What's the difference between swaging and crimping?

Swaging and crimping are both mechanical processes used to join components, but they differ in purpose, method, tools, and applications:

1. Purpose:

- Crimping: Primarily used to secure two parts together, such as attaching a connector to a wire. It ensures electrical conductivity and mechanical strength.

- Swaging: Focuses on reshaping or forming metal around another component, often to create a permanent, high-strength joint, such as in wire rope terminations.

2. Method:

- Crimping: Involves localized deformation (indentations or folds) using axial compression. The tool compresses the connector onto the wire, creating a series of grooves.

- Swaging: Employs radial compression to uniformly reduce the diameter or reshape a metal sleeve around a workpiece (e.g., cable), resulting in a smooth, seamless joint.

3. Tools:

- Crimping: Uses hand-held tools (e.g., crimpers) with specific dies for pinching connectors. Common in electrical work.

- Swaging: Often requires heavy-duty tools like hydraulic presses or rotary swagers that apply uniform radial force. Used in industrial settings.

4. Applications:

- Crimping: Found in electrical connections, automotive wiring, and telecommunications for secure, conductive joints.

- Swaging: Used in structural, aerospace, and construction applications (e.g., wire rope loops, hydraulic fittings) where high tensile strength is critical.

5. Outcome:

- Crimping: Leaves visible indentations; suitable for moderate strength.

- Swaging: Produces a smoother, stronger joint capable of withstanding heavy loads.

Summary: Crimping is about securing components with localized compression, ideal for electrical connections. Swaging involves reshaping metal through radial compression for robust, structural joints.