Autofrettage Systems for High-Pressure Tubing and Components

High-pressure components often face repeated internal loads throughout their service life. Manufacturers therefore need processes that address fatigue performance as well as pressure capacity.

We develop autofrettage pressure systems for treating suitable tubes, fuel rails, injection components, and other pressure-bearing parts. Our equipment offers pressure capability up to 1,000 MPa, with water or hydraulic oil as the process medium.

Explore the autofrettage system specifications, review component applications, or prepare an equipment specification for your project.

What Is Hydraulic Autofrettage?

Hydraulic autofrettage is a controlled manufacturing process that applies internal pressure to a suitable metal component.

The pressure causes limited plastic deformation in selected internal regions while surrounding material remains elastic. After pressure release, the interaction between these regions creates residual compressive stresses near the bore.

These stresses can counter part of the tensile loading produced during later operation. As a result, a correctly developed process can improve resistance to pressure fatigue.

The outcome depends on the material, geometry, manufacturing condition, and selected treatment pressure. Therefore, process parameters must be established for the specific component rather than taken directly from the machine’s maximum rating.

Equipment Development Around the Component

Our autofrettage equipment is designed to provide the pressure source required for this treatment process.

The system can use single-stage or multistage pressure intensification, depending on the operating requirements. Selection should account for target pressure, component volume, filling demand, and the planned production cycle.

Fixtures and connections also need to match the part. For example, a bent fuel pipe presents different handling and sealing requirements from a common rail or straight steel tube.

During equipment selection, provide drawings and material details so the proposed pressure circuit and fixture arrangement can be reviewed together.

Autofrettage System Technical Specifications

The maximum pressure of 1,000 MPa equals 10,000 bar. This defines the equipment’s listed upper capability.

The maximum flow requires confirmation against the selected pressure and operating conditions. It should not be assumed that the system delivers 1.2 L/min continuously at maximum pressure.

For procurement approval, request the proposed pressure-flow performance and configuration for your actual process.

Single-Stage and Multistage Pressure Generation

Pressure generation should suit both the treatment requirement and the component’s internal volume.

A single-stage arrangement may suit some duties, while a multistage arrangement can be selected where the required pressure and filling conditions call for it.

However, the number of pressure-generation stages does not define the component’s treatment programme. The approved process must separately establish the pressure sequence, holding requirements, and release conditions.

For equipment comparison, review filling time, pressure build-up time, and total cycle requirements. These factors give purchasing teams a more useful basis than maximum pressure alone.

Applications in Automotive, Aerospace, and Tube Manufacturing

Our system range addresses autofrettage requirements in research, development, and industrial production.

Suitability must be reviewed for each design. Material condition, wall thickness, bends, intersecting passages, and connection details can affect process development.

For aerospace parts, the equipment and treatment must be assessed against the applicable customer requirements. A machine pressure rating alone does not establish component approval.

Process Development and Performance Verification

Autofrettage aims to create a useful residual stress condition. It does not establish an identical strength or service-life improvement for every part.

First, define the component’s material properties and expected operating loads. Then develop the treatment conditions using appropriate engineering analysis and validation.

After treatment, inspection and testing should follow the approved product plan. Depending on the component, this may include dimensional checks, pressure testing, and fatigue evaluation.

For development projects, compare treated and untreated samples under consistent conditions. This helps engineers assess whether the chosen process provides the intended benefit.

For production, establish repeatable settings and clear acceptance criteria before releasing the process.

How to Specify an Autofrettage System

A complete inquiry helps align the equipment with the component and production requirement. Include:

• Component drawings, internal passages, and overall dimensions.

• Material grade, heat treatment, and mechanical property data.

• Normal service pressure and expected pressure cycles.

• Required autofrettage pressure or available process development data.

• Internal volume, connection details, and sealing requirements.

• Water or hydraulic oil requirements and fluid compatibility.

• Expected production quantity and target cycle time.

• Loading method, fixture requirements, and available space.

• Required controls, measurement, calibration, and process records.

• Site utilities, acceptance requirements, and delivery needs.

If the treatment pressure has not yet been established, identify this during the inquiry. Equipment selection and process development can then be reviewed as separate requirements.

Request an Autofrettage Equipment Quotation

Send your component drawings, material details, required pressure, and production targets to discuss a suitable system configuration.

Whether you are developing fuel injection parts or preparing high-pressure tubing for production, the quotation should identify the pressure-generation arrangement, fixtures, controls, and included documentation. Use the autofrettage equipment checklist to prepare your inquiry.