AA

AEROSPACE ENGINEERING BULLETIN

FORMED METAL
TUBING
172B
Supersedes AA-172A

ENGINEERED SYSTEMS GROUP

DESIGN RULE BOOK
FOR FORMED
METAL TUBING

AEROQUIP CORPORATION
Engineered Systems Group
300 S. East Ave.,
Jackson, Michigan 49203-1972
Phone: (517) 787-8121, Fax: (517) 787-5758
Internet : http://www.aeroquip.com
 ENGINEERED SYSTEMS GROUP
DESIGN RULE BOOK FOR FORMED METAL TUBING

TABLE OF CONTENTS
Paragraph Page

1.0 PURPOSE 1
1.1 GENERAL 1
1.2 FORMING TUBING 1
1.3 COST FACTORS 1

2.0 APPLICABLE DOCUMENTS 3

3.0 EQUIPMENT and TOOLING 3
4.0 MATERIALS and SPECIFICATIONS 3
5.0 TUBING SIZES, WALL THICKNESS AND WEIGHT 4
5.1 321 CORROSION RESISTANT STEEL (CRES) and ALUMINUM TUBING FOR 4
WELDED APPLICATIONS
5.2 321 CORROSION RESISTANT STEEL (CRES), CARBON STEEL and 4
ALUMINUM TUBING FOR BRAZED APPLICATIONS
5.3 TITANIUM TUBING 5
5.4 21-6-9 CRES TUBING (SPECIAL) 5
5.5 INCONEL 625 and INCONEL 718 TUBING (SPECIAL) 5

6.0 DESIGN PARAMETERS 6

6.1 BEND RADII 6
6.2 STRAIGHT LENGTHS 6
6.2.1 Minimum Straight Lengths Between Bends 6
6.2.2 Minimum Straight Length Required From End of Tube To Center of 7
First Bend Radius (Tangent Point) For The Following
6.2.2.1 Installation of An Aeroquip Rynglok Fitting 7
6.2.2.2 Single Flared Tube End 7
6.2.2.3 Beaded Tube End 7
6.2.2.4 Weld Joint 8
6.2.2.5 Braze Joint 8

7.0 STANDARD TOLERANCES 9

7.1 TUBE CONTOUR and END POINTS 9
7.2 BEND OVALITY (FLATNESS) 9
7.3 WALL THICKNESS THINOUT 9

i
 ENGINEERED SYSTEMS GROUP
DESIGN RULE BOOK FOR FORMED METAL TUBING

TABLE OF CONTENTS
(CONTINUED)
Paragraph Page

8.0 TUBE END PREPARATION 10

8.1 TUBE END SQUARENESS 10
8.1.1 Tube End Squareness, Orbital Weld 10
8.1.2 Tube End Squareness, Butt Weld and Braze 10
8.2 TUBE END SIZING 10
8.2.1 Tube End Sizing, Welded 10
8.2.2 Tube End Sizing, Brazed 11
8.3 TUBE END EDGE PREPARATION 11
8.3.1 Tube End Edge Preparation for Butt Weld and Orbital Weld 11
8.3.2 Tube End Edge Preparation for Brazed 11

9.0 QUALITY (SURFACE DEFECTS) 13

9.1 WRINKLE HEIGHT 13
9.1.1 Wrinkle Height, Radial 13
9.1.2 Wrinkle Height, Longitudinal 14
9.2 SCRATCHES and NICKS 15
9.3 DENTS 15
9.3.1 Depth 15
9.3.2 Frequency 15
9.3.3 Superimposed Scratches 15
9.4 CRACKS 15
9.5 OTHER IRREGULARITIES 15
9.5.1 “Tight Bend” Forming In Enclosed Cavity Dies 15
9.5.2 Mandrel Bump 15
9.5.3 Multiple Bends 15

ii
 ENGINEERED SYSTEMS GROUP
DESIGN RULE BOOK FOR FORMED METAL TUBING

LIST OF TABLES

Table Page

1 STANDARD TUBING MATERIAL 3

1A SPECIAL TUBING MATERIAL 3
2 321 CRES and ALUMINUM TUBING FOR WELDED APPLICATIONS 4
2A 321 CRES, CARBON STEEL and ALUMINUM TUBING FOR 5
BRAZED APPLICATIONS TUBING
2B TITANIUM TUBING 5
3 BEND RADII 6
4 MINIMUM STRAIGHT LENGTH BETWEEN BENDS 6

5 MINIMUM STRAIGHT LENGTH TO INSTALL AN AEROQUIP RYNGLOK FITTING 7
6 MINIMUM STRAIGHT LENGTH FOR SINGLE FLARE and BEADED TUBE ENDS 7
7 MINIMUM STRAIGHT LENGTH FOR WELD JOINTS 8
8 MINIMUM STRAIGHT LENGTH FOR BRAZE JOINTS 8
9 BEND OVALITY 9
10 TUBE END SQUARENESS FOR BUTT WELD and BRAZE 10
11 TUBE END SIZING DIAMETER, FOR BUTT WELD and ORBITAL WELD 10
11A TUBE END SIZING DIAMETER, BRAZED 11
12 BRAZE CHAMFER SIZE 12
13 WRINKLE HEIGHT, RADIAL 13
14 WRINKLE HEIGHT, LONGITUDINAL 14
15 SCRATCHES and NICKS 15

