Permaswage® D10045 Union Reducers are permanent tube fittings used in the Permaswage® 3,000 PSI Tube Connecting System. These fittings are designed to connect two sections of tubing with different outside diameters while maintaining a permanent, swaged connection.
The D10045 series is commonly used in aerospace hydraulic, fuel, pneumatic, lubrication, and fluid conveyance systems where a line must transition from one tube size to another. By combining the function of a straight union with a size reduction, D10045 Union Reducers help simplify tube routing while maintaining system reliability.
In this guide, we’ll explain what Permaswage® D10045 Union Reducers are, how they are used, and provide a dimensional reference for common tube size combinations.
What Is a Permaswage® D10045 Union Reducer?
A Permaswage® D10045 Union Reducer is a straight reducer fitting used to permanently connect two sections of tubing with different outside diameters.
One end of the fitting is designed for the larger tube size, while the opposite end is designed for the smaller tube size. During installation, each side of the fitting is swaged onto the corresponding tube, creating a permanent mechanical connection without welding, brazing, soldering, or tube flaring.
Union reducers are commonly used when a fluid line transitions between different tube sizes while maintaining a straight flow path.
Why Use Permaswage® Union Reducers?
Permaswage® union reducers are used where tube size transitions are required in high-performance aerospace fluid systems.
- Connects two different tube sizes
- Maintains a straight tube-to-tube flow path
- No tube flaring required
- Designed for 3,000 PSI applications
- Suitable for aerospace hydraulic and fluid systems
- Excellent vibration resistance
- Reliable permanent installation
- Helps reduce extra adapters and unnecessary fittings
Permaswage® D10045 Union Reducer Part Number Series
The D10045 series identifies Permaswage® union reducer fittings for 3,000 PSI permanent tube connection applications. Individual reducer configurations are based on the larger port size and the reduced port size.
| Fitting Family | Series | Function |
|---|---|---|
| Union Reducer | D10045 | Straight reducer for connecting two different tube sizes |
Permaswage® D10045 Union Reducer Size Reference
The following table shows common larger tube size and reduced tube size combinations for the Permaswage® D10045 Union Reducer series.
| Larger Tube Size | Reducer Tube Size | Series | Application |
|---|---|---|---|
| 1/4" | 3/16" | D10045 | Straight tube size reduction |
| 5/16" | 3/16" or 1/4" | D10045 | Straight tube size reduction |
| 3/8" | 3/16", 1/4", or 5/16" | D10045 | Straight tube size reduction |
| 1/2" | 3/16" through 3/8" | D10045 | Straight tube size reduction |
| 5/8" | 3/16" through 1/2" | D10045 | Straight tube size reduction |
| 3/4" | 3/16" through 5/8" | D10045 | Straight tube size reduction |
| 1" | 3/16" through 3/4" | D10045 | Straight tube size reduction |
| 1-1/4" | 1/4" through 1" | D10045 | Straight tube size reduction |
| 1-1/2" | 5/16" through 1-1/4" | D10045 | Straight tube size reduction |
Permaswage® D10045 Union Reducer Dimensional Reference
The table below provides dimensional reference data for common D10045 Union Reducer configurations. Dimension A refers to the fitting length for the applicable tube size combination.
