SAE AS 6116A-2016 Aluminum Fittings Axially Swaged Tube with Flareless Separable Fluid System Up to 1500 psi (10340 kPa) Maximum Specification for.pdf

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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 2016 SAE InternationalAll rights reserved. No part of this publi

3、cation 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 (out

4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on thisTechnical Report, please visithttp:/standards.sae.org/AS6116AAEROSPACESTANDARDAS6116 REV. AIssued 2011-11Revised 2016-10Superseding AS6116Aluminum Fittings, Axia

5、lly Swaged Tube with Flareless Separable, Fluid SystemUp to 1500 psi (10340 kPa) Maximum,Specification forRATIONALEChange operating pressure requirements of size 24 from 500 to 600 psi (including proof and burst pressures), add vibration curves requirements to Tables 10 and 11 for size 24, add the n

6、ew configuration part number AS6323 to Table 12, and add size 24 dimensions to some of the standards configurations.1. SCOPEThis SAE Aerospace Standard (AS) establishes the requirements for externally swaged aluminum tube fittings on aluminum tubing with flareless separable fitting ends for use in h

7、ydraulic supply and return aerospace fluid systems including pneumatic, coolants, and fire extinguishers up to a maximum operating pressure of 1500 psig (10340 kPa) and a maximum operating temperature range of -65 to +225 F (-54 to +107 C). This specification covers a common aluminum fitting that ma

8、y be used for a range of operating pressures up to 1500 psi with different tubing materials and tubing wall thicknesses, and is assembled with the same tooling in accordance with AS6124. Table 12 shows applicable aerospace fitting part number standard and tubing materials and operating pressures. 2.

9、 APPLICABLE DOCUMENTSThe 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 shall be the issue in effect on the date of the purchase order. In theevent of conflict between th

10、e 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 exemption has been obtained.2.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, W

11、arrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.AMS2700 Passivation of Corrosion Resistant SteelsAMS-QQ-A-225/8 Aluminum Alloy 6061, Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold FinishedAMS-QQ-A-225/9 Aluminum Alloy 7075

12、, Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold FinishedAMS-QQ-A-225/6 Aluminum Alloy, 2024, Bar, Rod, and Wire; Rolled, Drawn, or Cold FinishedSAE INTERNATIONAL AS6116A Page 2 of 39AMS4083 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T

13、6) Solution and Precipitation Heat TreatedAMS4081 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T4) Solution Heat Treated and Naturally AgedAMS4071 Aluminum Alloy, Drawn, Round, Seamless Hydraulic Tubing 2.5Mg 0.25Cr (5052-O) AnnealedAMS4070 Aluminum

14、 Alloy, Drawn, Round Seamless Tubing 2.5Mg - 0.25Cr (5052-O) AnnealedAMS2477 Conversion Coating for Aluminum Alloys Low Electrical Resistance CoatingAS478 Identification Marking MethodsAS603 Impulse Testing of Hydraulic Hose, Tubing, and Fitting AssembliesARP1185 Flexure Testing of Hydraulic Tubing

15、Joints and FittingsAS1241 Fire Resistant Phosphate Ester Hydraulic Fluid for AircraftAS1376 Alternate Dimensions, Center Body Section, Shape Fluid Fitting, Design StandardARP4784 Definitions and Limits, Metal Material Defects and Surface and Edge Features, Fluid Couplings, Fittings and Hose EndsAS33

16、514 Fitting End, Standard Dimensions for Flareless Tube Connection and Gasket SealAS5863 Fitting End, 24 Cone, Flareless, Fluid Connection, Design StandardAS6115 Fitting Assembly, Straight, Male Flareless, Axially Swaged, Hydraulic, Up to 1500 psiAS6117 Fitting Assembly, Union, Axially Swaged, Hydra

17、ulic, Up to 1500 psiAS6118 Fitting Assembly, Straight, Female Flareless, Axially Swaged, Hydraulic, Up to 1500 psiAS6119 Fitting Assembly, Elbow, 90, Axially Swaged, Hydraulic, Up to 1500 psiAS6120 Fitting Assembly, Elbow, 45, Axially Swaged, Hydraulic, Up to 1500 psiAS6121 Fitting Assembly, Tee, Ax

18、ially Swaged, Hydraulic, Up to 1500 psiAS6122 Fitting Assembly, Straight, Bulkhead, Flareless, Axially Swaged, Hydraulic, Up to 1500 psiAS6123 Fitting Assembly, Tee, Axially Swaged on the Run, Male Flareless on the Side, Hydraulic, Up to 1500 psi AS6124 Aluminum Axially Swaged Fittings, Installation

19、 and Inspection ProcedureAS6158 Fitting Assembly, Tee, Axially Swaged on the Run, Female Flareless on the Side, Hydraulic, Up to 1500 psiAS6159 Fitting Assembly, Tee, Axially Swaged to Female Flareless on the Run, Male Flareless on the Side, Hydraulic, Up to 1500 psiAS6445 Fitting Assembly, Tee, Axi

