Pipes and Unions

Identification - Types - Connectors used

Standard unions for aircraft hydraulic, fuel, oil, pneumatic and air system pipes
Rigid fluid lines

Metal tubing or rigid fluid line are used in stationary applications where
long and relatively straight runs are possible.
Widely used in aircraft for fuel, oil, coolant, oxygen, instrument and
hydraulic lines.
 Rigid fluid lines - Tubing Materials
Copper tubing

Earlier aircrafts uses in aviation fluid applications.

Replaced by Al alloy, steel (CRES) and titanium tubings.

Aluminum alloy tubing

1100 H14 or 3003 H14 used in general purposes such as instrument lines and
ventilating conduits.
2024-T3, 5052-O and 6061-T6 used in hydraulics and pneumatics systems, fuel and
oil lines (low and medium pressures 1000 to 1500 psi)
 Rigid fluid lines - Tubing Materials
Steel tubing

Used in high pressure hydraulic systems such as landing gear operation, flaps,
brakes and in fire zones. (above 3000 psi)
High tensile strength - thinner wall - less weight

Titanium tubing

30 % stronger than steel and 50 % lighter.

Used in high performance aircraft hydraulic system for pressure above 1500 psi.
Should not use in any oxygen system assembly. (oxygen reactive)
Rigid fluid lines - Tubing Materials

Titanium
Rigid fluid lines - Tubing Materials

Steel

Copper Aluminum
Rigid fluid lines - Material Identification

Aluminum alloy, steel or titanium tubing can be identified readily by sight.

Carbon steel, stainless steel and alloys of aluminum are difficult to
determine.
Compare code markings of the replacement tubing with the original
markings on the tubing for positive identification.
Rigid fluid lines - Material Identification
Rigid fluid lines - End Fittings

Thread types 1. Pipe threads 2. Machine threads

Rigid fluid lines - End Fittings

UNIVERSAL BULKHEAD FITTINGS

Rigid fluid lines - End Fittings

Fittings attach one piece of tubing to another or to the system units

1. Bead and clamp - low/med pressure - vacuum/ coolant system

2. Flared fittings - all systems regardless of pressure.
3. Flareless fittings - all systems regardless of pressure.
4. Permanent fittings - SWAGED - CRYOFIT - all systems regardless of
pressure.
Rigid fluid lines - End Fittings
1. Bead and clamp - low/med pressure - vacuum/ coolant system
Rigid fluid lines - End Fittings
2. Flared fittings - all systems regardless of pressure

Video - How to Install a Flare Fitting

Rigid fluid lines - End Fittings
3. Flareless fittings - all systems regardless of pressure

Video - Swaging Flaring and Bending Copper Tubing

Rigid fluid lines - End Fittings
3. Flareless fittings - all systems regardless of pressure

Video - Steel flareless fitting animation

Rigid fluid lines - End Fittings
4. Permanent fittings - SWAGED - CRYOFIT - all sys. regardless of pressure
Rigid fluid lines - End Fittings
4. Permanent fittings - SWAGED - CRYOFIT - all sys. regardless of pressure

Video - Swaging Flaring and Bending Copper Tubing

Flexible pipes

Flexible hose is generally used in moving parts or where the hose is

subject to considerable vibration.
Used in aircraft fluid systems to connect moving parts with stationary
parts in locations subject to vibration or where great flexibility is needed.
Flexible pipes
Flexible pipes - Construction

Consists of seamless synthetic rubber inner tube covered with layers of

cotton braid and wire braid and an outer layer of rubber impregnated
cotton braid.
Normally classified by the amount of pressure they are designed to
withstand under normal operating conditions.
Low pressure - below 250 psi. Fabric braid reinforcement.
Medium pressure - upto 3000 psi. One wire braid reinforcement. Small
sizes upto 3000 psi, larger sizes upto 1500 psi.
High pressure - all sizes upto 3000 psi.
Flexible pipes - Construction
Flexible pipes - Hose materials

Synthetic rubber materials are most commonly used.

Buna -N - excellent resistant to petroleum products, do not use for
phosphate ester base hydraulic fluid (Skydrol).
Neoprene - has a acetylene base. Resistance to petro product is not as
good as buna N but has better abrasive resistance, do not use for Skydrol.
Butyl - excellent material to use with Skydrol, do not use with petroleum
products.
Flexible pipes - Hose materials

Ethylene propylene diene monomer (EPDM) - outstanding heat, ozone and

weather resistance, used in seals such as doors, windows, trunk and hood
seals.
Teflon - tetrafluoroethylene resin, broad operating range (-65 to +450
), shelf life is limitless, covered with stainless steel wire braided over the
tube for strength and protection. Not affected by any known petroleum
products, synthetic base oils, alcohols and coolants, Broad usage.
Flexible pipes - Hose fittings
Flexible hose are equipped with either swaged fittings or detachable
fittings, they may be used with beads and hose clamps.
Flexible pipes - Hose fittings
Flexible hose are equipped with either swaged fittings or detachable
fittings, they may be used with beads and hose clamps.
Flexible pipes - Hose & Fluid line identification

Most hydraulic hose is marked to identify its type, the quarter and year of
manufacture and a 5-digit code to id the manufacturer.
Markings are made in contrasting colours of text and numbers.
Fluid line are marked by colour codes, words and geometric symbols.
These markings identify functions, content and primary hazard of each
line.
Fluid line are marked in tape or decals or steel tags.
Flexible pipes - Hose & Fluid line identification