| Larger Tube Size | Reducer Tube Size | Dimension A |
|---|---|---|
| 1/4" | 3/16" | 1.640 |
| 5/16" | 3/16" | 1.688 |
| 3/8" | 3/16" | 1.790 |
| 1/2" | 3/16" | 2.375 |
| 5/8" | 3/16" | 2.500 |
| 3/4" | 3/16" | 2.570 |
| 1" | 3/16" | 2.985 |
| 5/16" | 1/4" | 1.765 |
| 3/8" | 1/4" | 1.850 |
| 1/2" | 1/4" | 2.415 |
| 5/8" | 1/4" | 2.550 |
| 3/4" | 1/4" | 2.620 |
| 1" | 1/4" | 3.070 |
| 1-1/4" | 1/4" | 3.425 |
| 3/8" | 5/16" | 1.875 |
| 1/2" | 5/16" | 2.425 |
| 5/8" | 5/16" | 2.575 |
| 3/4" | 5/16" | 2.630 |
| 1" | 5/16" | 3.150 |
| 1-1/4" | 5/16" | 3.475 |
| 1-1/2" | 5/16" | 3.710 |
| 1/2" | 3/8" | 2.425 |
| 5/8" | 3/8" | 2.590 |
| 3/4" | 3/8" | 2.640 |
| 1" | 3/8" | 3.340 |
| 1-1/4" | 3/8" | 3.688 |
| 1-1/2" | 3/8" | 3.915 |
| 5/8" | 1/2" | 2.953 |
| 3/4" | 1/2" | 3.030 |
| 1" | 1/2" | 3.420 |
| 1-1/4" | 1/2" | 3.796 |
| 1-1/2" | 1/2" | 3.984 |
| 3/4" | 5/8" | 3.030 |
| 1" | 5/8" | 3.375 |
| 1-1/4" | 5/8" | 3.770 |
| 1-1/2" | 5/8" | 3.955 |
| 1" | 3/4" | 3.375 |
| 1-1/4" | 3/4" | 3.770 |
| 1-1/2" | 3/4" | 3.955 |
| 1-1/4" | 1" | 3.850 |
| 1-1/2" | 1" | 4.040 |
| 1-1/2" | 1-1/4" | 4.140 |
Common Applications
Permaswage® union reducers are used where a tube line must transition from one size to another without changing direction.
- Aircraft hydraulic systems
- Fuel systems
- Pneumatic systems
- Lubrication systems
- Environmental control systems
- System transition points
- Landing gear hydraulic circuits
- Flight control systems
- Military aircraft maintenance
- Aerospace manufacturing
- MRO repair operations
How the D10045 Union Reducer Works
The D10045 Union Reducer is installed by positioning the fitting between two properly prepared tubes of different sizes. Each side of the fitting is swaged onto its corresponding tube size, creating a permanent mechanical connection.
This eliminates the need for threaded adapters, tube flaring, welding, brazing, or multiple transition fittings. The result is a compact, permanent reducer connection suitable for demanding aerospace fluid systems.
Related Permaswage® Fitting Families
The D10045 Union Reducer is part of the larger Permaswage® 3,000 PSI fitting family.
- D10036 and D10136 Union Fittings
- D9856 and D10256 90° Elbow Fittings
- D10355 and D10356 90° Elbow Reducers
- D10559 and D10155 Tee Fittings
- D10023 and D10223 Tee Reducers
- D10564 and D10254 Cross Fittings
- D10164 Bulkhead Union Fittings
Frequently Asked Questions
What is a Permaswage® D10045 fitting?
The D10045 fitting is a straight union reducer used to permanently connect two sections of tubing with different outside diameters.
What is the difference between a union and a union reducer?
A standard union connects two tubes of the same size. A union reducer connects two tubes of different sizes.
What pressure system is the D10045 series designed for?
The D10045 series is part of the Permaswage® 3,000 PSI Tube Connecting System.
Can Permaswage® union reducers be reused?
No. Permaswage® union reducers are permanent fittings and are not designed to be reused after installation.
Where are D10045 union reducers commonly used?
They are commonly used in aerospace hydraulic, fuel, pneumatic, lubrication, and fluid conveyance systems where a tube size transition is required.
Do D10045 fittings change tube direction?
No. The D10045 series is a straight reducer fitting. For directional changes, elbow or elbow reducer fittings are typically used.
Why Buy Permaswage® Union Reducers from Top Flight Tools?
At Top Flight Tools, we specialize in sourcing new, surplus, and hard-to-find Permaswage® fittings and tooling for aerospace and industrial applications.
Whether you need a D10045 Union Reducer, a standard D10036 Union, or another Permaswage® fitting family, our team can help identify the correct part number for your application.
Conclusion
Permaswage® D10045 Union Reducers provide a permanent solution for connecting two different tube sizes in a straight fluid line. Their compact design, permanent swaged installation method, and broad range of size combinations make them an important fitting family within the Permaswage® 3,000 PSI Tube Connecting System.
For aerospace hydraulic, fuel, pneumatic, and fluid conveyance systems, the D10045 series helps simplify tube size transitions while maintaining reliable system performance.
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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.