Swage Aero training programme
- Course
- ATS-PSW-01
- Format
- 1-day programme
- Standards
- SAE AS5902 / AS4459
- Language
- English
Swage Mastery.
The complete one-day programme for technicians installing permanent tube connections in aircraft hydraulic systems — from preparation to certified installation.
SAE aerospace standards
Scope & purpose
Section 01 · The programme
Build technicians who get it right the first time.
This programme delivers in-depth, hands-on training in the installation of permanent tube connections using swage technology in aircraft hydraulic systems. Participants gain a complete working understanding of swaging principles and the full range of fittings used across modern aerospace platforms.
From tubing preparation and witness marking through installation, Go/No-Go gauge inspection and root-cause analysis of failed assemblies, every step is covered — the way it is performed in the field, and the way the relevant aerospace standards expect it to be performed. Theory is paired with practical exercises so participants leave with the muscle memory and the confidence to perform reliable, certifiable connections.
Throughout the day we maintain a strong focus on safety, FOD prevention, correct tool handling and adherence to manufacturer guidelines. On completion, participants are equipped to perform swage installations on hydraulic systems with the integrity these critical components demand.
Six modules · one day
Section 02 · The curriculum
From principle to production-grade install.
Each module is built around the practical realities of working on a hangar floor. Theory is kept tight; tool time is generous. The first hours establish the why and the how, the afternoon turns it into skill.
| # | Module | Level | Classroom | Practical |
|---|---|---|---|---|
| 01 | Introduction to Swage Technology | L1 | 0.5 h | – |
| 02 | Tubing Preparation & Witness Marking | L1 | 0.5 h | – |
| 03 | Swage Fitting Installation | L1 | 1.0 h | – |
| 04 | Safety & FOD Prevention | L1 | 0.5 h | – |
| 05 | Inspection, Defects & Root Cause | L1 | 1.0 h | – |
| 06 | Hands-On Swage Exercises | L3 | – | 4.5 h |
| Total hours | 3.5 h | 4.5 h |
Foundation · installation · quality
Section 03 · Module details
01 Introduction to Swage Technology
Participants are introduced to swage technology and its applications in aircraft hydraulic systems: the fundamental principles of swaging, the benefits and types of fittings, the tooling, and — critically — material compatibility across the most common aerospace tube and fitting combinations. This is the foundation everything else rests on.
Topics
- Principles of swaging
- Benefits of swage technology
- Applications in aircraft hydraulic systems
- Types of swage fittings
- Tube/fitting material compatibility — Ti, 21-6-9, 304 SS, 6061-T6 Al
- Pressure class and wall thickness considerations
On completion
- Understand the basic principles of swaging
- Identify the benefits and applications of swage technology
- Recognise different types of swage fittings
- Match fittings to compatible tube materials and pressure classes
- Become familiar with the tools and equipment used in the process
02 Tubing Preparation & Witness Marking
Proper tubing preparation is the difference between a connection that holds and one that fails. This module covers cutting, deburring, cleaning and inspection — alongside tube insertion depth, witness marking and FOD prevention. Precision and cleanliness are treated as non-negotiable.
Topics
- Cutting and deburring techniques
- Cleaning, inspection and FOD / contamination control
- Tube insertion depth and witness marking
- Contamination-safe marking methods
- Common preparation issues and remedies
- Tools and equipment for tubing preparation
On completion
- Understand the steps involved in tubing preparation
- Apply correct cutting, deburring and cleaning techniques
- Apply witness marking for insertion-depth verification
- Maintain FOD-free, contamination-controlled conditions
- Identify common issues and the correct remedies
03 Swage Fitting Installation
The core procedural module: the step-by-step process of installing swage fittings, correct use of swaging tools, serialised die matching, damaged-die identification and tooling calibration awareness — plus how to navigate OEM, SRM and CMM documentation to find the data the job demands.
