What is Aluminum Extrusion? The Process in 10 Steps

Extrusion of aluminum is the act of forcing aluminum alloy into a die with a predetermined cross-sectional profile. Consider a tube of toothpaste squeezer  extrusion is also similar. An electrically powered ram forces the aluminum into the die and the material comes out of the opening. As it comes out, it assumes the very shape of the die and is pushed along a run out table. The idea is simple at its level best. The force is similar to the one of your fingers on a tube of toothpaste. When squeeze red the paste oozes in the form of the tube opening. The pipe opening is used in place of the extrusion die in this analogy. The toothpaste is in the shape of a circular opaque strand due to the opening being a circle.

Such common extruded profiles are angles, channels, and round tubes.

The drawings employed to design the dies are seen above and the renderings of the completed aluminum profiles are shown below.

What is Aluminum Extrusion?

The extrusion of aluminum alloy is whereby aluminum alloy is forced to pass through a die that is in a definite profile cross sectional. One can imagine it by comparing it to squeezing toothpaste out of a tube: the ram presses on it, forcing the aluminum to flow through the die, and the material comes out in the specific shape of the die. When extruded, the profile is driven on a run out table. The basic principle of the process is simple  like squeezing toothpaste through a circular hole that creates a long and solid strand.

Common Extruded Shapes

• Solid: No internal empty spaces (e.g. rods, beams, angles)
• Hollow: A void that is enclosed (e.g. by a tube that is square or rectangular shaped).
• Semi-hollow: Voids that are partially enclosed (e.g., C channels with small gaps)

Applications Extrusion is extensively applied in the fields of architecture, automotive, aerospace, electronics and energy. Though, simple shapes (angles, channels) are typical, very complicated designs are also possible by means of the process. An example is the use of architectural systems that have several interlocking extrusions, and occasionally use thermal breaks as insulation.

The Aluminum Extrusion Process in 10 Steps

Step #1: The Extrusion Die Is Prepared and Its Movement to The Extrusion Press

The die is made of H13 steel in the form of a round die, or retrieved in the event it is already present. The die is heat treated to 450 -500 deg before it is used to prolong the life of the die and also to provide uniform flow of metal during extrusion. The die after being well preheated is inserted in the extrusion press and is ready to operate.

Step #2: An Aluminum Billet Is Preheated Prior to Heating Extrusion

The second phase of the extrusion is preparation of the raw material called a billet. A billet is simply a solid cylindrical alloy of aluminum which was cut off a larger log of aluminum. The billets are used as the starting material in production of the desired extruded profiles. The billet has to be properly preheated in a special industrial oven before the extrusion may occur. The characteristic temperature range in this step would be 400-500 degC. Such controlled heating is essential since it melts the aluminum enough to enable it be malleable to be able to flow easily through the die under pressure. Critically, the billet is not melted at this point, the billet is taken to a condition whereby they can be plastically deformed without cracking or breaking.

Step #3: The Extrusion Presses Transfers the Billet

Once preheated the aluminum billet is then transferred using mechanical power to the extrusion press. A lubricant or release agent is applied to the billet surface prior to the pressing process ensuring that less friction is caused. The agent also is coated onto the hydraulic ram, which guarantees the easy movement and the non-adhesion of the billet and the ram. This is needed to ensure that the extrusion is efficient as well as the integrity of the material and equipment.

Step #4: The Ram Moves the Die Material to the Container

This is done by putting the softened aluminum billet into the extrusion press to this stage. This is then propelled by a powerful hydraulic ram that causes a lot of pressure up to 15,000 tons. The billet is gradually forced to the press container under this force. The pressure accumulates and thus the aluminum pushes outward and completely fills the walls of the container. This makes sure that the material is compacted uniformly and ready to the next process of extrusion using the die.

Step #5: The Material to The Die Is Extruded

As the alloy of aluminum radiates in the press container, it is pressed against the extrusion die. Uninterrupted hydraulic pressure provides the material with the only way in front through the opening of the die. Out of this release, the aluminum acquires the shape of the die in all of its entirety and is a fully defined profile to be cooled and processed further.

Step #6: The Outgoing Extrusions Are Placed onto The Run Out Table and Are Pashed

After the aluminum profile has come out of the die, it is lifted by a puller that deliberately brings it round the run out table. The puller moves at a constant rate with the rate of extrusion so that there is smooth movement without distortion. The profile is allowed to cool down the table, this is quenching, done either by a water bath or fans mounted above it, balancing its properties and structure.

Step #7: The Extrusions Are Sheared to the Length of the Table

Once an extrusion is large enough to cover a full table it is cut off the process with a hot saw. This is the separation to make the profile manageable that would be later handled. During the extrusion, heat is highly important. The profile even though already extinguished once the press is removed has a lot of heat on it and still it is not that cold. This stage is suitable for the shearing preparation of the extrusion which is followed by the subsequent cooling and alignment.

Step #8: The Extrusions Are Brought to Room Temperature

With the extrusion runoff the runout table the extrusions are then moved to a cooling table mechanically to table length. In this case, the aluminum profiles are left to cool till they slowly cool down to room temperature. The cooling is an important step in stabilization of the material. When the profiles are cooled enough, they are moved on to the next stage namely stretching to get them properly aligned.

