Boiler Expanders

Boiler Expanders from Airetool

Tube expanding is the art of cold working the ends of tubes into intimate contact with the metal of the containing tube holes to form a leak proof mechanical seal and/or joint. In other words, it is a mechanical method of establishing a mechanical joint between a tube and a tube hole.

Boiler expanders do not include a mandrel when ordered because it is possible to obtain them with three different types of mandrels depending on the application.

Series B-1000 Boiler Expanders from Airetool

Series B-1000 Boiler Expanders

  • Tube expanding & tube flaring in one tool combines operations
  • Used when torque control is not desired or when space is limited
  • Self contained rolls keep tool components together
  • Convertible to B-2000 series
Series B-2000 Boiler Expanders from Airetool

Series B-2000 Boiler Expanders

  • Incorporates exclusive drift thrust collar
  • Adjustable positioning provides consistent joint expansion every time
Series B-3000 Boiler Expanders from Airetool

Series B-3000 Boiler Expanders

  • Straight roll expander for non-flare tube rolling
  • Use in conjunction with B-1000 & B-2000 expanders for thicker tube sheet applications
  • Convertible to B-2000 series
FTE Series Firetube Boiler Tube Expanders from Airetool

FTE Series Firetube Boiler Tube Expanders

Airetool product engineers have designed an economical, yet durable Firetube boiler tube expander for non-flaring (FTE) applications with 3/8" to 1" thick tube sheets. This unique design increases the expansion range for a given expander and includes a metal roll retainer that keeps the rolls in the expander’s cage when the mandrel is removed. Mandrels are sold separately with choices based on application and space limitations.

FTF Series Firetube Boiler Flaring Tube Expanders from Airetool

FTF Series Firetube Boiler Flaring Tube Expanders

The FTF series expanders complement the FTE series boiler expanders but include tube flaring capabilities. This design incorporates a thrust collar for torque controlled tube rolling, roll retainers, and offset flare rolls.

FTC Series Firetube Cutters from Airetool

FTC Series Firetube Cutters

FTC series firetube tube cutters are air cylinder operated to increase productivity. One operator can easily position the cutter in the tube with the aid of a tool balancer. A 2" x 13 gauge tube can be cut in less than ten seconds. Available for 2", 2-1/2", and 3" O.D. tubes with 10 - 14 gauge tube walls.

Mandrels from Airetool

Mandrels

There are times when the space inside a boiler drum will not allow use of the longer header or drum mandrels. Short series mandrel sets solve this problem by allowing you to expand the tube in multiple steps when space is limited. If you were to take the tapered portion of a header or drum mandrel, cut it in several pieces and add a drive to each section, you would have a short series mandrel set.

Refinery Expanders from Airetool

Refinery Expanders

Airetool refinery fitting tube expanders are self-feeding, with five expanding rolls which produce uniform tube expansion and tightness throughout the full thickness of the tube fitting. Contact your mdi sales representative for ordering details.

Boiler Expanders Accessories from Airetool

Boiler Expanders Accessories

Airetool provides ratchet wrenches and the various accessories needed to expand boiler tubes in even the most complicated and tight configurations, including adapter sleeves, right angle and parallel gear drives, universal joints, and ratchet extensions.


  Catalogs


Glossary of Terms

Header Mandrel – This is the longest mandrel that incorporates an extension that allows you to reach through manifolds or header boxes.

Drum Mandrel – This mandrel is used when you are expanding inside the boiler drum and can get to the tube at the end.

Short Series Mandrel Sets – There are times when the space inside a boiler drum will not allow use of the longer header or drum mandrels. Short series mandrel sets solve this problem by allowing you to expand the tube in multiple steps when space is limited. If you were to take the tapered portion of a header or drum mandrel, cut it in several pieces and add a drive to each section, you would have a short series mandrel set.

Rolls – A set of tapered cylindrical parts which are driven by mandrel and contact the tube wall to be expanded. The taper on the rolls is in the reverse direction and one-half the taper of the mandrel if it is a parallel roll expander.

Flare or Bell Rolls – This type roll is added to the back of the cage on boiler or furnace expanders to flare the tube end after it has been expanded.

