Flaring copper tubing is a skill that every plumber or DIY enthusiast should master. It’s an essential technique for creating leak-proof connections in copper pipe systems, and it’s not as difficult as you might think. With the right tools and a little practice, you can easily flare copper tubing to create secure and reliable joints. In this article, we will provide a step-by-step guide on how to flare copper tubing, as well as tips and tricks to ensure you get it right every time.
Before you begin, it’s important to gather the necessary tools and materials. You will need a flaring tool, a tubing cutter, a reamer, a deburring tool, and a pair of gloves. Once you have all of your tools and materials, you can begin the process of flaring copper tubing. First, cut the copper tubing to the desired length using the tubing cutter. Next, use the reamer to remove any burrs from the inside of the cut end. Finally, use the flaring tool to create the flare on the end of the copper tubing.
To create the flare, insert the end of the copper tubing into the flaring tool and tighten the thumbscrew. Then, use the flaring cone to press the copper tubing against the flaring block, which will create the flare. Be sure to apply even pressure to the tubing and to rotate the tubing as you flare it. Once the flare is complete, remove the copper tubing from the flaring tool and deburr the outside edge of the flare using the deburring tool. Now you have a flared copper tube that is ready to be connected to another piece of copper tubing or to a fitting.
Tools and Materials for Copper Tubing Flaring
Copper tubing is commonly used in plumbing, refrigeration, and gas lines. Flaring the end of a copper tube involves expanding the diameter of the tube to create a lip or flange. This flared end makes it easier to connect the tube to fittings or other components. There are two main types of flaring tools: hand-held flaring tools and bench-mounted flaring tools. Each type of tool requires specific materials to create a flare.
Hand-Held Flaring Tools
Hand-held flaring tools are portable and can be used in tight spaces. They typically consist of a handle, a cone, and a die. The cone expands the inside of the tube, while the die forms the flare on the outside. Hand-held flaring tools are suitable for small-diameter copper tubing (1/4 inch to 1 inch) and soft copper tubing. They are relatively inexpensive and easy to use, making them a good option for DIY projects or small-scale plumbing repairs.
To use a hand-held flaring tool, insert the end of the copper tube into the cone and tighten the handle. Then, insert the die into the tube and tighten the handle further until the desired flare size is achieved. Remove the tool and use a deburring tool or sandpaper to smooth any sharp edges on the flared end.
| Required Materials | Description |
|---|---|
| Copper tubing | The tube to be flared. Choose the correct diameter and temper for your application. |
| Hand-held flaring tool | The tool used to expand the tube and form the flare. |
| Deburring tool or sandpaper | Used to smooth any sharp edges on the flared end. |
Preparation and Measurement for Flaring
Assemble tools and materials:
Before beginning the flaring process, ensure you have the necessary tools and materials at hand. These include a flaring tool, tubing cutter, deburring tool, and a source of heat (torch or heat gun). Copper tubing in the appropriate size and type is also required.
Measure and Cut the Tubing:
Using a measuring tape or ruler, determine the desired length of the tubing for your project. Mark the measurement on the tubing with a marker or pencil. Align the tubing cutter with the marked line and rotate it around the tubing while applying firm pressure. Continue rotating until the tubing is cut completely.
Clean and Deburr the Tubing Edges:
Deburring inner edge:
Utilize a deburring tool or a sharp knife to remove any burrs or sharp edges from the inside diameter of the cut tubing. These burrs can create blockages or weaken the flared connection. Insert the deburring tool into the tube and rotate it gently while applying light pressure to smooth out the inner edge.
Deburring outer edge:
Similarly, deburr the outer edge of the tubing to remove any burrs or imperfections. This will help ensure a clean and uniform flared connection. Use a fine-grit sandpaper or a file to gently smoothen the outer edge, taking care not to remove too much material.
Chamfering:
For some applications, a slight chamfer may be desired on the outer edge of the tubing. This can be created using a chamfering tool or a file. Hold the file or tool at a slight angle to the tubing and gently remove material to create a smooth, beveled edge.
Selecting the Appropriate Flaring Tool
Choosing the right flaring tool is crucial for achieving a successful flare on copper tubing. There are two main types of flaring tools:
- Yoke-style flaring tool: This is a versatile and durable tool that can flare tubing in various sizes. It consists of a yoke that holds the tubing in place and a cone that forms the flare.
- Bar-type flaring tool: This tool is more compact and portable than a yoke-style flaring tool. It uses a bar with interchangeable flaring cones that fit different tubing sizes.
When selecting a flaring tool, consider the following factors:
Tubing Size:
Make sure the flaring tool can accommodate the size of tubing you are working with.
Material:
Choose a flaring tool made of durable materials such as steel or cast iron. A poor-quality flaring tool can deform or break during use.
Ease of Use:
Select a flaring tool that is easy to operate and requires minimal effort. Consider the weight and ergonomics of the tool.
Flare Type:
Determine the type of flare you need to create. Common flare types include single flares, double flares, and cone flares. Ensure that the flaring tool can produce the desired flare type.
