How to Use Swaging and Flaring Tools for Copper Pipe and Tubing

• Flaring tools use pressure to make a fabricated mechanical joint for joining or sealing copper tubing with a flare connection. Flaring allows you to connect tubes to each other or another kind of fitting.
• Flared ends tend to have a conical shape.
• The most popular flaring tool for copper tubing is the bar-type tool. It has include multiple bits to accommodate different pipe or tube sizes.
• Tubing and piping flares are not interchangeable. Tubing flares have a 45-degree angle while piping flares have a 37-degree angle.
  Use the right type for your material to get best results.

Swaging tools use pressure to expand or stretch the end of a piece of copper tubing. Once you use these tools, a tube can fit over another of the same diameter. Then, you can make a permanent soldered connection between them. While flared ends look like a cone, swaged ends are cylindrical.

When you swage, you increase the diameter of the tubing without having to use extra fittings. After welding, swaged copper tubes are unlikely to leak or come apart.

The types of swaging tools for copper pipe include spike-shaped punch tools, manual tube expanders and feed screw tools similar to flaring bars.

Tip: Often, a flaring tool kit will come with swaging bits or die blocks to convert a flaring bar into a swaging bar.

Before using flaring and swaging tools, prepare the length of copper pipe or tubing to be shaped.

Measure the copper tubing and cut to the desired length with a tubing cutter.
There are a few kinds of cutters. Some slice automatically, while others require you to spin or twist. Follow the instructions from the cutter manufacturers to trim the pipe or tube properly.

Bits of metal debris can get in the way of connection. Remove any excess metal with a deburring tool. To do so, hold the blade at an angle and slide it along the end of the pipe or tube. Continue scraping away burrs until the metal is smooth.

Tip: Before cutting metal for any project, measure twice for accurate results.

• When flaring, begin by choosing the tool accessories that match the diameter of the tube to be flared.
• Place the tubing inside the die block or clamp of the flaring tool. The end of the tube should extend about 1/8 inch (about the height of a nickel) from the flaring tool.
• Tighten the wing nuts to secure the tubing in the tool.

Tip: Place a drop of oil on the flaring cone to smooth the process.

• Place the flaring nut over the end of the tube. Center the flaring cone over the tubing.
• Tighten the flaring tool to lower the press into the tubing until it forms a flare. Do not over-tighten, which risks splitting the copper.
• Loosen and remove the flared tubing.

Tip: If you have a kit with swaging accessories and want to swage a tube, follow the same steps, replacing swaging bits for the flaring bits.

A punch swager is among the simplest and least expensive tools available for swaging.

• Secure the tube in a vise or hold by hand in a firm grip.
• Matching the diameter of the tube to the appropriately sized punch, put the narrow end inside the tube. Make sure that it’s aligned perfectly straight.
• Strike the end of the punch with a hammer until the tube meets the stop.

A tube expander makes it easy to swage tubing of different sizes.

• Attach an expander head that matches the diameter of the tube to the end of the tool.
• Fit the head into the end of the tube and gradually squeeze the handles.
• Release when the end of the tube is fully swaged.