Flexible Metal Hose Assemblies

Below are the products Aero-Flex can provide your company.

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Are all flexible metal hose manufacturers and companies the same?

Did you know all metal hose companies are NOT the same? There’s a variety metal hose companies to choose from BUT its the method used to assemble the hose that’s important. Flexible metal hoses usually don’t break in the middle, they break at the hose weld. This means that the method used to assemble and weld the hose is extremely important. Currently there are no codes or specifications governing metal hose welds. This is a relationship between you and the vendor you choose to fabricate your hose assembly. It’s very important to choose a flexible hose manufacturer that understands the ins and outs of how metal hoses work and how to fabricate them correctly. Aero-Flex is a flexible hose manufacturer that you can rely on!
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Why Makes Aero-Flex a Different Flexible Metal Hose Company?

Aero-Flex flexible metal hose company pays special attention to the way we fabricate our hoses. Most companies cut the hose from the reel and MIG weld a fitting or flange with no additional end fitting preparation. This may work for a low pressure non critical applications but unfortunately with this method you do not get full penetration in the hose weld. The hose material is just a few thousandths thick and the fitting you are welding to the hose can be 5-10 times thicker. If you put too much heat into the weld you will blow a hole through the wall of the hose material. If you do not reduce the thickness of the wall of the fitting, what you are left with is a hinge point that over time will fail. Hoses like this are not constructed for longevity, they are constructed for low price. This is what makes our flexible hose assemblies stand out of the rest flexible metal hoses!

So what is the right way to build a flexible metal hose?

Aero-Flex chooses a different method to fabricate our hoses. We have a proprietary method of preparing the hose for welding that is different than 99% of our competitors. It involves how we form the hose core and how it relates to the braid and the braid band that ties all 3 together. During prep we perform a process that thins out the wall of the end fitting so that when welded to the hose we get full penetration and that removes the hinge point we referenced earlier. The result is that Aero-Flex hoses are stronger and more durable for a longer lasting flexible hose assembly over time. This also creates a smooth transition between the hose core and the end fitting. It also removes sharp edges of the core that can interfere with flow inside the hose.

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Our hose assemblies are cleaned several times throughout the process. Once before prep and welding and then a final cleaning after pressure testing. During final cleaning Aero-Flex pickles the welds to remove impurities (carbon) that has risen to the surface during the cool down of the weld. This prevents any rusing on the welds once it hits moisture in the air or environment its installed in. Our competitors only use soap and water and in some cases a mild citric passivation. This is not strong enough to remove the impurities in the weld and that weld will rust within hours or days once in the field. These are just a few things that set us apart from the rest of the flexible metallic hose industry. We hope that you make the right choice and choose Aero-Flex for your next flexible metal hose project!

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WHEN SHOULD YOU USE A FLEXIBLE METAL HOSE

Flexible Metal Hose Replication Old VS New
Cryogenic Hose
Chemical Hose
There’s a lot of different types of hoses on the market today and each of them have their own specific application. Aero-Flex specializes in the fabrication of custom flexible metal hose assemblies for applications where other types of hose materials won’t work. In other words, a high temperature application or high corrosion environment. Below are some examples when a flexible metal hose is a perfect fit for your specific application.
  • Temperature Extremes
  • Chemical Compatibility
  • Permeation Concerns
  • Abrasion Concerns
  • Reduce High Vibration
  • Fire Safety
  • Full Vacuum Required

Choosing the right alloy for your metallic hose

We’ll choose an alloy to construct your flexible metallic hose that is compatible with your specific application. For example, using 316 Stainless Steel is great for minor corrosion or high purity environments. In instances where high corrosion is a factor, nickel or monel is widely used in these applications. For most applications the standard 321ss core with 304ss braid will work fine. Our Flexible Metal Hose Assemblies are extremely abrasion resistant and are widely used in industries where high vibration is a factor. Actually, reducing vibration in your machinery can have a lasting affect on the life span of your machinery.