LIST OF FIGURES

Figure Page

1 TUBE END EDGE PREPARATION FOR BUTT WELD AND ORBITAL WELD 11
1A TUBE END EDGE PREPARATION FOR BRAZED 12
2 WRINKLE HEIGHT, RADIAL 13
3 WRINKLE HEIGHT, LONGITUDINAL 14

iii
(1*,1((5('6<67(06*5283
 '(6,*158/(%22.
)25)250('0(7$/78%,1*

 385326(
• The purpose of this rule book is to establish design and processing requirements for the forming of metal
tubing at Aeroquip.
• All information in this rule book will be used for all assemblies manufactured by Aeroquip unless
otherwise negotiated. If special requirements are needed, please contact Aeroquip’s marketing
department so they can coordinate a design review by our engineering and manufacturing departments.
• This rule book will be reviewed and republished annually. Please address requests for additional copies,
or updated copies, to either Aeroquip’s marketing or engineering departments or contact your Aeroquip
applications engineer.

 *(1(5$/
• Tubing provides the designer with a high strength thin wall structural shape. Tubing is available in
seamless, welded and drawn or extruded conditions. It can be formed by bending, flaring, beading, sizing
and swaging.
• Aeroquip has manufactured formed metal tubing for fuel lines, hydraulic lines, oxygen system lines,
lubrication lines, coolant lines, compressed air lines and for other applications.
• Tubing cannot be used to accommodate relative motion. Hose assemblies, swivel joints, ball joints or slip
tube assemblies must be used when relative motion is present.
• All dimensions shown within this rule book are in inches.

 )250,1* 78%,1*

• The number of bends that can be formed in a length of tubing depends on several factors; the size of the
bend radius, the straight length between bends, the bend angle and angle of rotation between bends are
some factors that need to be considered.
• The overall length of a tube and long straight lengths must also be considered when designing a formed
tube. Very long dimensions on a formed tube may be impossible to form due to space limitations at the
bending machines. A joint may be required within long dimensions of some tubes depending on the bend
angles and the angle of rotation between bends. These types of formed tubes require design review by
Aeroquip’s engineering and manufacturing departments. If desired, for ease of installation, an Aeroquip
®
RYNGLOK union may be used to join the tubes together during assembly (see paragraph 6.2.2.1, also
see back cover).
• The maximum tube length should not exceed 9 feet for -12 size (.750 O.D.) and smaller and should not
exceed 12 feet for -16 size (1.000 O.D.) and larger.

 &267 )$&7256

There are several factors that must be considered when Aeroquip is calculating the cost of a formed tube
assembly. Some of these are explained as follows and should be avoided when designing a formed tube.

• Material: Special materials are very costly and require very long lead times to procure. Many times an
entire mill run (as much as 1,500 Feet), will need to be purchased regardless of how much material is
actually needed. Waiting 16 weeks or more is not uncommon when trying to procure these special
materials. See paragraph 4.0 regarding standard and special materials.

• Wall Thickness: Tubing with a special non-standard wall thickness is also very costly and very difficult to
procure. These also require very long lead times and many times an entire mill run (as much as 1,500
feet), will need to be purchased regardless of how much material is actually needed. Waiting 16 weeks
or more is not uncommon when trying to procure tubing with a non-standard wall thickness.
See paragraph 5.0 regarding tubing wall thickness.

PAGE 1
'(6,*158/(%22.)25)250('0(7$/78%,1*
 &267 )$&7256 FRQWLQXHG
• Components: If special materials, or standard materials with a non-standard wall thickness is used,
additional costs are generated due to the special components that are used with the special tube. Every
component used with the tube, such as shoulders, hose nipples and adapters, will have to be treated as
special. Each new component will have to be designed for each special application. The use of these
components would be very limited and therefore, very expensive. A special component may cost 10 or 20
times more than a standard component. It is not uncommon that a standard component might cost less
than $5.00. The same component with only a minor change to accommodate a special wall thickness,
may cost over $100.00, since special machining must be set-up to produce a limited number of parts. A
standard part might be produced by the hundreds since they are being used on many different
assemblies for many different customers.

• Method of Joining: The standard methods of joining components to a tube at Aeroquip is mechanical
swaging (such as Aeroquip Rynglok fittings) and fusion joining (welding and brazing). If a fusion joint is
required, in order to reduce costs, it is recommended that welded fittings be used rather than brazed due
to ongoing standardization of processes at Aeroquip.

• Number of Bends: The more bends there are, the longer the manufacturing and set-up time there is. A
formed tube with many bends will require a much longer set-up time thus adding to the cost. It may take
several hours to set-up the bending machine for a complex formed tube with several bends. Once the
set-up has been verified, the actual formed tube may be completed in only a few minutes but the next
time the part is ordered the entire process starts all over again.

• Bend Radius: Using multiple bend radii in a formed tube is also very expensive. It is recommended that
the same bend radius is used for all bends that are required in a length of tubing. This will avoid multiple
machine setups or the need to use more than one bending machine to complete the formed tube. See
paragraph 6.1 regarding bend radii.

