Airetool heat exchanger and condenser expanders have long been recognized as the standard to which all other brands are measured. The extra time spent manufacturing Airetool expanders results in consistent performance and incredible durability that OEM Heat Exchanger Manufacturers expect.
All G-800 Series tube expanders are supplied with a flip collar with a 10-32 UNF auto-lube port. The flip collar allows for flush and recessed tube rolling. The standard expander is supplied with a recess of 1/8" (3 mm). Other recess lengths are available.
O.D. Range: 1/4 — 3/8 Inches (6.3 — 9.5 mm)
All G-1200 Series tube expanders are supplied with a flip collar with a 10-32 UNF auto-lube port. The flip collar allows for flush and recessed tube rolling. The standard expander is supplied with a recess of 1/8" (3 mm). Other recess lengths are available.
O.D. Range: 3/8 Inches, 9.5 mm
O.D. Range: 1-3/4 — 4 Inches, 44.4 — 76.2 mm
NOTE: Step expanding becomes necessary if the tube sheet thickness exceeds the length of the roll. Specify "S" Type rolls for step expanding applications.
Tube expanders for specific applications, including:
Airetool offers a diverse line of accessories for tube installation, including:
Complete Cleaning Systems
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. Airetool manufactures condenser/heat exchanger expanders, boiler expanders, furnace expanders and many special application expanders.
Tube expanders consist of:
Condenser/Heat Exchanger Expanders
Airetool Condenser Heat Exchanger Expanders are self-feeding, parallel rolling, ball bearing thrust expanders. They are available in standard sizes for 1/4" O.D. through 3" O.D. for tube sheets up to 6-3/4" thick. Other sizes and lengths are available upon request. We supply most of the air conditioning manufacturers with expanders up to sixteen feet in length.
To select the correct tube expander, the following information is required:
It is very important to set the tube expander’s collar in the correct position inside the tube sheet. The expander’s roll high point should be positioned ~1/8" (3mm) from the inner side of the tube sheet as shown in the figure below. The purpose for setting the expander’s collar this way is to allow for thermal expansion and contraction of the tube while it is in service. If the tube is expanded beyond the tube sheet, thermal expansion and contraction of the tube will cause stress on the tube, which may cause the tube to crack or rupture at the inner tube sheet location. When tightening the set screw on the expander’s collar, be sure it is aligned with the cage grove.
In a double tube sheet application additional information is required. The thickness of the outer tube sheet (primary tube sheet) and inner tube sheet (secondary tube sheet) and the distance between the two must be known. When expanding the tube in the primary tube sheet the expanders collar is positioned as in the figure above with an 800 series tube expander. For the secondary tube sheet a 1200 series expander is required with "S" type (double radius) rolls. The "S" type rolls are required to allow the expander to have clearance on each side of the secondary tube sheet as shown in the figure below. The purpose of using "S" type rolls on an inner tube sheet and setting the expander’s collar this way is to reduce stresses in the tube due to thermal expansion and contraction of the tube while it is in service.
Many manufacturers prefer the five-roll expander for applications using tube materials that work harden quickly such as stainless steel and titanium. The five-roll expander inherently has more contact area with the tube than the three‑roll which reduces the amount of work hardening and spring back effect that is common with these tube materials. They are also used in applications with closely spaced tubes having triangular pitch. The thinner the tube walls, 18 BWG (.049"/1.25mm) and thinner, the more apt work hardening is to occur.
Step rolling is required when expanding tubes in thick tube sheets. Typically the first expansion is made at the innermost location, away from the inner side of the tube sheet. This is extremely important when rolling the opposite end of the vessel. This allows the tube material to grow in the proper direction towards the operator and keeps the tube from being stressed. After all the tubes have been expanded in this location, adjust the expander’s collar to overlap the previously rolled area. Repeat as necessary until the complete thickness of the tube sheet has been expanded. "S" type rolls (double radius) are recommended for step rolling to provide a smooth transition on the I.D. of the tube.
Tube expanders are precision tools and should be treated as such. The service demanded of them is severe. Therefore, they must be given a reasonable amount of care to insure satisfactory operation and long life.
All Tube Rolling Applications
Hand-Held Rolling Applications
Depending on the severity of the rolling application, the expander should be washed periodically (every 25-100 tubes) in any commercial solvent. For best expander life, the expander should be left in solvent to cool while a second expander is used to continue rolling.
DAS Automated Tube Rolling Applications
An optional automatic lubrication system is offered for the automatic tube rolling systems. Hand cleaning is virtually eliminated with the use of the automatic lubricating system as the air pressure that blows the lubrication into the expander to cool it also blows away dirt or foreign matter during each cycle.
All G-800 and G-1200 Series tube expanders are supplied with a flip collar with a 10-32 UNF auto-lube port. The flip collar allows for flush and recessed tube rolling. The standard expander is supplied with a recess of 1/8" (3 mm). Other recess lengths are available. Contact your mdi sales representative for details.
Fixed Recess Thrust Collars
Fixed recess collars are available for tube projections between 3/16" (4.7mm) to 7/8" (22.2 mm) from the tube sheet for special applications and require a quote from your mdi sales representative.
Full Recess Thrust Collars
The full recess collar accommodates tube projections up to 7/8" (22.2 mm) from the tube sheet.
Adjustable Recess Thrust Collars
The adjustable recess collar accommodates tube projections up to 1/2" (12.7 mm) from the tube sheet.
Thin Wall Thrust Collars
Thin wall thrust collars are recommended when expanding 20 BWG .035" (0.9 mm) or lighter wall tubes. This design limits the possibility of the tube being drawn up inside the thrust collar. Removing the collar’s collet allows the expander to be used as a full recess style compensating for various length tube projections from the tube sheet. These collars are application specific and require a quote from your mdi sales representative.
Small Diameter Thrust Collars
Small diameter thrust collars are recommended for rolling tubes in confined areas, close to tube sheet channels, or if there is interference from adjacent tubes.