Topics
- Step-by-step installation process
- Use of swaging tools and equipment
- Serialised die matching & damaged-die identification
- Tooling calibration and pressure-verification awareness
- Navigating OEM documentation, SRM and CMM references
- Manufacturer guidelines and industry standards
On completion
- Execute the full swage installation process
- Use swaging tools and equipment correctly
- Identify mismatched, damaged or out-of-calibration tooling
- Locate and apply the correct OEM installation data
- Achieve secure, leak-free connections to OEM standard
04 Safety & FOD Prevention
Safety is treated as a discipline, not a checklist: personal protective equipment, safe handling of tools and equipment, FOD prevention and hydraulic system cleanliness, a controlled workspace, hazardous materials and compliance with relevant industry safety regulations.
Topics
- Personal Protective Equipment (PPE)
- Safe handling of tools and equipment
- FOD prevention and hydraulic system cleanliness
- Workspace safety measures
- Handling and storage of hazardous materials
- Health hazards and prevention
- Compliance with industry safety regulations
On completion
- Apply correct PPE and safe-handling practices
- Maintain a clean, controlled and FOD-free workspace
- Recognise and mitigate health hazards on the job
- Work in alignment with industry safety regulations
05 Inspection, Defects & Root Cause
A swage that looks fine isn't always fine. Participants learn Go/No-Go gauge inspection — swaged diameter and length — acceptance criteria and re-swage rules, witness-mark verification and the typical installation defects seen in the field, followed by root-cause analysis on real failure patterns, pressure and leak-testing awareness and traceability.
Topics
- Go/No-Go gauge inspection — diameter & length
- Gauge acceptance and re-swage criteria
- Witness-mark verification after swaging
- Common defects: under-swage, over-swage, scoring, contamination, misalignment
- Root-cause analysis of failed swaged assemblies
- Pressure and leak-testing awareness
- Documentation and traceability
On completion
- Perform Go/No-Go gauge verification on swaged connections
- Apply inspection criteria including witness-mark verification
- Identify and classify common installation defects
- Conduct basic root-cause analysis on failed assemblies
- Understand pressure and leak testing principles
- Implement documentation and record-keeping practices
06 Hands-On Swage Exercises
The afternoon. Participants apply everything covered earlier in the day — tubing preparation, witness marking, installation, Go/No-Go gauge inspection and a defect-identification walk-through — with direct instructor feedback. The goal is the muscle memory needed to do this on a real aircraft, the day after the course.
Topics
- Practical tubing preparation and witness marking
- Hands-on installation of swage fittings
- Go/No-Go gauge inspection practice
- Defect identification and root-cause walkthrough
- Review and feedback on hands-on exercises
On completion
- Prepare tubing to spec, including witness marking
- Install swage fittings using correct technique
- Perform Go/No-Go gauge inspections in practice
- Identify and classify defects on bench samples
- Demonstrate confidence and proficiency with the tooling
Trained by the people who supply the tools
Section 04 · Why Swage Aero
Not just theory.
The whole craft.
Swage Aero supplies aerospace professionals worldwide with permanent radial swage toolkits, internal swage tooling and the consumables that go with them. We train the way we equip — for technicians who will use this on real aircraft, the day after the course.
What you walk away with
Working knowledge of swaging
The principles, applications and fitting types — not as trivia but as the framework you reach for when something on the tube does not look right.
Tool fluency
Confident, correct use of swaging tools and equipment — the kind of fluency that only comes from supervised hands-on practice.
Installation discipline
A repeatable installation routine grounded in OEM, SRM and CMM documentation — with serialised tooling and calibration awareness built in.
Inspection & root-cause eye
Go/No-Go gauge verification, defect classification, and the judgement to call a connection right — or call it back.
Next intake on request
Train the technicians who never miss.
One day. Six modules. Real tooling. Witness marking. Go/No-Go inspection. Swage installations done the way OEM standards demand — built into your team's muscle memory.
Visit us
Aviolandalaan 354631 RV Woensdrecht
The Netherlands
Course
Up to 8 trainees per courseTaught in English