• Set-Up Pieces: When the bending machines are being set-up, the same tubing that the final part is
made of must be used to set-up the bending machines. Depending on the complexity of the formed tube,
several set-up pieces must be used to verify that the bending machine has been set up correctly. If the
actual part that has been ordered uses 5 feet of tubing, and only 2 parts have been ordered, instead of
using only 10 feet of tubing we may need to use 30 or 40 feet of tubing depending on how many set-up
pieces are required. The more complex the part, the more set-up pieces will be required thus adding to
the cost.

• Tolerances: Standard tolerances should also be used to help reduce cost. Once special tolerances are
imposed it becomes very expensive. Non-standard tolerances create excessive scrap and also special
gauging might be needed which is also very expensive. See paragraph 7.0 regarding standard
tolerances.

• Inspection and Gauging: Aeroquip uses several methods for inspecting formed tubes. Our primary
method is to use a laser measuring machine. If the formed tube can not be inspected using the laser
machine we will use a setup that involves a mylar template and stanchions. If special tolerances are
invoked, a special fixture or gauge may be required thus adding to the cost.

• Surface Treatment: Passivation per QQ-P-35 is Aeroquip’s standard surface treatment for CRES
components. The standard surface treatment for aluminum components is to anodize per MIL-A-8625.
Titanium and Inconel components receive no surface treatment. If special surface treatment is required
for any material, additional costs will be incurred.

PAGE 2
'(6,*158/(%22.)25)250('0(7$/78%,1*

 $33/,&$%/('2&80(176
ACES 35 Forming Metal Tubing
AS 1577 Tube End Preparation (For Orbital Welding)
MS 33584 Single Flare
MS 33660 Beading
MS 33611 Tube Bend Radii

 (48,30(17DQG722/,1*
The tube diameter sizes that can be formed on Aeroquip bending machines, using existing tooling, is
addressed in paragraph 5.0. Any other sizes will require a design review by Aeroquip’s engineering and
manufacturing departments.

 0$7(5,$/6DQG63(&,),&$7,216
Table 1 and Table 1A lists the tubing materials and their specifications that are considered either standard or
special and have been used to manufacture formed tubing at Aeroquip.

  7$%/(67$1'$5'78%,1*0$7(5,$/
0$7(5,$/ 63(&,),&$7,21
-3 SIZE (.188 O.D.) THRU -16 SIZE (1.000 O.D.) WILL BE
SUPPLIED IN SEAMLESS ONLY PER AMS 5557, TYPE 1
321 CRES
-20 SIZE (1.250 O.D.) AND LARGER WILL BE SUPPLIED IN
SEAMLESS OR WELDED PER AMS 5557
TITANIUM AMS 4944 / AMS 4945 (SEAMLESS)
(Ti-3AL-2.5V)
1010 CARBON STEEL AMS 5053 (WELDED)
AMS 5050 (SEAMLESS)
6061-T6 ALUMINUM AMS 4082 (SEAMLESS)

  7$%/($63(&,$/78%,1*0$7(5,$/
0$7(5,$/ 63(&,),&$7,21
21-6-9 CRES AMS 5561 (WELDED)
INCONEL 625 AMS 5581 (SEAMLESS or WELDED)
INCONEL 718 AMS 5589 / AMS 5590 (SEAMLESS)













PAGE 3
'(6,*158/(%22.)25)250('0(7$/78%,1*


 78%,1*6,=(6:$//7+,&.1(66DQG:(,*+7
  &25526,21 5(6,67$17 67((/ &5(6 DQG $/80,180 78%,1* )25 :(/'('
$33/,&$7,216
When using 321 CRES or Aluminum, it is recommended that welded fittings be used. Table 2 lists the
standard tubing sizes, wall thickness by operating pressure and the weight of the tubing per inch in pounds
that are to be used with standard welded components. These are the standard Aeroquip recommended
321 CRES and Aluminum tubing for standard applications.

7$%/(&5(6DQG$/80,18078%,1*)25:(/'('$33/,&$7,216
 
23(5$7,1* 35(6685(
LOW AND MEDIUM PRESSURE HIGH PRESSURE SUPER HIGH
1,500 PSIG MAX 3,000 PSIG MAX PRESSURE
4,000 PSIG MAX
DASH TUBE ALUM WT 321 WT 321 CRES WT 321 WT
SIZE O.D. WALL PER CRES PER WALL PER CRES PER
NOM IN. WALL IN. IN. WALL IN.
-3 .188 - - .035 .0048 .035 .0048 .035 .0048
-4 .250 .049 .0023 .035 .0067 .035 .0067 .035 .0067
-5 .313 .049 .0030 .035 .0086 .035 .0086 .049 .0115
-6 .375 .049 .0049 .035 .0106 .049 .0142 .065 .0179
-8 .500 .065 .0087 .035 .0145 .065 .0251 .083 .0308
-10 .625 .065 .0112 .049 .0251 .083 .0400 .095 .0448
-12 .750 .065 .0137 .049 .0306 .095 .0553 .120 .0672
-16 1.000 .065 .0187 .065 .0540 .120 .0941 .120 .0941
-20 1.250 .065 .0237 .065 .0685 .120 .1208 .120 .1208
-24 1.500 .083 .0361 .065 .0831 - - - -
-32 2.000 .083 .0489 .065 .1120 - - - -
-40 2.500 .095 .0703 - - - - - -
-48 3.000 .095 .0850 - - - - - -

