Aluminum Ferrule: Types, Applications
Aluminum ferrules are essential in wire rope fittings, lifting equipment, and the marine industry. Their primary function is to secure wire ropes through a crimping process, ensuring a strong and reliable connection. What are the different types of aluminum ferrules? How should they be used correctly? How do you choose the right ferrule?
What is an Aluminum Ferrule?
An aluminum ferrule is a metal sleeve used for securing the ends of wire ropes, typically made of high-strength aluminum alloy. By using a hydraulic press, the ferrule is compressed onto the wire rope, creating a firm and secure end connection.
Main functions of aluminum ferrules:
- Forms a fixed looped end for lifting or connection purposes
- Enhances the durability of wire ropes and prevents unraveling
- Provides a lightweight yet high-strength connection solution
Types and Specifications of Aluminum Ferrules
DIN3093 Seamless Aluminum Ferrule(EN13411-3)
| Size | A | B | S | L | Weight | |||||
| mm | mm | mm | mm | mm | g/pc | |||||
| 1 | 1.2 | 2.4 | 0.65 | 5 | 0.11 | |||||
| 1.5 | 1.7 | 3.4 | 0.75 | 6 | 0.21 | |||||
| 2 | 2.2 | 4.4 | 0.85 | 7 | 0.24 | |||||
| 2.5 | 2.7 | 5.4 | 1.05 | 9 | 0.5 | |||||
| 3 | 3.3 | 6.6 | 1.25 | 11 | 0.84 | |||||
| 3.5 | 3.8 | 7.6 | 1.5 | 13 | 1.32 | |||||
| 4 | 4.4 | 8.8 | 1.7 | 14 | 1.81 | |||||
| 4.5 | 4.9 | 9.8 | 1.9 | 16 | 2.61 | |||||
| 5 | 5.5 | 11 | 2.1 | 18 | 3.57 | |||||
| 6 | 6.6 | 13.2 | 2.5 | 21 | 5.86 | |||||
| 6.5 | 7.2 | 14.4 | 2.7 | 23 | 7.85 | |||||
| 7 | 7.8 | 15.6 | 2.9 | 25 | 9.53 | |||||
| 8 | 8.8 | 17.6 | 3.3 | 28 | 13.7 | |||||
| 9 | 9.9 | 19.8 | 3.7 | 32 | 19.8 | |||||
| 10 | 10.9 | 21.8 | 4.1 | 35 | 26.4 | |||||
| 11 | 12.1 | 24.2 | 4.5 | 39 | 35.8 | |||||
| 12 | 13.2 | 26.4 | 4.9 | 42 | 45.8 | |||||
| 13 | 14.2 | 28.4 | 5.4 | 46 | 59.7 | |||||
| 14 | 15.3 | 30.6 | 5.8 | 49 | 73.5 | |||||
| 16 | 17.5 | 35 | 6.7 | 56 | 111 | |||||
| 18 | 19.6 | 39.2 | 7.6 | 63 | 159 | |||||
| 20 | 21.7 | 43.4 | 8.4 | 70 | 217 | |||||
| 22 | 24.3 | 48.6 | 9.2 | 77 | 292 | |||||
| 24 | 26.4 | 52.8 | 10 | 84 | 376 | |||||
| 26 | 28.5 | 57 | 10.9 | 91 | 481 | |||||
| 28 | 31 | 62 | 11.7 | 98 | 603 | |||||
| 30 | 33.1 | 66.2 | 12.5 | 105 | 735 | |||||
| 32 | 35.2 | 70.4 | 13.4 | 112 | 897 | |||||
| 34 | 37.8 | 75.6 | 14.2 | 119 | 1082 | |||||
| 36 | 39.8 | 79.6 | 15 | 126 | 1275 | |||||
| 38 | 41.9 | 83.8 | 15.8 | 133 | 1503 | |||||
| 40 | 44 | 88 | 16.6 | 140 | 1734 | |||||
| 42 | 46.2 | 92.4 | 17.5 | 147 | 2024 | |||||
| 44 | 48.4 | 96.8 | 18.3 | 154 | 2314 | |||||
| 46 | 50.6 | 101.2 | 19.2 | 161 | 2662 | |||||
| 48 | 52.8 | 105.6 | 20 | 168 | 3010 | |||||
| 50 | 55 | 110 | 20.8 | 175 | 3412 | |||||
| 52 | 57.2 | 114.4 | 21.6 | 182 | 3813 | |||||
| 54 | 59.4 | 118.8 | 22.5 | 189 | 4293 | |||||
| 56 | 61.6 | 123.2 | 23.3 | 196 | 4772 | |||||
| 58 | 63.8 | 127.6 | 24.2 | 203 | 5430 | |||||
| 60 | 66 | 132 | 25 | 210 | 5617 | |||||
Figure 8 Aluminum Ferrule
| Size(mm) | Dimensions(mm) | Weight | |||
| A | B | D | L | (kg/1000pcs) | |
| 1 | 1.2 | 2.8 | 4 | 8 | 0.138 |
| 1.2 | 1.5 | 3 | 5.2 | 9 | 0.29 |
| 1.5 | 2 | 4 | 6.2 | 9 | 0.34 |
| 2 | 2.5 | 5 | 7.3 | 9 | 0.44 |
| 2.5 | 3.1 | 6.1 | 9 | 12 | 1 |
| 3 | 3.6 | 7.3 | 11 | 15 | 1.79 |
| 3.5 | 4.3 | 7.8 | 12 | 15 | 2.07 |
| 4 | 4.7 | 9.3 | 13 | 16 | 2.46 |
| 5 | 5.5 | 11.4 | 15.8 | 22 | 4.52 |
| 6 | 6.9 | 13.8 | 18.5 | 26 | 11.8 |
| 8 | 9.5 | 19 | 27 | 32 | 20.7 |
| 10 | 11 | 22 | 30.5 | 36.5 | 28 |
| 12 | 13.6 | 27.4 | 36 | 38 | 35 |
Aluminum Ferrule VS. Copper Ferrule
Both aluminum and copper ferrules are widely used in wire rope applications, but they have distinct characteristics that make them suitable for different environments and requirements.