How To Order Flexible Metal Hoses

To properly design a flexible metal hose assembly for a particular application, certain parameters must be determined first. To help remember them, we have arranged them to form the acronym “S.T.A.M.P.E.D.”

  • S Size or diameter of hose and end fittings.
  • T Temperatures to which the assembly will be exposed to.
  • A Alloy of hose core and braid as well as end fittings.
  • M Motion type (bending, flexing, vibration etc.) and the frequency of said motion.
  • P Pressure requirements of hose assembly. Includes pressure spikes, pulsation and vacuum.
  • E Developed Length of the hose. This includes lateral or other movements the hose needs to achieve.
  • D stands for DELIVERY; testing, quality, packaging, and delivery requirements
STAMPED
14 Inch Flexible Metal Hose For Gas Turbine.

Flexible hose Sizes

Flexible metal hose and braid is manufactured in sizes from 1/4″ up to 12″ in diameter. Typically it comes with a single layer of braid or if you need a higher pressure rating you can add a second layer of braid. Typically the smaller the hose diameter the higher the pressure it can withstand. The exact opposite happens as you get larger in diameter. The larger the diameter the lower the maximum pressure rating is.

Cryogenic Hoses

Temperature

The reason flexible metal hose assemblies are widely used in a variety of industries is because of the extreme temperature range they can perform well in. For example a cryogenic application like liquid hydrogen or oxygen transfer hoses where temperatures can get down to -320°F.

In contrast by using a flexible metal hose assembly you can reach much higher temperatures than a PTFE or rubber hose. This is because of the materials the hose is made from.
FGlexible Metal Hose Assembly

Alloys

Flexible metal core and braid comes in a variety of different alloys. Each alloy of core and braid is tailored to a specific application. Typically the core and braid comes in 321ss, 316ss, Alloy 400 (Monel) and Nickel 625. The standard braid alloy is 304 stainless steel, however this can also be substituted with 316ss, Alloy 400 and Nickel 625.

In general, 321 stainless steel is used for higher temperature applications while 316L stainless steel is used in corrosive environments. The low carbon content and the addition of molybdenum provides the protection from salt and other chemicals used in manufacturing.

Pressure

The diameter of the hose and number of layers of wire braid determines the maximum allowable working pressure of a flexible metal hose. The temperature of what’s going through the hose or the environment its in can also affect the MAWP of a flexible metal hose.

For example a 1/4″ ID flexible metal hose with 2 layers of braid can handle 6000 psi working pressure while a 12″ flexible metal hose with 2 layers of braid handles 325 psi working pressure. Furthermore, if the temperature goes up past 300°F we would need to downgrade the pressure rating based on the higher temperature.
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Threaded End Connections

There are several different standard off the shelf threaded end connections that can be used on a flexible metal hose (stainless steel flex hoses). There are also several hydraulic fittings & adapters that can be welded on the hose or can be used to adapt the hose to existing equipment. For the most part materials include carbon steel, 304 stainless steel and 316L stainless steel. Below are a few of the threaded end connections we can provide.
    • Male NPT
    • Female NPT
    • Male JIC 37° Flare
    • Female JIC 37° Flare
    • ORFS – O-ring Face Seal
Aero-Flex can also machine a custom threaded end connector to the specific dimensions and alloys you require for your application. Ask us about custom threaded hose connectors and we would be happy to get you a quote.
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Flange End Connections

Typically flange end connections are used on hoses larger than 2″ in diameter. Aero-Flex supplies off the shelf ANSI B16.5 flanges in 150#, 300#, 600#, 900# and 1500# classes. Some of the typical off the shelf ANSI flanges we can supply are…
    • Weld Neck Flange
    • Lap Joint Flange (Floating)
    • Slip On Flange
    • Blind Flange
    • Socket Weld Flange
    • Threaded Flange
ANSI B16.5 flanges come standard in alloys like carbon steel, 304 stainless steel, 316L stainless steel and 321 stainless steel. When required an Alloy 400 or Nickel 625 flange can also be supplied. Aero-Flex can also machine custom flange connections upon request to your exact drawing specifications and specific alloys. Ask us about your next project that requires flexible metal hoses with custom flange connections and we would be happy to get you a quote.
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Aerospace End Connections

