. ...Missing: coolant | Show results with:coolant
[29]
How do I calculate press tonnage for swaging? - The Fabricator
Nov 30, 2015 · The formula to determine the tonnage required to swage the part is: Force = Final flat area x Ultimate tensile strength of copper x 1.2.
[30]
Rotary Swaging - Techniswage
Tolerances on 25mm Dia. Of 0.01mm with finishes of Ra 16u are achievable. What are the main principles of swaging? Rotary swaging, metal tube swaging, tube ...
[31]
[PDF] Rotary Swaging
Rotary swaging is a process for precision forming of tubes, bars or wires. ... Internal: Swaging over a mandrel achieves tolerances of +/-0.01 to +/-0.02 mm, and.
[32]
Material Flow in Infeed Rotary Swaging of Tubes - PMC - NIH
Dec 24, 2020 · Rotary swaging is an incremental precision forging process, which is used to reduce the cross–section of parts with full or hollow sections [1].
[33]
The Process of Rotary Swaging: How Rotary Swagers Work
Jul 10, 2023 · When the rotary swaging machine is on, the hammer blocks and dies form around the workpiece. As the material revolves, hammers and dies will ...Missing: oscillation yoke
[34]
[PDF] Rotary Swaging of Precision Barrels - DTIC
Jun 7, 2025 · The objective of this program was to optimize the relevant process vari- ables and heat treatments for the fabrication of fr-Mo-V,7-62mm, ...
[35]
Structural Phenomena Introduced by Rotary Swaging: A Review - NIH
Jan 18, 2024 · Rotary swaging is an industrially applicable intensive plastic deformation method. Due to its versatility, it is popular, especially in the automotive industry.Missing: 1960s Kegg
[36]
Swaging: Joining parts without heat or cutting - Lafarge & Egge
Hydraulic (or Stationary) Swaging: In this variation, the dies are stationary, and a hydraulic ram forces the workpiece into the dies. This method is often used ...
[37]
Swager and Swaging Machines - Chant Engineering Co. Inc.
Our range of swagers and wire rope press machines have a capacity ranging from 22 tons to 4200 tons. ... pressure limits with a pressure gauge. They are ...Missing: static | Show results with:static
[38]
Effect of rotary swaging on the microstructure and mechanical ...
Sep 18, 2025 · ... diameter of the rods was controlled to reduce by around 0.3–0.4 mm with each pass via adding shims between the swaging mold and hammer. The ...
[39]
Swaging Process Guide - Rapid-Protos
May 5, 2025 · There are two types of swaging techniques: hammer forging and press forging. This process is used to compress or expand metal tubes to insert ...
[40]
Leading Tube Swaging Machine Manufacturers
Tube swaging, also known as rotary swaging or tube end forming, is a cold-working metal forming process that reduces, reshapes, or configures the diameter of ...
[41]
Effect of thermomechanical processing via rotary swaging on grain ...
In the present work, the thermomechanical processing consisting of rotary swaging deformation and annealing treatment was performed to optimize the grain ...
[42]
Structural-phase state and mechanical properties of β titanium alloy ...
Aug 7, 2025 · The study of mechanical properties showed that rotary swaging at 800 °C and subsequent aging at a temperature of 420 °C for 10 h leads to an ...
[43]
Impacts of rotary swaging on the deformation behavior of ...
Jun 9, 2025 · This study compares the hot deformation behavior of Inconel 718 superalloy manufactured by the conventional and 3D-printing technology.
[44]
Effect of Rotary Swaging on the Structure, Mechanical ... - NIH
Dec 22, 2022 · A study of the effect of rotary swaging (RS) on the microstructure and properties of the pre-extruded and pre-quenched Cu-0.5%Cr-0.08%Zr alloy was performed.Missing: suitable | Show results with:suitable
[45]
Metal Properties: Total Elongation | MetalForming Magazine Article
Nov 1, 2022 · Elongation is one measure of ductility, as denoted by the E in the YTE abbreviation. This article discusses elongation at fracture and ...
[46]
Investigation of galling in forming galvanized advanced high ...
Aug 26, 2008 · Galling, a form of adhesive wear, affects the economics of forming advanced high strength steel (AHSS) in automotive stamping since it ...Missing: swaging | Show results with:swaging
[47]
Microstructure and mechanical properties of W-high entropy alloy ...
The W-HEA samples were swaged around 1300°C with the 10%, 15% and 20% of reduction in area. The results show that the strength and hardness of the W-HEA ...
[48]
None
Summary of each segment:
[49]
Heat Swaging – A Specialized Form of Heat Staking in ...
Heat swaging, as a specialized form of heat staking, plays a vital role in thermoplastic assembly. Its ability to create strong, precise, and reliable bonds ...
