Aluminum Ferrule Guide:How to choose the right one?

 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

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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

1. Select the appropriate ferrule size and wire rope
2. Insert the wire rope through the ferrule, forming the desired loop shape
3. Apply uniform pressure using a hydraulic press to ensure full compression
4. 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.

www.chinatoplifting.com

tracy@chinatoplifting.com