Aero-Flex provides end connections used on hose and tube assemblies used in Aerospace applications. The aerospace fittings are very similar to the JIC industrial end fittings especially since they are both 37° flares but they do have differences. The most notable difference between these standards are in the threads. For instance, AN fittings use an increased root radius thread (“J” thread) and a tighter tolerance (Class 3) to achieve a 40% increase in fatigue strength and a 10% increase in shear strength. In fact, material requirements can differ greatly. These two fittings function the same, they look the same but are slightly different. But, JIC fittings should not be used for Aerospace applications. Some examples of Aerospace end connections would be…
    • AN Nuts & Sleeves
    • MS Nuts & Sleeves
    • AS Nuts & Sleeves
    • V-Band Flange
Aero-Flex can supply off the shelf aerospace fittings or we can custom machine your aerospace hose end connections from your drawing or a specific SAE fitting specification. Please ask us about custom aerospace hose end fittings that are required for your next project.
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Hose Protection

Aero-Flex can also supply different types of protection for your flexible metal hose assembly. Whether its for abrasion resistance or fire resistance, In any case, we can provide the right solution for your needs. Interlocked Hose is sometimes used inside the flexible metal hose as a flow straightener when consistent pressure flow is required. More often you see interlocked hose used as an exterior abrasion guard. This helps protect the hose when its used in conditions where the hose and outer braid can be damaged by dragging around.
 
 
Fire sleeve is used on flexible metal hoses for heat and fire protection. This protects continuously to 500°F (260°C) and will withstand a molten splash at 2200°F (1200°C).Made of either knitted or braided high quality fiberglass yarns, it is then coated with a high-grade, fully-cured silicone rubber. Resistant to hydraulic fluids, lubricating oils, and fuels, fire sleeve insulates against energy loss in piping and hosing. Additionally, it protects employees from burns and provides flame and molten splash resistant protection for wires, hoses, and cables. We can offer other services once your flexible metal hose is complete . NDT, High Purity Cleaning and Pressure Testing to industry specifications or to your specific specifications are all available. Click our services tab to learn more.

What Industries Use Metal Hoses

 
There are many different industries that require the use of flexible metal hose assemblies. As mentioned above, there are certain applications where a flexible metal hose assembly is the only option. Below are some examples of where flexible metal hoses are crucial in keeping that particular industry running smoothly.
 

 

  • Gas Power Turbine’s – Fuel, Lube Oil, Water, Detergent, High Pressure Lube Lines and Hot Air.
  • Aerospace/Aircraft – Fuel, Hydraulic Fluid & Exhaust Gas
  • Cryogenic Hoses – Manufacture of Cryogenic Liquids and Transfer Hoses
  • Chemical Transfer or MFG. – Loading / Unloading Tank Cars, Process Piping, Steam Lines, Dry Bulk Conveying, Chlorine Transfer.
  • Oil Refining– Gas Burner Connections, Lube Lines, Metering System Flex Lines, Oil Burner Connections, Stand Pipe on Cat Crackers, Steam Hoses, Dock Hoses
  • Steel Production- Blast Furnace, BOF Furnace, Boiler & Generation Units, Coke Oven, Cooling Water Hoses, High Temp. Lube Lines, Oxygen Lance Hose, Vacuum Degasser, Lime Injection
  • Pulp & Paper Production- Compressed Gas Lines, De-Inking Process, Lube Lines, Steam Connections, Tank Car Unloading, Connections for Liquor and dryer rolls.
  • Dry Bulk Transfer – Pneumatic Dry Bulk Conveying.
  • Water Treatment – Chlorine Transfer, Piping Systems
  • Petrochemical – Chemical Transfer, Loading / Unloading Tank Cars, Process Piping, Steam Lines, Dry Bulk Conveying, Dock Hose.

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