Banjo Fittings | Types | Uses

Banjo fittings are very common in the automotive industry. Although you may find them under other names most of the times, you should recognize them easily by their shape. They have a long pipe and a circular head with a hole in the middle, which makes them look exactly like a banjo. They can support high pressures; therefore the banjo fittings are used in other industries as well.

The technological processes of manufacturing banjo fittings depend on pretty much of the size and the number of pieces that have to be created. They have important roles, of sustaining, guiding or fixing. Most new cars use banjo fittings, of different sizes and shapes. The mechanical capability of a car is determined first of all by the quality and the precision of the zones that ensure stable contacts. They make the connection with the kinematics and other elements in a functional environment. Their manufacturing is executed and detailed through actions of cogging, semi finishing, finishing and cutting. The operations of banjo fittings manufacturing is done with turning lathes, correcting machines and sometimes with milling machines. Picking the procedure is determined by the quality of the material and the way to obtain the fittings.

The banjo fittings manufacturing process includes a few stages:

  • Preparing operations - manufacturing the front surfaces
  • Mechanical operations - manufacturing the main and auxiliary surfaces
  • Main surfaces finishing
  • Final control

A regular banjo fitting is made out of steel and covered with copper, zinc or nickel. However, there are cases when a particular manufacturer may decide on a different material, depending on the purpose of the banjo fittings. Picking the material is the draftsman's job and it is based on the requests of the fitting during the motion and the technological and economical aspects that come up during the manufacturing. The most common types of steel used for manufacturing are OL42, OL60, OT45, OT60, OLC25 and OLC40. These are the superior quality steel types. Sometimes, when specified physical properties are needed, the manufacturer might use other metallic or nonmetallic materials.

Some banjo fittings may come connected with banjo valves, but this is not common in the automotive industry. You may find this system in the oil and hydraulic systems though. A special type of fitting you may also find is the banjo rubber fitting. Believe it or not, some systems use rubber, but of course, the industries they are involved in are completely different. The banjo rubber fitting comes with a high resistance due to its elasticity. It is also resistant against electricity. However, imagine what elasticity would mean in the breaking system of a car. These rubber imitations are mostly used in the industries that involve electricity.

The banjo fittings may often be mistakable with flare fittings. It is a common mistake among newbie mechanics, so pay attention. There is a huge difference between their purposes. Their looks are also just as different; however from a particular angle they may seem identical and confuse the young aspiring mechanics.

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