Permaswage tooling is essential in aerospace and hydraulic tube assembly systems. If you're using DLT series swage heads such as the DLT05PSHA3004, DLT20PSHA3010, or DLT10PSHA3006, routine inspections are critical for performance, safety, and compliance. This article breaks down the official inspection criteria to help you extend tool life, maintain perfect swages, and ensure your tooling remains within spec.
Visual Inspection: What to Look For
Die Serial Numbers Must Match When inspecting die sets such as the DLT20PSDI3010 or DLT05PSDI3004, make sure both halves share the same serial number. Using mismatched dies will compromise swage quality and tool longevity.
Cleanliness is Critical
Inspect heads like DLT10PSHA3005, DLT05PSHA3004, and DLT30PSHA3012 regularly. Remove debris and foreign objects from:
Die slots
Yoke surfaces
Lower Die Block areas
Proper Lubrication
Lubricate the inner radius of the Lower Die Block (e.g., DLT20MADA0001) and Yoke (e.g., DLT20MA) using DLTSWLUB0001 (Deutsch Swage Lube). Lack of lubrication increases wear and leads to swage inconsistencies.
Verify End Plate Configuration
DLT40PSFU3016: Upper Outboard End Plate for DLT40PSHA3016
DLT20PSEU4010: Upper Inboard End Plate for DLT20PSHA3010
MS24671-1 / MS24671-2: Standard mounting screws
Slot Width Tolerances
Inspect dies such as DLT05PSDI3003 or DLT10PSDI3006 for over-compressed slots. Ideal slot width range: .035" – .040".
Signs of Wear or Cracks
Check for:
25% or more gouging or deformation
Cracks (use dye penetrant annually)
Bent or deformed die halves
Need a replacement? Look for DLT-compatible die sets like:
DLT20PSDI3008 (5/8" tube)
DLT40PSDI4016 (for aluminum-specific swages)
DLT10PSDI3005 (5/16" tube size)
Maintenance Schedule for DLT Head Assemblies
Monthly:
- Clean and inspect die sets (e.g., DLT05PSDI3004, DLT20PSDI3010) for visual damage or wear.
Annually:
- Conduct dye penetrant testing for cracks on dies and lower blocks (e.g., DLT40MADA0001, DLT10MADA0001).
Regular Checks:
Replace worn Upper Outboard End Plates such as DLT40PSFU3020
Inspect Lower Die Block (e.g., DLT30MADA0001) for gouges
Assembly Tips: How to Rebuild a Swage Head Correctly
Step-by-Step:
- Install Upper Outboard End Plate (e.g., DLT20PSFU4010) on the Yoke
- Lubricate contact points with DLTSWLUB0001
- Insert die halves like DLT20PSDI3010 into yoke and orient correctly
- Install Upper Inboard End Plate (e.g., DLT20PSEU4010) and secure with MS24671-1 screws
- Repeat for the lower assembly using DLT20PSFL4010 and DLT20PSEL4010
Looking for Parts or Replacements?
At Top Flight Tools, we stock and resell:
Used DLT Swage Heads (e.g., DLT30PSHA4012, DLT05PSHA3003)
DLT Power Units like DLT05MAPW0000, DLT10MAPW0000
Full swage die sets from DLT05 to DLT40 Series
Every used item is quality-checked and includes a 90-day warranty.
⚠️ Disclaimer Top Flight Tools (TFT) is an independent reseller and is not affiliated with, sponsored by, or endorsed by Permaswage® or Precision Castparts Corp. (PCC). All product names, trademarks, and registered trademarks are the property of their respective owners. Any reference to Permaswage® products, specifications, or part numbers is provided for informational purposes only. All Permaswage® trademarks and part numbers remain the property of their respective companies.
While every effort is made to ensure the accuracy of the information provided, it is the customer’s responsibility to verify all specifications, compatibility, and suitability of products for their intended application prior to use. TFT assumes no liability for errors, omissions, or the misuse or misapplication of this information, and disclaims any responsibility for damages resulting from reliance on it.