(1) Material Properties
- Aluminum Ferrule: Lightweight, corrosion-resistant, cost-effective
- Copper Ferrule: Denser, more conductive, higher resistance to extreme weather conditions
(2) Strength and Durability
- Aluminum: Strong enough for general lifting and marine applications but may deform under extreme loads
- Copper: More robust and better suited for heavy-duty industrial use
(3) Corrosion Resistance
- Aluminum: Naturally resistant to rust and oxidation, making it ideal for marine and outdoor environments
- Copper: Offers better resistance to extreme weather conditions but can develop a patina over time
(4)Application Suitability
| Feature | Aluminum Ferrule | Copper Ferrule |
|---|---|---|
| Weight | Lightweight | Heavier |
| Corrosion Resistance | Good (oxidation-resistant) | Excellent (patina formation) |
| Strength & Load Capacity | Moderate | High |
| Cost | Lower | Higher |
| Best Use Case | Marine, lifting, general rigging | Heavy-duty, electrical, extreme environments |
Proper Usage of Aluminum Ferrules
(1) Required Crimping Tools
Use a hydraulic press or specialized crimping tool to securely attach the ferrule.
(2) Crimping Steps
- Select the appropriate ferrule size and wire rope
- Insert the wire rope through the ferrule, forming the desired loop shape
- Apply uniform pressure using a hydraulic press to ensure full compression
- Inspect the crimped ferrule for cracks or looseness
(3) Common Mistakes and How to Avoid Them
- Insufficient Crimping: This may cause the ferrule to loosen, affecting safety
- Excessive Crimping: This can damage the ferrule structure, reducing strength
- Mismatched Wire Rope and Ferrule: Always use properly paired components
How to Choose the Right Aluminum Ferrule?
(1) Choosing Based on Wire Rope Diameter
Ensure that the ferrule’s inner diameter matches the wire rope’s outer diameter, such as:
- 5mm Wire Rope → 5mm Ferrule
- 10mm Wire Rope → 10mm Ferrule
(2) Identifying High-Quality Ferrules
- Smooth surface with no cracks
- Compliance with international standards (e.g., DIN 3093)
- No looseness or deformation after crimping
Seamless vs. Seamed Aluminum Ferrules: How to Differentiate?
Aluminum ferrules can be categorized into seamless and seamed types based on their manufacturing process.
(1) Manufacturing Process
- Seamless Aluminum Ferrules: Made through extrusion, where the material is formed into a continuous tube without any welded seams.
- Seamed Aluminum Ferrules: Manufactured by rolling a flat aluminum strip into a cylindrical shape and welding or joining the edges together.
(2) Appearance Differences
- Seamless Ferrules: Have a uniform, smooth exterior with no visible joint lines.
- Seamed Ferrules: May exhibit a faint seam line along their surface, which is often visible upon close inspection.
(3) Strength and Performance
- Seamless Ferrules: Offer higher strength and are less likely to crack under pressure due to their uniform structure.
- Seamed Ferrules: Generally weaker at the seam point and may be more prone to failure under extreme loads.
(4) Common Applications
- Seamless Ferrules: Preferred for heavy-duty lifting, marine rigging, and critical load applications.
- Seamed Ferrules: Used in light-duty or non-load-bearing applications where cost savings are prioritized.
A special extrusion machine extrudes the seamless aluminum sleeve, and the whole aluminum sleeve is free from extrusion damage and no damage. So Seamless aluminum ferrules are safer than Seamed aluminum ferrules.
Conclusion
Aluminum ferrules play a crucial role in wire rope fastening. Choosing the right ferrule ensures safety and extends service life. We hope this guide helps you understand aluminum ferrule types, proper usage, and selection tips.