  &25526,21 5(6,67$17 67((/ &5(6 &$5%21 67((/ DQG $/80,180 78%,1*
)25 %5$=(' $33/,&$7,216
Table 2A lists the standard tubing sizes, wall thickness by operating pressure and the weight of the tubing per
inch in pounds for 321 CRES, carbon steel and Aluminum tubing that are to be used with standard brazed
components.
NOTE: 321 CRES and Aluminum are listed in this section but as discussed in paragraph 5.1, it is
recommended that welded fittings be used for CRES and Aluminum tube assemblies due to standardization
of processes at Aeroquip. Brazed CRES and Aluminum tubing assemblies should be avoided.


PAGE 4
'(6,*158/(%22.)25)250('0(7$/78%,1*


7$%/($&5(6&$5%2167((/DQG$/80,18078%,1*)25
%5$=('$33/,&$7,216
23(5$7,1* 35(6685(
/2: $1' 0(',80 35(6685( +,*+ 35(6685(
, 36,* 0$;  36,* 0$;

DASH TUBE 321 WT WT WT 321 WT WT

SIZE O.D. CRES PER ALUM PER STL PER CRES PER STL PER
NOM WALL IN. WALL IN. WALL IN. WALL IN. WALL IN.
-4 .250 .035 .0067 .049 .0023 .035 .0067 .035 .0067 .049 .0088
-5 .313 .035 .0086 .049 .0030 .049 .0115 .035 .0086 .049 .0115
-6 .375 .035 .0106 .049 .0049 .049 .0142 .049 .0142 .049 .0142
-8 .500 .035 .0145 .065 .0087 .049 .0196 .049 .0196 .065 .0251
-10 .625 .049 .0251 .065 .0112 .049 .0251 .065 .0324 .083 .0400
-12 .750 .049 .0306 .065 .0137 .049 .0306 .065 .0396 .083 .0492
-16 1.000 .049 .0414 .065 .0187 .049 .0414 .083 .0677 .095 .0764
-20 1.250 .049 .0523 .065 .0237 .049 .0523 .095 .0976 - -
-24 1.500 .065 .0831 .083 .0361 .065 .0831 - - - -
-32 2.000 .065 .1120 .083 .0489 .065 .1120 - - - -
-40 2.500 .083 .1784 .095 .0703 .083 .1784 - - - -
-48 3.000 .083 .2153 .095 .0850 .095 .2454 - - - -

 7,7$1,80 78%,1*

Table 2B lists the standard tubing sizes, wall thickness by maximum operating pressure and the weight of the
tubing per inch in pounds. These are the standard Aeroquip recommended Titanium tubing for standard
applications and will be used with orbital weld fittings.

7$%/(%7,7$1,8078%,1*
OPERATING PRESSURES (MAX)
DASH TUBE 1500 WT 3000 WT 4000 WT 5000 WT 8000 WT
SIZE O.D. PSIG PER PSIG PER PSIG PER PSIG PER PSIG PER
NOM WALL IN. WALL IN. WALL IN. WALL IN. WALL IN.
-4 .250 .018 .0022 .018 .0022 
.020 & .028 .0024 & .0032 .028 .0032 .028 .0032
-5 .313 - - - - .028 .0041 .032 .0046 .035 .0050
-6 .375 .019 .0035 .019 .0035 .028 .0050 .038 .0066 .038 .0066
-8 .500 .022 .0054 .026 .0064 .035 .0084 .043 .0102 .051 .0118
-10 .625 .023 .0071 .032 .0098 .044 .0132 .054 .0159 .064 .0185
-12 .750 .027 .0101 .039 .0143 .052 .0188 .065 .0230 .074 .0258
-16 1.000 .036 .0179 .051 .0250 .070 .0336 .088 .0415 .099 .0461
-20 1.250 .045 .0280 - - .087 - - - - -
-24 1.500 .054 .0403 - - - - - - - -
Z= If tubing is going to be used in a 4,000 psi system with Aeroquip Rynglok fittings, the .020 wall thickness tubing must be
used for the - 4 size.

  &5(6 78%,1* 63(&,$/

The use of 21-6-9 CRES tubing is considered special. However, Aeroquip has manufactured formed tubing
using this material for unique applications. Therefore, any requirements that will be using 21-6-9 CRES
tubing will require a design review by Aeroquip’s engineering and manufacturing departments.

 ,1&21(/  $1' ,1&21(/  78%,1* 63(&,$/

The use of INCONEL 625 and INCONEL 718 tubing is considered special. However, Aeroquip has
manufactured formed tubing using this material for unique applications. Therefore, any requirements that will
be using INCONEL 625 and INCONEL 718 tubing will require a design review by Aeroquip’s engineering
and manufacturing departments.

