Control Cables – Swaging

This is a process that is widely used in the aviation industry an in most applications it has replaced the traditionally spliced on ends.

The actual process is simple enough in theory but can be quite a difficult task to a less experienced engineer. It is basically the correct type of end fitting i.e. for end fitting with a hollow shaft deformed to clamp the cable. It is recommended that a kink be made in the end of the cable so that it does not move during the swaging process as this has the potential to be disastrous with a possibility of a catastrophic event. Once the cable has been swaged it must be crack detected by the dye penetrant method. If any cracks are detected the assembly is rejected. All swaged cables must be proof loaded to determine their serviceability. Before proof loading a cable you must put an approved paint on the joint between the cable and the fitting and allowed to dry. Any cracking of the paint indicates slippage of the cable in the fitting and this is most certainly a cause for rejection.

Note: BRITISH CABLES ARE PROOF LOADED TO 50% OF THEIR MINIMUM BREAKING STRENGTH BUT THE AMERICAN CABLES ARE PROOF LOADED TO 60% OF THEIR MINIMUM BREAKING STRENGTH.