Step #9: The Extrusions Are Brought to The Stretcher and Are Aligned Stretched

The extruded profiles usually acquire slight twisting or distortion as the profiles cool off, which has to be corrected. The profiles are moved to a stretcher in order to regain their correct shape. In this case, both ends of each extrusion are firmly clamped, and the extrusion is mechanically pulled with regulated force. This elongation process removes any imperfections and straightens the aluminum therefore rendering them to exact dimensional requirements thus completely straight and prepared to undergo the final steps of cutting and finishing.

Step #10: The Extrusions Are Brought to The Finishing Saw and Are Cut to the Required Length

As soon as the table-length extrusions are straightened and properly working hardened, it is moved to the finish saw table. In this case, the profiles are of a predetermined length usually between 8 and 21 feet. At this point, the extrusion of T4 properties are taken over. After sawing, they can be put into aging ovens so that they will obtain the stronger T5 or T6 tempers.

Benefits of Aluminum Extrusion

 Lätt och stark

Aluminum has an amazing ratio strength to weight hence using it on aircraft component, structural frames and so on.

Motståndskraft mot korrosion

Aluminum is impervious to corrosions, unlike steel, which has its layer of oxide, and hence it is ideal in exterior use.

Flexibilitet i designen

Extrusion It can be shaped indefinitely by the use of basic bars to the complex arrays of hollows and channels.

Kostnadseffektivitet

The process reduces wastage and enables mass production, which maintains the cost of materials and machining low.

Uses of Aluminum extrusion.

You may be surprised to realize that there are very numerous industries that depend on extrusions.

Konstruktion

The extrusion of aluminum has become an important part of the modern construction as it is strong, durable and allows flexibility in its design. It is commonly applied in the production of window frames that are lightweight and yet durable to support weight, smooth-finished doors, and curtain walls that are made to strengthen the beauty of the building and even maintain its stability. Aluminum is also extruded to create railings which are so safe yet attractive and roofing which provides protection against the rain and performance durability. With these applications, one can see the versatility of aluminum, and thus the need to use this component of architecture and structures design.

Fordon

Most applications in the automotive industry embrace the Aluminiumprofiler as it is a strong material, lightweight, and able to perform well thermally. Among these, one is EV battery trays that need to be durable and resistant to corrosion, and make vehicles efficient and safe at the same time. Structural components are also made of extruded aluminum that is non-rigid and does not contribute to the increased weight. The applicability of aluminum in heat exchangers is as a good thermal conductor which aids in cooling and improves the energy and performance efficiency of the entire vehicle.  

Elektronik  

Aluminum extrusion is widely used in the production of components that require a combination of strength, precision, and thermal efficiency. An example is heat sinks which have extruded fins that assist in the retention of heat in order to minimize damage to sensitive machines. The extrusion serves a double purpose of creating a lightweight design, thus protecting the equipment in an effective manner, and a tough casing to defend against mechanical damage.

Flyg- och rymdindustrin

The capability of Aluminiumprofiler is important in aerospace engineering because of strength-weight ratio and versatility. It also finds a wide range of application in aircrafts frames and offers lightweight and durable frameworks which enhance efficiency of fuel consumption. Interior components are also produced by extruded aluminum, including seating supports and cabin structures and provide safety as well as lesser weight. We also have support beams that consist of extrusions, which provide rigidity and stability to assist aircraft to endure the highest level of stresses during their operations and ensure that their overall performance and stability remain intact.

Konsumentprodukter

The light weight and versatility of aluminum made it application with the best use in consumer products. It also manufactures long lasting furniture frames, strengthens sports equipment like bike bikes and rackets and also aids fitness machine with components of precision. Extruded aluminum has also been utilized in the technology we use daily such as laptops whereby it offers slick cases that offer not only durability but functionality and good design as well.

Choosing the Right Aluminum Extrusion Alloy

There is no substance unity of all aluminum alloys.

6000 Series Extrusions

The most common are 6061 and 6063. They are an amalgamation of strength, corrosion protection and extrudability.

Strength vs. Formability

Stronger alloys are more difficult to extrude and more popularly the softer alloys have higher formability. This is because the right choice will be based on the requirements of your project.

Final Thoughts on Aluminum Extrusion

Extrusion is a very versatile, inexpensive, and environmentally friendly method of manufacturing Aluminum. It takes crude billets, and turns them into the high performance billets used in the modern-day industries. You need a balance of flexibility and strength in what you are designing; be it within the structural component or in the miniature electronics, extrusion provides an ideal combination of both.

Vanliga frågor

What is the most used type of extrusion of aluminum?

It weighs less, is durable, flexible, and it is economical to make than machining or casting.

What is the strength of aluminum extrusions?

The alloy and heat treatment is about strength but the extruded aluminum can always be extremely strong yet also light.

In what shapes is aluminum extrusion provided in?

Virtually all shapes solid, hollow, channels, angles, T-shapes plus part-shaped profiles all possible.

Being able to recycle aluminum extrusion?

Yes! Extrusion is environmentally friendly and 100 percent recyclable; this is because aluminum does not lose its quality during recycling.

What are the leading industries in the extrusion of aluminum?

Construction, automotive, aerospace, transportation and electronics.