The DMC Permaswage System

1
The DMC Permaswage System

• Steve Mack
• Designed Metal Connections
• Manager Swage Products

2
Todays Presentation Elements

• Background of DMC
• Background of DMC Permaswage
• Tube Repair Types
• Basic Repair Sequence
• Demonstration of the DMC Permaswage system

3
The DMC Background

• Company started in Los Angeles in 1938
  manufacturing hydraulic fittings for the U.S. war
  effort as a Deutsch Company
• In Jan 2005, Gardena and France purchased in MBO
  transaction
• Manufacturing facilities in Gardena, CA and
  Paris, France
• Continues as a US based company
• DMC manufactures mechanically attached connectors
  for
• Aerospace
• Military
• Commercial (large transport, regional jets and
  business jets)
• Electric utility substations

4
DMC Permaswage System Profile

• DMC Permaswage fittings are radial compressed
  (mechanically attached) onto compatible tubing to
  provide a permanent joint with metal to metal
  sealing. The fitting to tube relationship is
  effected by differential springback caused by the
  annealed condition of the connector, relative to
  the tubing.

5
Typical Sectioned Union Attributes

• Metal to metal contact - Silicone back up seals
• 6 to 7 swage deformation
• Minimal pressure drop
• Negligible restricted flow
• 360 Deg. Swage Min. Ovaltity to Max Extent
  Possible
• Gradual taper
• Float tolerance
• Eases installation

6
Permaswage System History

• Technique developed by Douglas Aircraft Company
  in mid 1960s
• Deutsch acquired license in early 1970s
• Develops and trademarks Permaswage
• Installation tooling improvements
• Configuration development
• DMC purchases assets and all contractual
  obligations from Deutsch Metal Components in
• 1-05

7
System Features and Benefits

• Metal to metal seal
• Silicone back up seal for tube surface flaws
• Fitting geometry includes gradual taper
• Provides optimum flexure performance
• Repeatable, consistent process
• Controlled dimensions
• Simplified, lighter weight tooling
• Allows for use in tight tube clusters

8
System Tube and Fitting Compatibility

• 21-6-9 DMC Permaswage fittings
• Compatible with 21-6-9 tubing (per AMS 55611)
• 304 1/8 CRES (per AMS 5564/55661) (repair use)
• 3 Al 2.5 Titanium (per AMS 49442)
• 6061 T6 Aluminum (per AMS 40833) - repair use

9
System Tube and Fitting Compatibility

• 6061 T6 Aluminum Deutsch Permaswage fittings
• Compatible with 6061T6 tube material (per AMS
  40833)

10
System Tube and Fitting Compatibility

• 3Al 2.5 Titanium DMC Permaswage fittings
• Compatible with 3Al 2.5 CWSR Titanium tubing
  (per AMS 49442)

11
System Operating Pressures

• 21-6-9 CRES Permaswage fittings - up to 3000 PSI
• 6061 T6 Al Permaswage fittings - up to 1500 PSI
• 3Al 2.5 Ti Permaswage fittings - up to 4000 PSI
  (DNR/DMD)

Note All rated at -65 degrees F to 275
degrees F
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Basic Repair Procedure

• Always Prevent Preloading of Tubes
• Loosen tube clamps as necessary
• Maximum of 1/2 inch offset per 12 inches of tube
  from union to clamp
• Always Check Tube Condition
• Do the finger nail checkif you can feel its
  excessive, if not its acceptable!

13
Basic Repair Procedure

• Select correct tube cutter
• Tighten cutter wheel 1/4 turn with hex key

14
Basic Repair Procedure

• Select correct deburring tool
• Insert proper stem assembly into deburring tool

15
Basic Repair Procedure

• To begin the deburring procedure
• Push in (depress) RED plunger button
• Insert stem assembly into ID of tube
• Release Red plunger button
• Rotate deburring tool withdraw plunger

16
Basic Repair Procedure

• To complete the deburring procedure
• Without depressing the RED plunger button
• Withdraw stem assembly from tube

17
Basic Repair Procedure

• Select correct insertion marking tool
• Apply witness mark in window

18
Basic Repair Procedure
Lower die holder/block snaps into place on the
power unit. The head assembly is designed so
that it slides onto the power unit with the
knurled side of the head assembly matching with
the knurled side of the power unit. The swage
dies must be bevel-mated and the bevel side of
the swage dies are positioned towards the center
of the fitting during swaging.
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Basic Repair Procedure

• Select correct swaging tool
• Assemble tool around end to be swaged
• Knurled side, click sound, ends flush

20
Basic Repair Procedure

• Position DMC Permaswage fitting on insertion mark

21
Basic Repair Procedure

• Observe the Minimum, Maximum, and Optimum
  fitting position in relation to insertion mark

22
Basic Repair Procedure

• Position tool on the fitting end
• Beveled end of die toward fitting center
• Slide swage tool until fitting end is flush with
  fitting stop - Actuate 10ksi pump (/- 250 psi)

23
Basic Repair Procedure

• Remove swage tool
• Inspect visibility of witness mark
• Inspect length of swage
• Use go-no-go gage - rotate again 90 degrees

24
Tube Repair Techniques

• Type 1 Small hole/short crack

Make one or two cuts to remove damaged tube
section not to exceed .30. Use compatible DMC
Permaswage union fitting
25
Tube Repair Techniques

• Type 2 Longitudinal tube crack exceeds .30

Make two cuts to remove damaged tube section
that exceeds .30. Use two compatible DMC
Permaswage union fittings and tubing to recreate
removed tube section. Ensure proper fit before
swaging.
26
Tube Repair Techniques

• Type 3 Leaking elbow, tee or cross

Remove damaged fitting. Recreate section by using
DMC Permaswage shape fitting and union fittings.
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Tube Repair Techniques

• Type 4a Leaking flared sleeve

Fitting Length (/- .010) -3 .282 -4 .275 .5 .27
5 -6 .226 -8 .243 -10 .204 -12 .234 -16 1.647
-20 1.035 -24 1.045
DMC Permaswage allows for duplication of
original OAL with flared sleeves, by using the
cut-off length, from end of the flared tube, in
the accompanying table.
28
Tube Repair Techniques

• Type 4b Leaking flareless sleeve

Fitting Length (/- .010) -3 .432 -4 .541 -5 .55
7 -6 .508 -8 .588 -10 .600 -12 .628 -16 2.110
-20 1.456 -24 1.504
DMC Permaswage allows for duplication of original
OAL with flareless sleeves, by using the
cut-off length, from end of the tube, in the
accompanying table.
29
Recommended Tube Wall Thicknesses
30
Minimum Distance Before Tube Bends for
Installation
31
DMC Lightweight Tooling

• Kits available in various size configurations
• Designed though FEA, manufactured from super
  alloys
• Factory warranty for two years
• Excludes swage dies
• Factory training upon purchase, no additional
  charge

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The DMC Permaswage System

• Steve Mack
• Deutsch Metal Components
• Manager, Swage Products