What Are Hydraulic Fittings?

 Hydraulic fittings connect hydraulic hoses to other components and are essential in various machines and equipment across all major industries. They are widely used in manufacturing hydraulics, assembly lines, water and sewage systems, oil refineries, and construction site hydraulics.

 

Types and Characteristics

 

Hydraulic fittings come in various types, each designed for specific purposes. They vary in size, material, type of seal, and tolerance to temperature and pressure. Some fittings allow the flow of fluid, while others prevent it. Certain fittings are dual-purpose, capable of both allowing and preventing fluid flow. The most crucial aspect of a hydraulic fitting is its ability to create a tight seal.

 

What Are Hydraulic Hose Fittings Made Of?

 

Hydraulic fittings are crafted from various materials, with the most common being plastic, stainless steel, or brass. The choice of material depends on the specific assembly or industry application.

 

Common Materials Used in Hydraulic Fittings

 

Plastic Hydraulic Fittings  

Plastic fittings are highly resistant to corrosion compared to metal ones, but they are physically weaker and less durable. Due to these limitations, plastic fittings are less suitable for high-pressure hydraulic applications, despite their lower cost. Metal fittings are preferred for the demanding conditions in industrial settings.

 

Steel Hydraulic Fittings  

Made from steel alloys, these fittings are much more robust than plastic ones. Carbon steel fittings, for example, can endure temperatures ranging from -53°C to 260°C, making them ideal for high-pressure environments.

 

Stainless Steel Fittings  

These fittings are a stainless steel variant of steel fittings, designed to withstand extreme temperatures from -253°C to 648°C. Their durability makes them ideal for highly corrosive environments. Stainless steel fittings are typically rated up to 10,000 psi, with some designs capable of withstanding up to 20,000 psi. However, their high cost often leads industries to seek alternatives for less demanding applications.

 

Brass Fittings  

Brass fittings are less strong and durable than stainless steel ones, but they provide a reliable seal to prevent leaks. They meet standards such as SAE, ISO, DIN, and JIS. Brass fittings are suitable for temperatures from -53°C to 204°C and can handle pressures up to 3,000 psi.

 

Aluminium Fittings  

Less common than other materials, aluminium fittings are used in specific applications. They are lighter than steel and resistant to corrosion, making them suitable for transportation hydraulics, such as in the automotive industry.

 

Types of Hydraulic Fittings

 

When selecting a hydraulic hose fitting, consider whether it should be permanent or reusable. Additionally, assess the type of port connections, fitting ends, and the sealing method required for the application.

 

Permanent vs. Field Reusable Fittings

 

Permanent Hydraulic Fittings  

Also known as crimped fittings, these are attached to hoses using a crimping machine. Permanent fittings are widely used in the fluid power industry due to their reliability and ease of assembly with a hydraulic crimper. They are the most common type of hydraulic fitting because they provide secure and dependable connections.

 

Reusable Hydraulic Fittings  

These fittings connect to hoses using a wrench and a vice, without the need for a crimping machine. Although reusable fittings offer the flexibility to be attached and detached multiple times, they are less popular because they are generally more expensive and require a more time-consuming installation process.

 

With the increasing use of portable hydraulic crimpers, which are convenient for mobile technicians and on-site applications, the demand for reusable hydraulic fittings has been declining.

 

Fitting Ends and Connector Types

 

Hydraulic fittings come with various ends and connector types, the most common being O-ring, mated angle, and tapered thread connectors. While these are widely used, there are numerous other specialized connectors for specific applications.

 

Given the variety in sealing methods, professional or technical advice is crucial to prevent leaks and ensure safety.

 

Primary Fittings and Connector Types

 

O-Ring Face Seal (ORFS)  

ORFS fittings offer a secure elastomeric seal, ideal for preventing leaks in systems operating at pressures up to 6,000 psi. They are categorized into:

 

- Straight ORFS Fitting: Features a straight screw connection with a male ORFS connection point to male PRT, G, or metric threads.

- Elbow ORFS Fitting: Has an elbow screw connection with an ORFS female connection and an ORFS male connection at an angle.

- Tee ORFS Fitting: A T-shaped fitting with one female ORFS port and two male ORFS ports.

- Cross ORFS Fitting: Contains four male ORFS ports, useful for distributing or combining fluids.

 

DIN or BSP  

These fittings are standards-based, commonly used across Europe:

 

- DIN (Deutsches Institut für Normung): Interchangeable with various brands, they are used in industrial, construction, and oil sectors.

- BSP (British Standard Pipe): Feature screw threads conforming to BSP standards, primarily for pipe interconnection and sealing. They are widely used in plumbing industries globally, except in North America, where the NPT (National Pipe Tapered Thread) standard is prevalent.

 

Mated Angle  

These fittings use angled seats with either straight or parallel threads for sealing. The seal is formed by the mating angle seats rather than the threads themselves.

 

Tapered Threads  

Tapered thread fittings have male threads on the outside and female threads on the inside. The threads deform under pressure when connected, creating a seal. However, they can shred and contaminate sensitive areas, often making them unsuitable for hydraulic and pneumatic systems. Over-torquing is another issue due to their lubricity.

 

How Do You Choose the End Fittings For a Hydraulic Hose?

 

Choosing the right end fittings for hydraulic hoses involves evaluating several critical criteria to ensure safe and reliable connections:

 

- Size: Consider the internal and external diameters of the hydraulic fittings. Proper sizing ensures a secure seal and prevents leaks or connection failures.

  

- Material: Different materials have varying properties that affect compatibility with hydraulic fluids and the working environment. Materials such as brass, aluminum, steel, or stainless steel should be chosen based on their compatibility with the fluid and operational conditions. O-rings made from NBR (Nitrile) are commonly used for sealing.

 

- Temperature: Ensure the fittings can withstand operating temperatures without degradation or failure.

 

- Pressure: Select fittings rated for the specific pressure range required by the application to avoid leaks or hazards.

 

- Application: Choose fittings such as T-shape or cross-shape based on whether they are used for mixing or distributing fluids in the industry or application.

 

- Assembly: Consider the need for quick-connect fittings for systems requiring frequent hose or tube connections and disconnections. Hydraulic compression fittings provide a tight seal without requiring welding or soldering.

 

- Permanence: Decide between permanent fittings (crimped fittings) or field attachable fittings based on whether the fitting needs to be changed frequently or remain in place permanently.

 

In addition to these criteria, compatibility with the hydraulic fluid used (petroleum-based, water-based, or synthetic-based) is crucial, as not all fittings are suitable for all types of hydraulic fluids.

 

How To Install Hydraulic Hose Fittings

 

Installing hydraulic hose fittings involves several steps to ensure proper assembly and performance:

 

- Select the Right Hose: Choose the correct type and size of hydraulic hose needed for the application. Use hose cutters to trim it to the required length with clean ends to minimize assembly risks and contamination.

 

- Identify the Correct Fitting: Consider factors such as size, temperature, pressure rating, style, material, and orientation when selecting the hydraulic hose fitting. Ensure compatibility with the type of hydraulic fluid used in the system.

 

- Determine Insertion Depth: Mark the insertion depth on the hydraulic hose. Apply lubricant if necessary, then insert the hose into the fitting, aligning it with the mark for proper placement.

 

- Use a Hydraulic Crimper: Adjust the crimper according to the fitting's diameter using the crimp chart for guidance. Place the end of the hose securely within the crimper for the crimping process.

 

- Clean the Assembly: Before crimping, ensure the hose assembly is clean to prevent contamination that could affect performance.