PAGE 5
'(6,*158/(%22.)25)250('0(7$/78%,1*


 '(6,*13$5$0(7(56
 %(1' 5$',,
Table 3 shows the Aeroquip preferred standard bend radius by material. Use of other bend radii will require
design review by Aeroquip’s engineering and manufacturing departments.
7$%/(  %(1' 5$',,

0$7(5,$/ $(5248,3 35()(55('

67$1'$5' %(1' 5$',86
321 CRES, ALUMINUM AND
CARBON STEEL 2 TUBE DIAMETERS
TITANIUM, 21-6-9 CRES 3 TUBE DIAMETERS
INCONEL 625 AND INCONEL 718 2 TUBE DIAMETERS

3/($6( 127(
The bend radii shown are the most cost effective and preferred standard bend radii used at Aeroquip. Tubing has
been formed at Aeroquip using smaller bend radii than what is shown, but please be aware that these may require
special processing, such as fluorescent penetrant inspection, thus creating additional costs.
For example; Titanium tubing manufacturers will not certify their material for use at less than a 3:1 bend ratio.
We have formed Titanium tubing at less than a 3:1 bend ratio, however the standard ovality and wrinkle heights
shown in paragraphs 7.2, 9.1.1 and 9.1.2 must be addressed if the bend radius required is less than 3 tube
diameters.
Also, some of our customers specify a larger 4:1 bend radius for Titanium tubing. Larger bend radii are available if
your design requires a larger bend radius than those shown in Table 3.
Use of a bend radius other than what is shown in Table 3 will require a design review by Aeroquip’s engineering and
manufacturing departments.

 675$,*+7 /(1*7+6

 0,1,080 675$,*+7 /(1*7+ %(7:((1 %(1'6

The minimum straight length of tubing required between bends (tangent points) is shown in Table 4. This is
the distance from the center of a bend radius to the center of the next bend radius. These values apply if the
degree of bend is 90 degrees or less and the rotation between bends is less than 180 degrees. A design
review will be required by Aeroquip’s engineering and manufacturing departments if other requirements are
needed.

7$%/(  0,1,080 675$,*+7 /(1*7+ %(7:((1 %(1'6

'$6+ 78%( 2' 0,1,080 ',67$1&( %(7:((1 %(1'

6,=( 120 &(17(56
-3 .188 1.000
-4 .250 1.000
-5 .313 1.000
-6 .375 1.125
-8 .500 1.500
-10 .625 1.875
-12 .750 2.250
-16 1.000 3.000
-20 1.250 3.750
-24 1.500 4.500
-32 2.000 6.000
-40 2.500 7.500
-48 3.000 9.000

PAGE 6
'(6,*158/(%22.)25)250('0(7$/78%,1*

 0,1,080 675$,*+7 /(1*7+ 5(48,5(' )520 (1' 2) 78%( 72 &(17(5

2) ),567 %(1' 5$',86  7$1*(17 32,17  )25 7+( )2//2:,1*


 ,167$//$7,21 2) $1 $(5248,3 5<1*/2. ),77,1*
Table 5 shows the minimum straight length of tubing that is required to install an Aeroquip RYNGLOK
fitting (see back cover). This is the distance from the end of the tube to the center of the first bend radius.
Note: These values only apply if you are using our RYNGLOK “Universal” tool to install the fitting. If you are
using our standard tool, a longer straight length will be required. Please consult our Rynglok engineering
department for further information.
7$%/(   0,1,080 675$,*+7 /(1*7+ 72 ,167$//

$1 $(5248,3 5<1*/2. ),77,1*
'$6+ 78%( 2' 0,1,080 ',67$1&( )520 (1' 2)
6,=( 120 78%( 72 &(17(5 2) ),567 5$',86
-3 .188 .863
-4 .250 .936
-5 .313 .999
-6 .375 1.062
-8 .500 1.130
-10 .625 1.278
-12 .750 1.427
-16 1.000 1.709
-20 1.250 2.013
-24 1.500 2.318
SIZES LARGER THAN -24 SIZE ARE NOT AVAILABLE AT THIS TIME

 6,1*/( )/$5(' 78%( (1'

Single flared tube ends shall conform to MS33584. Table 6 shows the minimum straight length of tubing
required. This is the distance from the end of the tube to the center of the first bend radius. The maximum
recommended tube wall thickness that will allow flaring per MS33584 is .065 for all materials except Titanium,
21-6-9 CRES, Inconel 625 and Inconel 718. Flaring Titanium, 21-6-9 CRES, Inconel 625 and Inconel 718 is
not recommended.

 %($'(' 78%( (1'

Beaded tube ends shall conform to MS33660. Table 6 shows the minimum straight length of tubing required.
This is the distance from the end of the tube to the center of the first bend radius. It is recommended that
Titanium, 21-6-9 CRES, Inconel 625 and Inconel 718 tubing should not be beaded.