20、ally Swaged on the Run, Bulkhead Flareless on the Side, Hydraulic, Up to 1500 psiSAE INTERNATIONAL AS6116A Page 3 of 39AS6446 Fitting Assembly, Tee, Axially Swaged on the Run, Internal Port End on the Side, Hydraulic, Up to 1500 psiAS6457 Fitting Assembly, Tee, Axially Swaged to Male Flareless on th

21、e Run, Male Flareless on the Side, Hydraulic, Up to 1500 psiAS6458 Fitting Assembly, Tee, Axially Swaged to Female Flareless on the Run, Female Flareless on the Side, Hydraulic, Up to 1500 psiAS6192 Fitting Assembly, Elbow, 90, Axially Swaged, Female Flareless, Hydraulic, Up to 1500 psiAS6193 Fittin

22、g Assembly, Elbow, 45, Axially Swaged, Female Flareless, Hydraulic, Up to 1500 psiAS6194 Fitting Assembly, Tee, Axially Swaged, Female Flareless on the Run, Axially Swaged on the Side, Hydraulic, Up to 1500 psiAS6195 Fitting Assembly, Tee, Male Flareless, Bulkhead Flareless on the Run, Axially Swage

23、d on the Side,Hydraulic, Up to 1500 psiAS6323 Fitting Assembly, Extended Union, Axially Swaged, Hydraulic, Up to 1500 psiAS7003 Nadcap Program RequirementsAS7112 National Aerospace and Defense Contractors Accreditation Program Requirements for Fluid System ComponentsAS85449/2 Clamp Assembly, Saddle

24、Type, Cushioned, Phosphate Ester Fluid ResistantAS85449/3 Clamp Assembly, Saddle Type, Cushioned, High TemperatureARP5416 Aircraft Lightning Test MethodsARP5412 Aircraft Lightning Environment and Related Test Waveforms2.2 ASME PublicationsAvailable from ASME, P.O. Box 2900, 22 Law Drive, Fairfield,

25、NJ 07007-2900, Tel: 800-843-2763 (U.S./Canada), 001-800-843-2763 (Mexico), 973-882-1170 (outside North America), www.asme.org.ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)2.3 ASTM PublicationsAvailable from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohock

26、en, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM A580 Standard Specification for Stainless Steel WireASTM E8 Tension Testing for Metallic MaterialsASTM E499 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in the Detector Probe ModeASTM D1193 Standard Specification fo

27、r Reagent Water ASTM D1655 Standard Specification for Aviation Turbine FuelsSAE INTERNATIONAL AS6116A Page 4 of 392.4 ISO PublicationsCopies of these documents are available online at http:/webstore.ansi.org/.ISO 7137 Environmental Conditions and Test Procedures for Airborne Equipment2.5 PRI Publica

28、tionsAvailable from Performance Review Institute, 161 Thorn Hill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616, www.pri-network.org.PD2001 Qualified Product Management Council Procedures for Qualified Products GroupPD2101 Aerospace Quality Assurance, Product Standard, Qualification Procedures,

29、Fluid Systems2.6 RTCA PublicationsAvailable from RTCA, Inc., 1150 18th Street, NW, Suite 910, Washington, DC 20036, Tel: 202-833-9339, www.rtca.org.RTCA/DO-160 Environmental Conditions and Test Procedures for Airborne Equipment2.7 U.S. Government PublicationsCopies of these documents are available o

30、nline at http:/quicksearch.dla.mil.MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8 + 100MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance (Inactive for New Design as of 2

31、9 March 1996) MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon BaseMIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircraft and MissileMIL-A-8625 Anodic Coatings for Aluminum and Aluminum AlloysMIL-DTL-5541 Chemical Conversion Coating o

32、n Aluminum and Aluminum AlloysMIL-PRF-16173 Corrosion Preventive Compound, Solvent Cutback, Cold-ApplicationMIL-PRF-23377 Primer Coatings: Epoxy, High-SolidsMIL-HDBK-831 Preparation of Test ReportsSAE INTERNATIONAL AS6116A Page 5 of 393. TECHNICAL REQUIREMENTS3.1 QualificationFittings supplied in ac

33、cordance with this document shall be representative of products which have been subjected to and which have successfully passed the qualification tests specified in this standard.3.1.1 Manufacturer QualificationA manufacturer producing a product in conformance to this procurement specification shall

34、 be accredited in accordance with the requirements of PD2101, AS7003, and AS7112, and shall be listed in a Performance Review Institute (PRI) Qualified Manufacturers List (QML).3.1.2 Product QualificationAll products shall conform to the requirements of this procurement specification and shall be ap