Cage – This is the expander body or housing since it holds the mandrel and rolls in place. The slots which contain the rolls also provide a feed angle which helps pull the mandrel in to provide expansion of the rolls.

Thrust Assembly – This assembly attaches to the cage and allows adjustment of the expanding depth. The thrust collar will remain stationary against the tube sheet or tube end while the cage, mandrel and rolls expand the tube. A thrust assembly is used on condenser/heat exchanger expanders, some furnace expanders and special boiler expanders.


When selecting a boiler expander, you must know:

  • Tube O.D.
  • Tube wall thickness or BWG
  • Tube sheet or drum thickness
  • Minimum straight section at end of tube
  • Drum diameter if less than 18"

This information will allow you to select the proper type boiler expander and mandrels.

Series B-2000 and B-3000 Boiler Expanders from Airetool

B-1000 Series Boiler Expanders - The B-1000 series expanders incorporate tube expanding and tube flaring into one tool. They are used when torque control is not desired or where space is limited such as in a small diameter header. Both expanding and flaring rolls are self contained in the cage. The B-1000 series expanders are available for 1 — 4-1/2" O.D. tubes and can accommodate tube sheet thicknesses from 1/2 — 2-3/4". Short series mandrels are also available. A B-1000 series expander can be converted to a B-2000 series by simply adding the thrust mechanism.

B-2000 Series Boiler Expanders - The B-2000 series expanders are the same basic expander as the B-1000 series except that they have an exclusive drift thrust assembly that makes torque control possible. The thrust assembly is adjustable and allows accurate positioning of the expander in the tube in relation to the drum for consistent joint expansion on every tube. The B-2000 series expanders are available for 1 — 4-1/4" O.D. tubes and can accommodate tube sheet thicknesses from 1/2 — 2-3/4".

B-3000 Series Boiler Expanders - Straight roll expander for non-flare fire tube boiler applications. It can be used in conjunction with Airetool B-1000 or B-2000 flare type expanders in thicker tube sheet applications. The B-3000 expanders are available for 1-1/4 — 4-1/4" O.D. tubes and can accommodate drums up to 5-3/8" thick.


B-2000 Operation

Operation of Series B-2000 Boiler Expanders from Airetool

The Airetool B-2000 Series boiler tube expander, with its exclusive drift thrust assembly, represents a major advancement in boiler tube expanding. Using a ball bearing, spring loaded drift thrust collar, the B-2000 Series expanders can be accurately positioned in the boiler tube in relation to the drum for consistent joint expansion.

In operation, the initial positioning of the expander in the tube allows the self-feed rolls to draw the expander into the tube and to engage the flaring rolls at the proper point during the operation. The use of either an electric or air driven torque controlled rolling motor with the B-2000 Series expanders produces more uniform flares and very precise tube wall reduction.

The B-2000 accomplishes three unique functions in one operation:

First

Series B-2000 Boiler Expanders from Airetool

The unique depth adjustable ball bearing drift thrust collar enables the B-2000 Series expander to be positioned into the tube at exactly the same setting every time. Once set, the mandrel is inserted in the expander causing the rolls to be forced outward into contact with the tube I.D., starting the rolling process.

Second

Series B-2000 Boiler Expanders from Airetool

As the mandrel is rotated, the initial rolling of the straight section takes place. As the mandrel rotation is continued, the drift thrust collar stops the expander at its final operating depth in the tube. During this phase the flaring rolls have also moved into their final depth position.

Third

Series B-2000 Boiler Expanders from Airetool

Continued mandrel rotation now will allow the straight rolled area to be finished. At this point the amount of torque required is greatly increased. The torque mechanism in the motor measures the torque and when the set torque is reached the motor automatically shuts off. During this phase the expander being held in place by the thrust collar allows the flare rolls to iron out the end of the tube to a smooth and precisely located flare. After shut-off, reversing the motor will back the expander out of the finished tube while at the same time resetting it for the next tube.