7$%/(   0,1,080 675$,*+7 /(1*7+ )25 6,1*/( )/$5( DQG

%($'(' 78%( (1'6
'$6+ 78%( 2' 6,1*/( )/$5( %($'(' (1'
6,=( 120 06 06
-3 .188 .84 1.25
-4 .250 .88 1.25
-5 .313 .90 1.25
-6 .375 .96 1.25
-8 .500 1.03 1.25
-10 .625 1.13 1.25
-12 .750 1.28 1.25
-16 1.000 1.39 1.25
-20 1.250 1.56 1.25
-24 1.500 1.78 2.00
-32 2.000 2.05 2.00
-40 2.500 2.50 2.00
-48 3.000 2.50 2.00

PAGE 7
'(6,*158/(%22.)25)250('0(7$/78%,1*

 :(/' -2,17

Table 7 shows the minimum straight length of tubing required at a weld joint. This is the distance from the
end of the tube to the center of the first bend radius. Minimum straight lengths vary based on the type of weld
joint (butt weld or orbital weld), tubing material and the system operating pressure. Use orbital weld fittings
only with Inconel and Titanium tubing.


7$%/(0,1,080675$,*+7/(1*7+)25:(/'-2,176
25%,7$/ :(/' ),77,1*6 %877 :(/'

6<67(0 6<67(0

78%,1* 23(5$7,1* 23(5$7,1* $//

0$7(5,$/ 35(6685(

 36,* 25
35(6685(

*5($7(5
35(6685(6

/(66 7+$1 

36,*
321 CRES .250 MIN .250 MIN .250 MIN
21-6-9 CRES .250 MIN .250 MIN .250 MIN
INCONEL 625 and .250 MIN .250 MIN ----
INCONEL 718
TITANIUM .250 MIN .250 MIN ----
ALUMINUM -------- -------- .250 MIN

 %5$=( -2,17

Table 8 shows the minimum straight length of tubing required at a braze joint. This is the distance from the
end of the tube to the center of the first bend radius. Minimum straight lengths vary based on the tube size.

7$%/(0,1,080675$,*+7/(1*7+)25%5$=(-2,176
'$6+ 78%( 2' 0,1,080 675$,*+7
6,=( 120 /(1*7+
-10 OR SMALLER .625 OR SMALLER .300
-12 AND LARGER .750 AND LARGER .500


PAGE 8
'(6,*158/(%22.)25)250('0(7$/78%,1*


 67$1'$5'72/(5$1&(6
 78%( &217285 $1' (1' 32,176
Formed tubes shall conform to an envelope-type tolerance zone. This zone is created by requiring that the
tube straight lengths must conform to its basic (or true) contour within ±.060, this zone is of uniform
diameter. This tolerance applies to all straight lengths except for the straight lengths that are adjacent to the
end points. These straight lengths are controlled by the location of the end points. The tolerances on end
points are established by allowing ±.015 for each bend in the tube up to a maximum of ±.060. An additional
±.010 is allowed for each weld or braze joint making ±.080 the maximum tolerance for a subassembly from
the end of assembly to the end of assembly.

 %(1' 29$/,7<  )/$71(66 

Ovality, or flatness, in the area of the tube bend shall be determined by the following formula;
MAXIMUM O.D. - MINIMUM O.D.
OVALITY PERCENTAGE = X 100
NOMINAL O.D.
NOTE: The maximum O.D. and the minimum O.D. is the largest and smallest cross sectional diameter
measured within the area of the bend.

The ovality in the area of the tube bend shall not exceed the values shown in Table 9. These values are
based on the tubing material, and system operating pressure.
NOTE: The tube bend radius must be in accordance with paragraph 6.1. Maximum ovality must be
negotiated if the bend radius used is less than those specified in paragraph 6.1 .

7$%/(%(1'29$/,7<

23(5$7,1* 35(6685(
0$7(5,$/  36,* *5($7(5 7+$1
0$;  36,*
321 CRES 10 PERCENT 5 PERCENT
ALUMINUM 10 PERCENT 5 PERCENT
TITANIUM 5 PERCENT 3 PERCENT
21-6-9 CRES 5 PERCENT 3 PERCENT
INCONEL 625 5 PERCENT 3 PERCENT
INCONEL 718 5 PERCENT 3 PERCENT
CARBON STEEL 7.5 PERCENT 7.5 PERCENT

 :$// 7+,&.1(66 7+,1287

In the area where wall thickness thinout occurs on the outside of a bend, the wall thickness shall not be
reduced to less than 50 percent of the original wall thickness due to the forming operation.
NOTE: The tube bend radius must be in accordance with paragraph 6.1 . Tube wall thickness thinout must
be negotiated if the bend radius used is less than those specified in paragraph 6.1 .

PAGE 9
'(6,*158/(%22.)25)250('0(7$/78%,1*

 78%((1'35(3$5$7,21
 78%( (1' 648$5(1(66

 78%( (1' 648$5(1(66 25%,7$/ :(/'

For tubing that will be welded using components designed for orbital welding, tube ends must be
perpendicular to the tube O. D. within ±0° 30'.

 78%( (1' 648$5(1(66 %877 :(/' DQG %5$=(

For tubing that will be butt welded or brazed, tube ends must be perpendicular to the tube O. D. within the
limits shown in Table 10.

7$%/(  78%( (1' 648$5(1(66 )25 %877 :(/' DQG %5$=(
78%( (1' 72 78%( 2' 7,5 0$;
'$6+ 78%( 2' 7,5
6,=( 120  0$; 
-3 .188 .008
-4 .250 .010
-5 .313 .012
-6 .375 .014
-8 .500 .016
-10 .625 .018
-12 .750 .020
-16 1.000 .022
-20 1.250 .024
-24 1.500 .026
-32 2.000 .028
-40 2.500 .030
-48 3.000 .032

 78%( (1' 6,=,1*

 78%( (1' 6,=,1* :(/'('

Table 11 shows the tube O.D. size and tolerance for tube ends that will be butt welded or welded using
components designed for orbital welding.