35、proved in accordance with the requirements of PD2001 and PD2101 for listing in a Performance Review Institute (PRI) Qualified Parts List (QPL).3.2 MaterialsThe fitting materials shall be uniform in quality, free from defects, consistent with good manufacturing practices and shall conform to the appl

36、icable specifications and the requirements specified herein.3.2.1 Bars and ForgingsAMS-QQ-A-225/8 Aluminum Alloy 6061 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold FinishedAMS-QQ-A-225/9 Aluminum Alloy 7075 Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished3.2.2 WireAMS

37、5637 Steel, Corrosion Resistant, Bars and Wire 18Cr - 9.0Ni (SAE 30302) Solution Heat Treated and Cold Drawn 125 ksi (862 MPa) Tensile StrengthAMS5685 Steel, Corrosion Resistant, Safety Wire, 18Cr - 11.5Ni (SAE 30305), Solution Heat Treated, Cold FinishedAMS-QQ-A-225/6 Aluminum Alloy, 2024, Bar, Rod

38、, and Wire; Rolled, Drawn, or Cold FinishedASTM A580 Standard Specification for Stainless Steel Wire3.2.3 Tube RequirementsAluminum tubing shall meet the requirements of AMS4083, AMS4071, or AMS4070 as defined per Tables 1A and 1B.3.3 Design and dimensions shall be such that fittings will meet all r

39、equirements of this specification and the associated aerospace standard part drawings.SAE INTERNATIONAL AS6116A Page 6 of 393.4 Fabrication3.4.1 Fluid Passages3.4.1.1 Drill OffsetIn the run, tees where the fluid passage is bored from each end, the offset between the bores at the meeting point shall

40、not exceed 0.015 inch. A sphere with a 0.020 smaller diameter shall be capable of traversing the bore intersection. The cross sectional area of the bore junction of angle fittings shall not be less than the cross-sectional area of the smaller passage.The mismatch in straight couplings shall be contr

41、olled such that a maximum OD tube (nominal + tolerance) will pass through the entire fitting.3.4.1.2 Maximum Reduction of Cross Section in Swaged Area The cross-sectional area of the swaged fitting/tubing joint shall not be reduced by more than 12% of the minimum tube internal diameter prior to swag

42、e. A ball whose diameter is not less than 0.87 times the minimum tube internal diameter shall pass through the swaged area of the fitting/tubing joint.3.4.2 Finish3.4.2.1 Aluminum: As specified in the associated aerospace standard part drawings.CRES: Passivation per AMS27003.4.2.2 Coating ColorThe r

43、ing shall be anodized (Green) similar to No. 14187, 14193, or 14223 of FED-STD-595. The fitting bore shall be colored green with a pigmented polytetrafluoroethylene (PTFE) or fluid resistant paint.3.4.2.3 Dry LubeA lead free solid film lubricant per AS5272 Type I or III, or per AS6449 shall be used

44、to facilitate assembly process.3.4.2.4 Backup SealingThe fitting bore shall be enforced with heat cured elastomeric Dimethyl siloxane as an additional backup seal. The elastomeric compound shall be cured at a temperature that does not have adverse effect on the fitting material properties, and shall

45、 have a Durometer of (54A-60A) and tensile strength of 800 to 1150 psi (5516 to 7930 kPa). The elastomericcompound shall be filled and completely bonded in the internal grooves of the fitting ends. The bonded elastomeric seal level shall be determined using the following “Go Gage” values below (e.g.

46、, a plug gage with a diameter equals to the maximum tube diameter (Go Gage) shall be possible to pass through the fitting/ring assembly prior to swage with some friction but not causing any damage to the seal). A minimum of two grooves (fitting end sizes -05 and larger) shall be filled with elastome

47、ric Dimethyl siloxane compound. Smaller fitting end sizes shall have a minimum of one groove filled with the sealing compound.Table 1Dash Size Tube Size(Inch)Go GageDiameter (inch)1/4 0.250 0.25305/16 0.3125 0.31553/8 0.375 0.37801/2 0.500 0.50305/8 0.625 0.62903/4 0.750 0.75401 1.000 1.00401-1/4 1.

48、250 1.25501-1/2 1.500 1.5050SAE INTERNATIONAL AS6116A Page 7 of 393.4.2.5 Aluminum Tubing Test SamplesAluminum tubing used for impulse, corrosion conditioning, and stress corrosion (including electrical conductivity) tests as defined in Table 6 do require the application of one coat (0.0005 to 0.000

49、9 inch thick) of fluid resistant epoxy structural primer per MIL-PRF-23377, Type II, Class C1, or C2 on the entire outside of the tubing excluding the tubing area to be swaged with the fitting (up to the maximum insertion depth). Primer and touch-up of tubing after swage in the tube-fitting interface is allowed. For maximum corrosion protection the tubing shall be entirely chemical conversion coated (OD and ID) per MIL-DTL-554