Roll Set Model Numbers & Ordering Numbers

Drag your finger across the table to scroll

Model Number Material Number
079-3-FS  
079-3-RS 5523172
079-5-FS 5525164
079-5-RS  
079-7-FS 5526561PT
079-7-RS  
079-9-FS  
079-9-RS  
079-11-FS  
079-11-RS  
083-3-FS 5523046
083-3-RS  
083-5-FS  
083-5-RS  
083-7-FS 5526562PT
083-7-RS  
083-9-FS  
083-9-RS  
083-11-FS  
083-11-RS  
087-3-FS  
087-3-RS  
087-5-FS  
087-5-RS  
087-7-FS  
087-7-RS  
087-9-FS  
087-9-RS  
087-11-FS  
087-11-RS  
095-3-FS 5522322
095-3-RS  
095-5-FS 5522412
095-5-RS  
095-7-FS  
095-7-RS  
095-9-FS  
095-9-RS  
095-11-FS  
095-11-RS  
099-3-FS  
099-3-RS  
099-5-FS 5526003
099-5-RS  
099-7-FS  
099-7-RS  
099-9-FS  
099-9-RS  
099-11-FS  
099-11-RS  
103-3-FS  
103-3-RS 5526024
103-5-FS 5522390
103-5-RS  
103-7-FS  
103-7-RS  
103-9-FS  
103-9-RS  
103-11-FS  
103-11-RS  
111-3-FS  
111-3-RS  
111-5-FS 5522312PT
111-5-RS  
111-7-FS 5524554
111-7-RS 5522493
111-9-FS  
111-9-RS  
111-11-FS  
111-11-RS  
118-3-FS 5522786
118-3-RS 5526018
118-5-FS 5522361
118-5-RS  
118-7-FS 5522814
118-7-RS 5522828
118-9-FS  
118-9-RS 5523453
118-11-FS  
118-11-RS  
126-3-FS 5522792PT
126-3-RS 5525356
126-5-FS 5522876
126-5-RS  
126-7-FS 5523731
126-7-RS 5522989
126-9-FS 5521849
126-9-RS 5525691
126-11-FS 5525168
126-11-RS 5524958PT
142-3-FS  
142-3-RS  
142-5-FS 5522392
142-5-RS 5525911PT
142-7-FS 5522066PT
142-7-RS 5522065
142-9-FS 5521850
142-9-RS 5522947
142-11-FS 5522235
142-11-RS 5522028
150-3-FS 5522813
150-3-RS  
150-5-FS 5522781
150-5-RS 5524531
150-7-FS 5521884
150-7-RS 5522086
150-9-FS 5521891
150-9-RS 5522518
150-11-FS 5521864
150-11-RS 5521863
158-3-FS 5522238
158-3-RS  
158-5-FS 5522302
158-5-RS 5523693
158-7-FS 5522373
158-7-RS 5522225
158-9-FS 5521848
158-9-RS 5522519
158-11-FS 5522048PT
158-11-RS 5521911
166-3-FS 5522348
166-3-RS 5523155
166-5-FS 5522049
166-5-RS 5522064
166-7-FS 5522027
166-7-RS 5522531
166-9-FS 5522036
166-9-RS 5522779
166-11-FS 5522037
166-11-RS 5522126
174-3-FS 5523113
174-3-RS 5523950
174-5-FS 5522051
174-5-RS 5525683PT
174-7-FS 5522050
174-7-RS 5522271
174-9-FS 5522270
174-9-RS 5522992
174-11-FS 5522052
174-11-RS 5523215
181-3-FS 5524738
181-3-RS  
181-5-FS 5522369
181-5-RS  
181-7-FS 5522164
181-7-RS 5522913
181-9-FS 5522849
181-9-RS  
181-11-FS 5523786
181-11-RS 5522850
205-3-FS 5522867
205-3-RS  
205-5-FS 5522395
205-5-RS 5522529
205-7-FS 5522177
205-7-RS 5522317
205-9-FS 5522316
205-9-RS  
205-11-FS 5522221
205-11-RS 5522033
213-3-FS 5522339
213-3-RS 5523777
