How Aluminum Extrusion is Made?

When making an aluminum extrusion, you’ll want to know how the aluminum billets are formed. The aluminum billet is divided into two sections – the butt and the core. The butt contains oxides from the billet skin, so it’s not used in the extrusion process. This is then sheared off and discarded. Once the butt is removed, the process continues with the next billet loaded. Then, the aluminum alloy is cut with a shear or profile saw. The metal is then transferred via belt systems or walking beam systems to a stretcher. This step performs work hardening and straightening the aluminum alloy.

Problems with wall thickness in aluminum extrusion

Having the right wall thickness is critical in obtaining quality aluminum profiles. Incorrect wall thickness causes distortion of the metal during the extrusion process. When choosing the thickness for your profiles, consider the following factors:

Unbalanced shapes have less strength. In addition, shapes with large variations in wall thickness will deform unevenly and are difficult to hold together. Aim for a wall thickness of at least 50% of the largest wall thickness. Inexperienced designers often specify wall thicknesses that are too thin or too thick. If the thickness changes abruptly, it will cause distortion and can be difficult to control dimensionally.

Die design

The design of the die is one of the most critical components of the aluminum extrusion process. The design of the product determines several production parameters, including the alloy to be used and the finish desired. For example, the diameter and circumscribed circle of the profile will depend on its function and will be determined using a cross-sectional drawing. The complexity of the profile also influences the type of aluminum extrusion machine to be used.

The die’s features are divided into five nodes. They are the mandrel, die plate, bearing, and bridges. The die plate defines the outer contour of the hollow section, while the mandrel provides the interior contour. The portholes on the die are designed to permit aluminium flow into the bearing zone. The steel zones between the portholes are known as bridges. These dies have several advantages, so a thorough understanding of their design is important.

Platen pressure ring

A platen is a cylindrical canister that includes one or more apertures. The inert material that enters the die ring is usually nitrogen, although it may be near or entirely absent of oxygen. It may be partially or completely closed, and the inerting gas is pumped in by a fluid supply tube into the platen’s bore. During aluminum extrusion, the inerting gas is usually kept at a desired range.

The pressure ring supports the die stack and acts as a guide for the die. The pressure applied by the main cylinder forces the ring to flex and wear, but it is essential to ensure that the dies are stable. In direct and indirect aluminum extrusion, the die assembly moves against the billet, creating a constant pressure and stress on it. The resulting aluminum is called “tempered,” a combination of strength and hardness.

Canister guide

An aluminum extrusion canister is used to guide the extrusion from the die. The canister has the same number of holes as the die, and has tie rods to connect the back and front press platens. The main cylinder, which is the driving force of the press, is responsible for exerting pressure on the die stack, causing stress and wear. This wear is remedied by a canister guide, which prevents the aluminum from falling out of the die.

Extrusion is a process that shapes aluminum by forcing heated alloy material through a die. The metal is then pushed out of the canister as a long piece with the same profile as the opening of the die. It can be hollow, solid, or semi-hollow, and can be simple or complex. Once extruded, the metal can be finished or fabricated according to specifications. Aluminum extrusion is commonly used in aerospace, automotive, and appliance manufacturing.

Aluminum alloys used in extrusion

When forming components, the best metal to use is aluminum. Because of its high strength and corrosion resistance, it is used in a variety of end applications. Extrusion companies typically provide a wide range of alloys. In addition to construction and automotive applications, aluminum is also widely used in appliances, electronics, and infrastructure. Here, we’ll examine the most common aluminum alloys and the ways they can benefit the end user.

Listed below are some common alloys that are used in aluminum extrusion. Alloys offer different strengths. Some aluminum alloys are stronger than others, while others are harder or more flexible. Each of these alloys has its own advantages and disadvantages. For example, some alloys have a higher strength than others, while others are softer and can be fabricated into different shapes. If you need a particular aluminum alloy for a specific application, try a 6061 alloy.