7$%/(  78%( (1' 6,=,1* ',$0(7(5

)25 %877 :(/' DQG 25%,7$/ :(/'
'$6+ 78%( 2' %877 :(/' 25%,7$/ :(/'
6,=( 120 “    
-3 .188 .187 .186
-4 .250 .250 .248
-5 .313 .312 .310
-6 .375 .375 .373
-8 .500 .500 .498
-10 .625 .625 .623
-12 .750 .750 .748
-16 1.000 1.000 .998
-20 1.250 1.250 1.248
-24 1.500 1.500 1.498
-32 2.000 2.000 1.998
-40 2.500 2.500 2.498
-48 3.000 3.000 2.998

PAGE 10
'(6,*158/(%22.)25)250('0(7$/78%,1*

 78%( (1' 6,=,1* %5$=('

Table 11A shows the tube O.D. size and tolerance for tube ends that will be brazed. The tube sizes and for
which materials that it applies are shown.

  7$%/($78%((1'6,=,1*',$0(7(5%5$=('
'$6+ 78%( 2' $/80,180 &$5%21 67((/ &5(6
6,=( 120 “
-3 .188 .182 .198 +.004 / -.005 .186 +.001 / -.002
-4 .250 .245 .261 +.004 / -.005 .248 +.002 / -.003
-5 .313 .307 .323 +.004 / -.005 .310 +.002 / -.003
-6 .375 .370 .386 +.004 / -.005 .373 +.002 / -.003
-8 .500 .495 .511 +.004 / -.005 .498 +.002 / -.003
-10 .625 .620 .636 +.004 / -.005 .623 +.002 / -.003
-12 .750 .745 .745 ±.005 .748 +.002 / -.003
-16 1.000 .995 .995 ±.005 .998 +.002 / -.003
-20 1.250 1.245 1.245 ±.005 1.248 +.002 / -.003
-24 1.500 1.495 1.495 ±.005 1.498 +.002 / -.003
-32 2.000 1.995 1.995 ±.005 1.998 +.002 / -.003
-40 2.500 2.495 2.495 ±.005 2.498 +.002 / -.003
-48 3.000 2.995 2.995 ±.005 2.998 +.002 / -.003

 78%( (1' ('*( 35(3$5$7,21

 78%( (1' ('*( 35(3$5$7,21 )25 %877 :(/' $1' 25%,7$/ :(/'
Figure 1 shows the standard dimension for how the outside corner edge of a tube end is prepared for butt
weld and orbital weld joints.

#  +  
− 
),*85(
  78%( (1' ('*( 35(3$5$7,21 )25 %877 :(/' $1' 25%,7$/ :(/'









PAGE 11
'(6,*158/(%22.)25)250('0(7$/78%,1*

 78%( (1' ('*( 35(3$5$7,21 )25 %5$=('

Figure 1A shows the standard dimensions for how the outside corner edge of a tube end is prepared for
brazed joints. This applies to the tubing wall thickness and materials as shown in Table 12.

   °±°




 6((7$%/(
   )25&+$0)(56,=(
),*85($
78%( (1' ('*( 35(3$5$7,21 )25 %5$=(' 

7$%/(%5$=(&+$0)(56,=(
&+$0)(5 6,=( )25 ),*85( $ ',0(16,21

0$7(5,$/
78%,1* :$// &5(6 67/ DQG $/80,180
7+,&.1(66
.028 OR LESS .010 ±.005 .010 ±.005
+.002
GREATER THAN .028 .013 −.003 .020 ±.005




PAGE 12
'(6,*158/(%22.)25)250('0(7$/78%,1*



 48$/,7<685)$&('()(&76

 :5,1./( +(,*+7

 :5,1./( +(,*+7 5$',$/

If radial wrinkles are present, in the area shown in Figure 2, they must not exceed the values specified in
Table 13. This applies to the materials by system operating pressure as shown in Table 13. If the system
operating pressure is not known, use the values shown for operating pressures of 500 psig and greater. Any
wrinkle with sharp corners or edges is not permitted regardless of wrinkle height.
NOTE: The tube bend radius must be in accordance with paragraph 6.1 . Radial wrinkle height must be
negotiated if the bend radius used is less than those specified in paragraph 6.1 .


WRINKLE
HEIGHT


),*85(
:5,1./( +(,*+7 5$',$/


7$%/(:5,1./(+(,*+75$',$/

6<67(0 23(5$7,1* 78%( 0$;,080 :5,1./( +(,*+7

35(6685( 0$7(5,$/ 3(5&(17 2) 78%( 2'
36,* 6(( 7$%/(6  $
LESS THAN 500 ALL 2 PERCENT

500 AND GREATER ALL EXCEPT TITANIUM 1 PERCENT

500 AND GREATER TITANIUM NO VISIBLE WRINKLE




PAGE 13
'(6,*158/(%22.)25)250('0(7$/78%,1*


 :5,1./( +(,*+7 /21*,78',1$/

If longitudinal wrinkles are present, in the area shown in Figure 3, they must not exceed the values specified
in Table 14. This applies to the materials by system operating pressure as shown in Table 14. If the system
operating pressure is not known, use the values shown for operating pressures of 500 psig and greater. Any
wrinkle with sharp corners or edges is not permitted regardless of wrinkle height.
NOTE: The tube bend radius must be in accordance with paragraph 6.1 . Longitudinal wrinkle height must be
negotiated if the bend radius used is less than those specified in paragraph 6.1 .








