Metal forming is mainly done on machines, but hand tools also play an important role. Two common examples are crimping and swaging tools. The former joins two metals by pressing them while the latter reshapes metal using a die without producing scrap. 

Thanks to this process, swaging tools are widely used across many industries. If you’re considering buying, it’s worth looking at a few key features and factors to find the right option for your needs.

Factors That Matter

Integrated Cutter

Not all swagers include this feature, but an integrated cutter can make the tool far more practical. That’s because this way, you can size and trim cables without using two separate tools. An integrated cutter function makes for more efficient hydraulic swagers, as they can handle multiple tasks and support a wider range of projects.

Multi vs Single-Cavity

Another factor that affects how versatile or specific a hydraulic swager will be depends on whether you go for a single- or multi-cavity tool. For instance, if you want better precision, especially with large-diameter fittings, single-cavity swagers are the way to go. Multi-cavity swagers, on the other hand, are best used for general maintenance as they work with different diameter fittings, but nothing extreme.

Gauges

You should take into consideration what happens after you’ve swaged a cable, which is best done with Go/No-Go gauges. These precision tools are used to help you ensure that the connections you’ve made are structurally sound and meet load standards. They are used across various industries and different projects because of their straightforward design.

Snap-Over-Centre Action

This mechanical feature ensures that the jaws of the tool close fully, delivering uniform compression with each use. When the hydraulic ram is engaged, it drives the internal linkage past its dead point, which is where the feature gets its name.

Ferrules & Thimbles

Metal sleeves known as ferrules are used to compress the wire when working with a swaging tool. However, this can cause the wire to kink. To prevent this, thimbles are used to support the loop, helping create durable, load-bearing ends. These are especially useful in marine applications, as well as cable railing and rigging systems.

Compatibility

The die profile and shape, crimp material, and the tool’s maximum tonnage all play an important role in choosing a compatible solution. Hydraulic swagers should also have the correct tolerances to be compatible with the fittings or cables you’ll be working with.

Uses of a Swaging Tool

Plumbing

Swaging tools are commonly used to create copper tubing connections for refrigeration systems and in plumbing installations. You can also make threaded stainless steel fittings for use in corrosive environments and multi-layer pipe systems when it comes to radiant heating. Swaged connections are made even for medical gas line installations where cleanliness is key.

Electrical Industry

Be it used with wiring in conduit bends or separately, swaged cables are quite common, especially when it comes to grounding connections and cable terminations, as swaging tools are exclusively used for these tasks. They are also useful in lightning protection systems and for creating splice connections in underground electrical installations.

Cable & Rigging

Making swaged fittings for critical safety-related connections is also best done with a hydraulic swager. You can make marine rigging hardware for sailing vessels, aircraft control cables, and slings for crane and lifting equipment, as well as use the tool for architectural cable systems.

Aerospace & Automotive Industry

Both the automotive and aerospace industries are highly dependent on swagers, as they enable lightweight yet high-strength connections, including leak-proof fuel system joints and hydraulic fittings. They are also used to make brake line fittings and control cable assemblies for steering and throttle systems.

Benefits of Hydraulic Swagers

Consistency

With hydraulic versions of swaging tools, you get a consistent pressure ranging from 8 to 10 tons. This makes hydraulic swaging tools quite reliable and easy to use even on the most demanding projects.

Precision

With hydraulics on your side, you can expect a clean and symmetrical finish on all fittings and cables. That’s because the force is precisely controlled, so you get things done professionally even if you’re working in your garage.

Usability

Since you’re not all muscle on the tool itself, you can rest assured that you won’t be tired after the third swaging. This way, you can make more terminations per project without experiencing the same level of fatigue you would with a manual tool. This is also why hydraulic tools are able to reduce the risk of human error, as they require less manual force to complete a termination.

Longevity

Connections made with a hydraulic swager are designed to last, since the tool helps produce a termination rather easily and with a clean finish. As long as you pair the correct fittings with the right cables, you can expect a long-lasting result.