[50]
Advanced Technology for Staking and Swaging Medical Plastics
Nov 4, 2020 · Ultrasonic swaging or staking employs vibratory energy—also applied through metal tooling—to create frictional heat used to melt and form ...
[51]
Swaged couplers for splicing GFRP reinforcing bars - ScienceDirect
Aug 15, 2023 · This paper focuses on an experimental investigation conducted on splicing No. 4 (13 mm nominal bar diameter) Glass FRP (GFRP) bars using swaged steel couplers.
[52]
Performance Test of Swage Anchorage According to the Insert of ...
The tests revealed that the swage anchor without insert developed about 92% of the tensile strength of the CFRP tendon whereas the swage anchor with metallic ...
[53]
In-Depth Articles - The Tools and Trade Techniques of the Blacksmith
Blacksmiths used tools for hearth, anvil, and shoeing. They used charcoal iron, drawing out, welding, and joining with riveting, collaring, and pinning.Missing: industrialized mass
[54]
The Blacksmith in Eighteenth-Century Williamsburg, by Thomas K ...
Nov 20, 2018 · The hardie hole (also called the swage hole) is designed to take the square shanks of a variety of special-purpose bottom tools—which make their ...
[55]
Saw-tooth swage - US309534A - Google Patents
JAMES E. EMERSON, OF BEAVER FALLS, PENNSYLVANIA. SAW-TOOTH SWAG E. .IZBZCIFICATION forming part of Letters Patent NO. 309,534, dated December 23, 1884.
[56]
US2800039A - Machines for swaging saw teeth and the like
The saw tooth swaging machine of the present invention has for its object to provide shoes between which the saw tooth to be treated is firmly clamped, an anvil ...
[57]
https://ntrs.nasa.gov/api/citations/20080004865/downloads/20080004865.pdf
[58]
The Art and History of Brass Musical Instruments
Fixing copper and brass instruments is an art passed down in generations. Vincent Dell'Osa, Jr., well-known as one of the last of the brass masters in ...
[59]
Medieval Blacksmith
Swages - Tools, variously shaped or grooved on the end or face, used by ... weapons and armor of lords, knights and men-at-arms; City of Town Blacksmith ...
[60]
Arms and Armor in Medieval Europe - The Metropolitan Museum of Art
Oct 1, 2001 · European warriors of the early Middle Ages used both indigenous forms of military equipment and arms and armor derived from late Roman types.
[61]
[PDF] 20080004865.pdf - NASA Technical Reports Server (NTRS)
Oct 1, 1996 · Many metals and alloys of those metals exhibit the requisite softness, including silver, gold, tin, platinum, indium, rhodium and cadmium.
[62]
[PDF] PLUMBING DICTIONARY - ASSE International
swedge joint, or swage joint (swedge joint, or swage joint) the connection of pipe or fitting ends by expanding the bore of one so that the mating fitting.
[63]
[PDF] Seamless Refined Copper Pipe and Tube from Vietnam - usitc
ASTM‐B280, ASTM‐B302, ASTM‐B306, ASTM‐B359, ASTM‐B743, ASTM‐. B819, and ASTM ... 29 Swaged ends are deformed so the copper tube can mate with another coper tube.
[64]
[PDF] Wire Rope End Connections - Roland Verreet
The minimum requirements for asymmetrical wedge sockets are standardised in EN. 13411-6, and a great number of different executions can be found on the market.<|separator|>
[65]
[PDF] Lockbolts, Structural Blind Fasteners and Tooling
1 Wide bearing collar and head spread load to ensure structural integrity. 2 Initial long length of fastener enables pull-out of large gaps. 3 Excellent gap ...
[66]
[PDF] Copper Tube Handbook
ASTM B 306. - Drain, waste, vent - HVAC - Solar. Straight lengths: 1¼ inch to 8 inch. 20 ft. N/A. ACR. Blue. ASTM B 280 - Air conditioning - Refrigeration - ...
[67]
Introduction to Swage Assembly | Mill-Max Mfg. Corp.
Swage assembly is a method of mechanically fastening pin terminals to a circuit board, similar in style to riveting. It is commonly used with solder terminals ...
[68]
Swaging & Crimping: What's the Difference? - Fenn Torin
Aug 5, 2020 · Both swaging and crimping are “chipless” methods to metal forming, they displace the material by sheer force rather than cutting it away, ...
[69]
Good In A Pinch: The Physics Of Crimped Connections - Hackaday
Feb 9, 2017 · The result is cold-welded, gas-tight junctions between the strands and the crimp connector. Most crimping tooling also takes care of strain ...
[70]
Swaging machine for cylindrical (18650) lithium-ion secondary ...