  WRINKLE WRINKLE
HEIGHT HEIGHT

NOTE: Wrinkle height is measured from peak to valley except a single

wrinkle is measured from a line tangent to the curvature of the tube.

),*85(
:5,1./( +(,*+7 /21*,78',1$/


7$%/(:5,1./(+(,*+7/21*,78',1$/

6<67(0 23(5$7,1* 78%( 0$;,080 :5,1./( +(,*+7

35(6685( 0$7(5,$/ 3(5&(17 2) 78%( 2'
36,* 6(( 7$%/(6  $
LESS THAN 500 ALL 2 PERCENT OF NOMINAL TUBE O.D.
OR .040, WHICHEVER IS SMALLER

500 AND GREATER ALL EXCEPT TITANIUM 1 PERCENT OF NOMINAL TUBE O.D.
OR .020, WHICHEVER IS SMALLER

500 AND GREATER TITANIUM NO VISIBLE WRINKLE





PAGE 14
'(6,*158/(%22.)25)250('0(7$/78%,1*

 6&5$7&+(6 DQG 1,&.6

If scratches or nicks are present, they must not exceed the values specified in Table 15. This applies to all
materials shown in Tables 1 and 1A and is listed by system operating pressure as shown in Table 15. If the
system operating pressure is not known, use the values for operating pressures of 500 psig and greater.

7$%/(6&5$7&+(6$1'1,&.6
6<67(0 23(5$7,1* 0$;,080 6&5$7&+ 25 1,&.
35(6685( '(37+
36,* 3(5&(17 2) 78%( :$//
LESS THAN 500 10 PERCENT

500 AND GREATER 5 PERCENT

 '(176
For the purpose of this rule book, a dent is defined as a depressed or raised condition in the surface of the
tube whose longest dimension exceeds 15 percent of the nominal tube O.D. Deformed areas whose longest
dimension is less than 15 percent of the tube diameter shall be considered a wrinkle, see paragraph 9.1, and
shall meet the requirements specified therein. The following requirements apply to dents.

 '(37+
Dents shall not exceed a depth of 10 percent of the nominal tube I.D. No radius within the dent or between
the dent and its adjacent surface shall be less than 3 times the nominal wall thickness.

 )5(48(1&<
No more than one dent for each two inches of tube length shall be permitted or one dent for tubes less than
two inches long.

 683(5,0326(' 6&5$7&+(6

The requirements of paragraph 9.2 shall apply to scratches and nicks superimposed on a dent.

 &5$&.6 Crack’s are never permitted. Any crack in any tube of any material shall be cause for rejection.

 27+(5 ,55(*8/$5,7,(6

 ´7,*+7 %(1'µ )250,1* ,1 (1&/26(' &$9,7< ',(6 Depending on the degree of wear
in the dies, a flash may develop on the exterior surface of the tube at the die parting lines. This flash is
permissible providing it is not sharp or thin enough to become detached from the tube during service.

 0$1'5(/ %803 Irregularities on the outside of the tubing (mandrel bump), due to mandrels
used in the forming operation, are permissible provided the formed tube appearance is consistent with good
workmanship and the mandrel marks do not exceed 2 percent of the tube O.D.
 
 08/7,3/( %(1'6 Tubing with a large sweeping radius may be fabricated using multiple bends
of smaller radii. The tube contour shall be within the total envelope requirements and meet all other
acceptance criteria.

Information contained within this document may change prior to republishing.

PAGE 15
 ENGINEERED SYSTEMS GROUP

DESIGN RULE BOOK

FOR
FORMED METAL TUBING

PRINTED and PUBLISHED BY

HOSE PRODUCTS DIVISION, PRODUCT ENGINEERING
Initial Publication: JULY 29, 1996

Revised: JANUARY, 1998

 ®
Rynglok Tube Fitting System
Ask for
Aerospace Engineering Bulletin AB2
DESIGN FEATURES:
• Lightweight, constructed of 6AL-4V Titanium • Generous insertion tolerance of .300" or more
• Metal-to-metal seal, no elastomers • Operating pressures up to 8000 psi • Non-time-critical
• Compatible with a variety of tubing materials and wall thickness • Minimal training required
• Safe, simple assembly process • Fittings and installation tooling designed for production and
"in-aircraft" tubing repair. • Many varieties of fitting sizes, configurations and connections.

®
THE AEROQUIP RYNGLOK TUBE FITTING SYSTEM
REPRESENTS THE FIRST NEW TOTAL TUBE FITTING
SYSTEM TECHNOLOGY IN 20 YEARS FOR AEROSPACE
HYDRAULIC TUBING PRODUCTION AND REPAIR.