What is Hydraulic Swaging?

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A coil of G316 1x19 Stainless Steel Wire Rope
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A coil of G316 1x19 Stainless Steel Wire Rope

Hydraulically swaged Fittings

This guide will deal with the process of pressure welding  G316 Stainless Steel fittings onto Stainless Steel Wire Rope.

The process and concepts applies to all diameters and structures of Stainless Steel Wire Rope (albeit, wire rope with a diameter larger than 4.0mm using hydraulically swaged fittings - should probably be handled / swaged by a professional as the required tools are quite specialized - and large). And while all structures (7x7, 7x19, 1x19) will work - we STRONGLY recommend using 1x19.
Two Compressive Spot Welds from a Hydraulic Hand Swaging Tool
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Two Compressive Spot Welds from a Hydraulic Hand Swaging Tool

How to Swage Fittings


"How do I connect the fittings to the wire?" is actually a good question - and not intuitive if you are not already familiar with the process of swaging (also known as pressing, crimping...)

You actually pressure weld the wire into the fittings. Either with a 'seam weld' or a series of 'spot welds' (two suffices for architecture work)

The process is that you insert the wire into the fittings and then swage/compress the fittings hard enough to have them weld into the wire at the compression points.  Clearly, you need a tool with some oomph... (we sell such a tool) pictured above.

Our tool has a quick open "C" gate which allows very fast application of the tool, it has been factory set at the proper pressure for swaging stainless steel wire (both 3.2mm and 4.0mm) to the appropriate fittings, it incorporates a safety valve so that the tool does not break by experiencing excessive unregulated pressure.  There are other tools out there and please inspect them.  

We strongly recommend that the tool you use delivers adequate pressure to achieve the 'spot welds' necessary for proper attachment, that the tool has a safety valve (or a gauge) to prevent self destruction, that there are replaceable dies (and a source of replacement dies), and your vendor has a history of selling and supporting the tools they sell over a course of years.

At Low Cost Wire, we are here to deliver an excellent experience offering advice, service, and excellent prices for both the Professional Tradesperson, the weekend DIY guy/gal, and the inventive individualist / artist / charity.
So grab the fittings, buy/borrow/rent a swager as described, give LCW a call for the more detailed advice - and have a GREAT weekend. 

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