Machine to swage external can of cylindrical lithium-ion batteries etc.
[71]
High-Precision Integration of Optical Sensors into Metallic Tubes ...
By utilizing a mandrel, the disc is positioned inside the tube and fixed within during the rotary swaging process. In this case, the stiffness ratio between the ...
[72]
Swaging 101 - Bead Electronics
Jul 1, 2013 · Swaging is a cold-formed manufacturing process that involves using a tool, such as a die, to bend cold metal to a required shape.
[73]
[PDF] The Bead Electronics Swaging Process: - From Concept to Reality
Swaging is a high-speed, virtually scrapless process where metal is moved and not removed. It's capable of producing small, tubular metal components that are ...<|separator|>
[74]
Archived | Firearms Examiner Training | Button Swaged
Jul 10, 2023 · Button-swaged rifling is one of two forms of swaged or cold-formed rifling. Metal is moved, not removed, to produce the pattern of lands and grooves.
[75]
Rifling Types 101 - Vortakt Barrel Works
Button rifling is a cold forming process that swages rifling in the barrel ... swaging performed when button rifling. A unique tool is needed for every ...
[76]
Button Rifling - AFTE
A process in which grooves are pressed into the interior of the barrel using a tool called a button. The button is made from solid carbide.
[77]
[PDF] MIL-STD-171F - American Tinning & Galvanizing
May 31, 2011 · MIL-STD-171F establishes finish system codes for metal and wood surfaces, linking specifications for finishing and treating surfaces.Missing: swaging | Show results with:swaging
[78]
[PDF] Forming Nitinol - Confluent Medical Technologies
A length of annealed wire is cold worked by rotary swaging to a reduced diameter. The undefonned end is hot coined. This section will be converted into a hinge ...
[79]
Tube Swaging and Forming for Medical Devices - IMC Intertech
Precision Swaging for Medical Devices. Swaging is a cold forming process that involves reducing the diameter of a tube by forcing it through a die. As a result, ...
[80]
ENDOSCOPY - Minitubes
Choice of materials, because stainless steel is not always the best answer ... A variety of fabrication processes: Swiss turning, bending, swaging, flattening, ...
[81]
The Effect of Cold Swaging Deformation on the Microstructures and ...
Aug 27, 2020 · The solution-treated alloy bar shows superior cold workability in the swaging process. The plasticity remains at a moderate level because the ...
[82]
Automotive Tube Applications in Exhaust, Fuel, And Brake Systems
Sep 7, 2025 · The Role of Exhaust Tubes. Exhaust systems channel harmful gases produced during combustion away from the engine and safely out of the vehicle.1. Automotive Tubes In... · 2. Automotive Tubes In Fuel... · 3. Automotive Tubes In Brake...
[83]
The Role of Swaging in Producing Durable Automotive Components ...
Jun 12, 2025 · Swaging is a cold-forming process used to reduce or shape metal by applying high-pressure force through a set of dies or rollers.Missing: roll battery housings
[84]
Swaged Tube Products - Explained - Woodsage
Swaging: The swaging process involves reducing the diameter of the tube while increasing its length. This is accomplished using specialized machinery known as ...Missing: construction | Show results with:construction
[85]
Tube Swaging Service in the Real World: 5 Uses You'll Actually See ...
Oct 2, 2025 · Swaging is used to produce fuel lines, brake lines, and other fluid transfer components. These connections must endure extreme conditions and ...Missing: exhaust roll cage battery
[86]
EV Battery Mass Reduction Through Materials and Design - XRAY
Sep 12, 2025 · Fiber-Reinforced Thermoplastic and Polymer-Based Battery Casings ... Pressed-steel trays with welded ribs can add 60-70 kg to a mid-size EV.Fiber-Reinforced... · Cell-to-Pack and Monolithic... · Embedded Cooling, Heating...
[87]
Tube Expanders and Swagers - Huth Ben-Pearson
Tube Expanders & Swagers. Swage, expand or reduce tubing anywhere for flexible creative affordable tube connecting.
[88]
[PDF] Aeroquip® Rynglok® Tube Repair System - Eaton
The Rynglok system is for aerospace hydraulic tubing repair, approved by major manufacturers, works with all tubes, and simplifies repair with one titanium ...
[89]
[PDF] Globe Engineering Specification Master List
Proof Pressure Testing of Welded Titanium Hydraulic System. Lines. LES1389. A ... Pressure Testing, Aircraft, Hydrostatic and Pneumatic, Safety.
[90]
Trends in electric car markets – Global EV Outlook 2025 - IEA
While sales volumes may be impacted by economic and policy uncertainties, more than one in four cars sold in 2025 is expected to be electric. Building on ...Missing: frames drone<|control11|><|separator|>
[91]
Heavy Lift Drones in 2025: Navigating a New Era of Innovation ...
