What is the Difference Between Crimping and Swaging?
In situations where cables, wires, or metal fittings are used, crimping and swaging are crucial because they are employed to create solid joints. These processes may appear similar, but they have several key differences that make one more suitable for a specific application. In this article, we will elaborate on the definitions of crimping and swaging and outline the general differences between the two in terms of project applications, tools, safety, and durability.
What is Crimping?
Crimping can be described as clamping a metal sleeve or ferrule around any cable or wire. Applications of this product are typical in electrical wiring, metal fabrication applications, and cable assembly. Most crimping tools feature a ratchet mechanism to ensure that the sleeve and cable are compressed, creating an airtight seal. The Wire Rope Crimping Tool Kit is an ideal example.
Crimping is a process where accuracy is the key. A crimping tool must correspond depending on the sleeve size or terminal to be crimped. If not done correctly, the crimping is likely ineffective and may cause problems, leading to failure under pressure. In most cases, crimping is used instead of soldering because it’s quicker and creates a strong connection without further damaging the wire.
What is Swaging?
Swaging is a process in which a metallic part is formed by pressing it around a cable. Swaging is often employed in heavy-duty applications, such as hydraulic systems involving hoses and fittings, rigging and lifting, and all industries where cables are subjected to particular force and tension, like marine applications. A cable swaging tool applies force to the sleeve or fitting without slicing or harming the cable. The Swaging Tool for Crimping Aluminum Wire Rope End Sleeve is a good example.
Swaging uses heavier materials, such as stainless steel, which forms a permanent bond that is difficult to undo. The cable becomes as sturdy as the swaged fitting or occasionally more robust.
The Key Differences: Crimping vs. Swaging
While both crimping and swaging aim to secure cables to fittings, below are their differences:
Tools
Crimping involves squeezing the cable within a crimping tool, which can be a ratchet. Cable swaging is typically performed using a cable swaging tool or a press for constructions that require a higher holding force.
Applications
Crimping suits are ideal for assembly applications, electrical work, and general light and small wire connections. Swaging is commonly employed in rigging and tensioning, or, more often, in hydraulic or industrial applications.
Reversibility
It is easier to disassemble crimped parts than swaged parts. Swaged connections are permanent, while the double-ended screwed connections are designed to carry more force.
Material
While crimping is primarily applied in wires and connectors, swaging is more used in metal tubes and rods.
Process
In crimping, the two components are joined through dimensional reduction, while in swaging, there is actual deformation of the material.
Read more: What Can I Use to Crimp Wire Rope?
Bottom line
Most of the time, you will be faced with the choice between crimping and swaging; you must consider factors such as the strength of the cables, the type of material, and sizes. Light electrical work is best solved through crimping. Swaging, however, is preferred for more Industrial, high-strength applications of the tubes. Purchasing a cable swaging tool is essential for a professional appearance, especially when working with large cables or requiring robust connections. That’s why, with the right tools, not only are your jobs made easier but safer, too. Therefore, iCrimp offers professional cable swaging tools and crimping kits for your projects.
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