213-5-FS 5522805
213-5-RS 5522530
213-7-FS 5522176
213-7-RS 5522315
213-9-FS 5522314
213-9-RS  
213-11-FS 5522053
213-11-RS 5522155
221-3-FS  
221-3-RS  
221-5-FS 5522054
221-5-RS  
221-7-FS 5522055
221-7-RS 5523687
221-9-FS  
221-9-RS  
221-11-FS 5522056
221-11-RS 5522150
237-3-FS 5523599
237-3-RS  
237-5-FS 5526021
237-5-RS  
237-7-FS 5523399
237-7-RS 5523818
237-9-FS 5522144
237-9-RS  
237-11-FS 5522142
237-11-RS 5522141
252-3-FS 5524791
252-3-RS  
252-5-FS 5522328
252-5-RS  
252-7-FS 5522183
252-7-RS 5522436
252-9-FS 5522848
252-9-RS 5524331
252-11-FS 5522038
252-11-RS 5522087
260-3-FS 5523152
260-3-RS  
260-5-FS 5522057PT
260-5-RS  
260-7-FS 5522058
260-7-RS 5522911
260-9-FS 5522059
260-9-RS  
260-11-FS 5522060
260-11-RS 5522481
268-3-FS  
268-3-RS  
268-5-FS 5522370
268-5-RS 5522895
268-7-FS 5525323
268-7-RS 5525876
268-9-FS  
268-9-RS  
268-11-FS 5522061
268-11-RS 5521976
276-3-FS 5524737
276-3-RS  
276-5-FS 5523091
276-5-RS  
276-7-FS 5523092PT
276-7-RS 5524323
276-9-FS  
276-9-RS  
276-11-FS 5525382PT
276-11-RS 5525381
284-3-FS 5523578
284-3-RS  
284-5-FS 5522873
284-5-RS 5523246
284-7-FS  
284-7-RS 5523415
284-9-FS  
284-9-RS  
284-11-FS 5523695
284-11-RS  
292-3-FS  
292-3-RS  
292-5-RS  
292-5-RS  
292-7-FS  
292-7-RS 5524449
292-9-FS  
292-9-RS  
292-11-FS  
292-11-RS  
315-3-FS  
315-3-RS  
315-5-FS 5523697PT
315-5-RS  
315-7-FS  
315-7-RS 5523762
315-9-FS  
315-9-RS  
315-11-FS  
315-11-RS  
323-3-FS  
323-3-RS  
323-5-FS 5525499
323-5-RS 5525500
323-7-FS  
323-7-RS 5523764
323-9-FS  
323-9-RS  
323-11-FS 5523776
323-11-RS 5522031
331-3-FS 5522893
331-3-RS  
331-5-FS  
331-5-RS  
331-7-FS  
331-7-RS 5523221
331-9-FS  
331-9-RS  
331-11-FS 5525200
331-11-RS 5525199
355-3-FS  
355-3-RS  
355-5-FS 5522483
355-5-RS  
355-7-FS 5523090
355-7-RS 5524220
355-9-FS 5524222PT
355-9-RS  
355-11-FS 5523010PT
355-11-RS 5523011
363-3-FS 5526393
363-3-RS 5526392
363-5-FS  
363-5-RS  
363-7-FS 5522182
363-7-RS 5523024
363-9-FS  
363-9-RS  
363-11-FS 5523309
363-11-RS 5523310
370-3-FS  
370-3-RS  
370-5-FS  
370-5-RS  
370-7-FS  
370-7-RS 5522441
370-9-FS  
370-9-RS  
370-11-FS  
370-11-RS  
378-3-FS  
378-3-RS  
378-5-FS  
378-5-RS  
378-7-FS  
378-7-RS  
378-9-FS  
378-9-RS  
378-11-FS  
378-11-RS 5526557PT
386-3-FS  
386-3-RS  
386-5-FS  
386-5-RS  
386-7-FS  
386-7-RS  
386-9-FS  
386-9-RS  
386-11-FS  
386-11-RS  
394-3-FS  
394-3-RS 5526219
394-5-FS 5523360
394-5-RS  
394-7-FS  
394-7-RS  
394-9-FS  
394-9-RS  
394-11-FS  
394-11-RS