It is also helpful to consult the manufacturer’s instructions for specific flaring tool models to ensure proper usage and safety precautions.
Inserting the Copper Tubing into the Flaring Tool
To properly flare the copper tubing, it must be securely inserted into the flaring tool. Follow these steps to ensure the tubing is positioned correctly:
- Choose the appropriate flaring block: Select the flaring block that corresponds to the diameter of the copper tubing.
- Insert the flaring block into the tool: Place the flaring block into the flaring tool and secure it firmly.
- Clean the tubing: Remove any burrs or debris from the end of the copper tubing using a sharp knife or deburring tool.
- Insert the tubing into the tool: Insert the copper tubing into the flaring tool, ensuring that it is fully inserted and seated properly against the flaring block.
- Tighten the collet: Using a wrench or the provided handle, tighten the collet to secure the copper tubing firmly in place.
Colet Selection for Different Tube Diameters
| Tube Diameter (inches) | Colet Size |
|---|---|
| 1/4 | 1/4 collet |
| 3/8 | 3/8 collet |
| 1/2 | 1/2 collet |
| 5/8 | 5/8 collet |
| 3/4 | 3/4 collet |
Tightening the Flaring Tool
Tightening the flaring tool is a crucial step in flaring copper tubing. Improper tightening can result in leaks or damage to the tubing.
Here are the steps on how to tighten the flaring tool properly:
- Check the flaring tool and ensure that it is clean and free of dirt or debris.
- Insert the copper tubing into the flaring tool. The tubing should be inserted to the specified depth marked on the tool.
- Tighten the collet of the flaring tool by rotating the handle clockwise. It should be snug but not overly tight.
- Lubricate the flaring cone with a small amount of flaring oil or petroleum jelly.
- Insert the flaring cone into the collet and rotate it clockwise to tighten it.
- Tighten the flaring cone gradually and evenly using the following steps:
Step Description 1 Tighten the flaring cone until it just touches the copper tubing. 2 Tighten the flaring cone an additional 1/8 to 1/4 turn. 3 Check the flaring tool instructions for the recommended tightening torque. 4 Tighten the flaring cone to the manufacturer’s specifications. - Ensure that the flaring cone is centred properly.
- Hold the flaring tool steady and flare the copper tubing.
Inspecting and Testing the Flared Connection
After flaring your copper tubing, it’s crucial to inspect and test the connection to ensure its integrity and reliability. Here are the steps involved in performing these checks:
1. Visual Inspection
Examine the flared cone for any cracks, splits, or imperfections. Check if the diameter of the cone is within the specified tolerance for your fitting.
2. Diameter Gauge Verification
Use a diameter gauge or micrometer to measure the diameter of the flared cone. Ensure it meets the manufacturer’s specifications.
3. Flare Sizing
Insert the fitting into the flared tubing. Check if the connection creates a snug fit without difficulty. Removing and reinserting the fitting several times should not damage or deform the flare.
4. Leak Testing
Apply a light soapy solution to the flare connection. Pressurize the system with water or compressed air. Inspect for any leaks or bubbles around the connection. If leaks are detected, adjust the flare or replace the fitting.
5. Pressure Testing (Optional)
For critical applications, a high-pressure test can be performed using a pressure gauge. Gradually increase the pressure to the maximum allowable operating pressure. Monitor for any leaks or unusual pressure drops.
6. Temperature Testing (Optional)
If the system is intended to carry hot water or other high-temperature fluids, conduct a temperature test. Heat the water to the desired temperature and monitor for any leaks or changes in the connection.
7. Torque Verification
Tighten the flare nut to the specified torque value. Use a torque wrench to ensure the proper tightness. Avoid overtightening, as it can damage the flare or fitting.
8. Retightening After Use
After the system has been in use for some time, retighten the flare nut to ensure the connection remains secure. This is especially important for applications that experience vibrations or thermal cycling.
9. Troubleshooting Leaks
If leaks occur after flaring, the following table provides some common troubleshooting steps:
| Issue | Possible Causes | Solutions |
|---|---|---|
| Leak from flare cone | – Undersized flare – Improperly seated flare – Damaged flare |
– Re-flare tubing – Reseat flare – Replace fitting |
| Leak from threads | – Loose fitting – Stripped threads |
– Tighten fitting – Replace fitting |
| Leak from fitting body | – Damaged fitting – Faulty seal |
– Replace fitting |
Advanced Techniques for Complex Flaring
10. Special Considerations for Thin-Walled Copper Tubing
Thin-walled copper tubing requires extra care during flaring, as it is more susceptible to deformation and damage. Use a specially designed thin-wall flaring tool that provides ample support while minimizing stress on the tubing. Additionally, consider annealing the tubing before flaring to soften the material and make it more pliable.
The following table provides a summary of key steps when flaring thin-walled copper tubing:
| Step | Description |
|---|---|
| 1 | Anneal the tubing to soften it. |
| 2 | Use a thin-wall flaring tool for support. |
| 3 | Apply a light lubricant to the flaring cone and die. |
| 4 | Flare the tubing slowly and evenly to minimize stress. |