As 2025 unfolds, heavy-lift drones are on the cusp of unprecedented evolution, driven by technological breakthroughs and a shifting regulatory landscape.
[92]
[PDF] Power Swaging
The reduction ratio from input to output of our wheel system must take the 1725 RPM of the motor down to 40.431 RPM for the cam wheel that drives the ram. This ...<|control11|><|separator|>
[93]
Overcome Steel Framing Fabrication with Swaging in Roll Forming ...
Oct 8, 2025 · Swaging is a controlled deformation process that reduces or offsets the profile of a cold-formed steel section at specific points. This can ...
[94]
https://beadelectronics.com/blog/swaging-vs.-machining
[95]
[PDF] A portable and efficient swaging device saves the Navy time, money
The final product included a high-pressure hydraulic system which minimizes the actuator size, an efficient swaging schedule which reduces the force required ...
[96]
What Is a Swage Nut? | OneMonroe
Dec 4, 2019 · Swage nuts allow for a strong and permanent anchor thanks to their ability to swage the sheet metal in which they are installed.
[97]
https://strecon.com/felss-rotary-swaging
[98]
Insert & Swage Nuts | Fastener Innovation Technology
A global leader in the production of specialist fasteners, such as inserts and swage nuts, designed to withstand the stresses of the aerospace and defense ...
[99]
Swaging vs. Machining: Choosing the Right Method for Custom ...
Sep 24, 2024 · Precision and Tolerances: Swaging is highly precise for certain shapes and pin geometries. Machining also offers extremely tight tolerances ...Missing: control | Show results with:control
[100]
Swaging - an overview | ScienceDirect Topics
Swaging is defined as a manufacturing process that involves shaping materials through mechanical deformation, utilized in the near-term development of accident ...
[101]
Felss Rotary Swaging Machine - STRECON
High-precision swaging is achievable with the method of recess swaging with a mean value up to Ra 0,1 µm in surface roughness. For in-feed swaging, the ...Missing: finish | Show results with:finish
[102]
Advantages of Swaging Machines
Jul 12, 2024 · Swaging machines promote material conservation by shaping metal without removing material. This approach not only lowers material costs but also ...
[103]
Why is swaging used in metal forming? | Tanfield
Jun 14, 2024 · Swaging has been a fundamental technique in metalworking ... ancient civilisations that used primitive tools to shape metals for various purposes.
[104]
[PDF] Bulk Deformation Processes 3.1 3.1 Introduction Mechanical ...
Ductility of the metal is decreased during the process. Only ductile metals can be shaped through the cold working. Over-working of metal result in brittleness ...Missing: challenges | Show results with:challenges
[105]
[PDF] EFFECTS OF ROTARY SWAGING, WIRE DRAWING AND THEIR ...
The total area reduction was. 81 %. Values of area reduction per pass were 12–20 %. The rotary-swaging process was carried out in an HMP. R4-4 ...
[106]
Swaging Wire Drawing Homework Help, Assignment Help, Online ...
In this process, the diameter of a rod or a tube is reduced by forcing it into a confining die. A set of reciprocation dies provides radial blows to cause the ...
[107]
[PDF] PRECISION STEEL TUBE HANDBOOK - ME Racing
In any case, the tube is not supported from the inside by the mandrel, causing thin walled tubes to wrinkle, collapse or to assume an excessive oval-shape.<|separator|>
[108]
Role of mandrel in NC precision bending process of thin-walled tube
The mandrel is of importance to improving both the forming limit and the bending quality. So the research on the role of the mandrel is of great significance in ...
[109]
Correcting Springback - AHSS Guidelines
Springback correction can take many forms. The first approach is to apply an additional process that changes the elastic strains to a less damaging form.Missing: swaging | Show results with:swaging
[110]
9mm custom Swaging complete die set | brass2bullets - Wix.com
9mm custom Swaging complete die set. $500.00Price. Quantity* ... Dies are made from 4140 steel, dies are heat treated and rams are hardened. Dies are ...
[111]
Workplace Ergonomics 2025: OSHA Guidance for Reducing Strain ...
May 13, 2025 · Workplace Ergonomics 2025: OSHA guidance to reduce strain & MSDs. Learn essential tips for a healthier, safer workspace.Ergonomics For Office... · Ergonomics For Manual... · Ergonomics In The Industrial...<|control11|><|separator|>
[112]
Robotics and Automated Assembly relieve repetitive strain injury in ...
Robotics and automation offer positive benefits to workers, not the least of which is a safer, easier, and more comfortable work environment.Missing: swaging | Show results with:swaging