Aluminum Extrusion: Essential Details You Need To Know
1. What Is Aluminum Extrusion?
Aluminum extrusion is a process that includes pushing an aluminum metal material through a specific cross-sectional form cylinder (die). Aluminum extrusions look like an expanded component with about the same thickness as the aluminum die opening.
Usually, this extrusion process involves turning an extrusion ingot into an uninterrupted piece of the uniform cross-section by pushing it to run under extremely high pressure through a die opening designed in a similar appearance to the die opening.
Aluminum extrusion from Homii Bottles Company is more effective at transmitting heat and cold, making it ideal for applications requiring an aluminum extrusion heat exchanger.
Figure 1: Extruded Aluminum Products
2. How Does Aluminum Extrusion Work?
The aluminum extrusion process requires that the billet is forced to pass through a die aperture with a relatively narrower cross-sectional area compared to the billet itself. On the other hand, the extruded aluminum takes on the form of the die’s crack.
In this way, JITA Company’s professional experts can extrude aluminum into any form you can imagine by utilizing massive hydraulic presses that exert pressure of up to 15,000 tons.
Aluminum extrusion may be carried out directly or indirectly. The most common and widely utilized technique of aluminum extrusion is direct extrusion. The die head is kept stationary through indirect extrusion, while the aluminum billet is driven through the die by a moving ram.
Shapes such as hollow tubes, Solid rods, and bars are commonly produced by direct extrusion. The die’s design may be changed to provide a broad range of open and solid shapes. When using direct extrusion, the billet is the one that moves.
The billet is held stationary during indirect aluminum extrusion as the ram moves the die. This process results in pressure being applied to the billet while standing. Maintaining the billet stable is that friction is kept to a bare minimum, which is beneficial. The cross-sectional form of the extrusion is planned before the extrusion process begins.
To optimize functionality, ease assembling, reduce weight, and reduce finishing costs, the form and characteristics of the extruded aluminum are meticulously determined before being produced. Because of the particular qualities of aluminum, it is a cost-effective material that provides outstanding functionality and a beautiful appearance.
Figure 2: Direct And Indirect Aluminum Extrusion Process
3. Aluminum Extrusion Advantages And Disadvantages
Advantages of aluminum extrusion
- Aluminum extrusions are very resistant to corrosion. They do not rust, and a naturally occurring oxide film protects the surface.
- Our aluminum extrusion products have exact dimensions.
- We offer aluminum extrusion that avoids the need for labor-intensive operations like welding.
- Our aluminum extrusion allows for the creation of complex cross-sections.
- Our aluminum extrusion enables the reuse and recycling of aluminum alloy resources.
- The aluminum extrusion process requires inexpensive tooling.
- Our aluminum extrusion provides an aluminum product that has been extruded may be coated, polished, plated, and textured.
- The aluminum extrusion process is easy to operate.
- Extrusion increases rigidity while reducing the weight of aluminum material. As a result, it’s a suitable fit for load-bearing applications.
- Our aluminum extrusion produced lightweight products. Extruded sections also have the advantage of putting material just were required, which possibly lowers weight.
The disadvantage of aluminum extrusion
- The cost of the initial setup may be high.
- The aluminum products may vary in size, which needs fixing to meet the standard size.
- Only one sort of cross-section may be generated at a time.
4. What Kinds Of Shapes Can Be Extruded?
Complex profiles that are created using the aluminum extrusion method in a range of shapes that include;
- Hollow square tube shapes
- Round or oval tube forms
- channel shapes
- Z shapes
- T shapes
- H or I beam shapes
- L shapes
- other structural profiles may all be extruded from the aluminum alloys materials
5. What Is The Difference Between Drawn And Extruded Aluminum?
The way aluminum is created in the die is the primary difference between extruded and drawn aluminum. Drawn aluminum is formed by pressing it into a mold, while extruded aluminum is started by pressing it through a die. For example, drawn aluminum is often used to create pans, pots, plus other circular items.
The extrusion technique that results in extruded aluminum is cost-effective over the drawn aluminum tube manufacturing process. Cold drawing aluminum typically requires a more comprehensive variety of equipment and materials.
Extrusion and drawing are two procedures that are often employed to manufacture various goods. For example, extruded aluminum may be used to construct tubes, aluminum extruded frames, windows and doors, connectors, and railings. Boxes and other items such as cans and pots will be made from drawn aluminum utilized in similar ways.
The extruded aluminum procedure begins with preheating the material to an elevated temp before extrusion. Using the aluminum extrusion die, the metal is driven through the die once it has become soft and flexible. The significant distinction between drawn and extruded aluminum is the temperature disparity.
The drawing uses cold working performed at room temperature rather than at a high temperature.
6. What Material Is Used For Aluminum Extrusion?
Our professional experts utilize 6063 aluminum alloy for both custom and conventional aluminum extrusion design and various other applications and components.
6063 aluminum is famous for aluminum extrusion because it has a high-quality finishing and excellent corrosion resistance. Because of its high electrical conductivity, it is a perfect option for electrical piping and general applications.
7. How Are Aluminum Extrusions Made?
Aluminum extrusion is done in two ways as direct extrusion and indirect extrusion. Aluminum material emerges from the opposite end after being shoved through the die. There’s a run-out table where it’s taken out in the form of the dice. This process involves steps as follows.
Loading the aluminum extrusion press: in this step, the die (round-shaped) is heated up to 450-500 ° c. before extrusion to extend its life and maintain an equal metal flow. Then, the aluminum extrusion press may be loaded with the preheated aluminum alloy.
Preheating aluminum billet: As soon as the billet has been split from an extended aluminum alloy bar, it’s ready to be made into a new piece of aluminum alloy. It is first preheated in the oven to a temperature of up to 500 ℃ but not so hot that it will melt to make it pliable enough for the extrusion process.
Transferring billet into extrusion press: After preheating the aluminum bitten, it is lubricated and then moved to the extrusion press by an aluminum extrusion machine. The lubricator is placed on the aluminum extrusion ram to prevent the billet and ram from sticking together.
Putting in aluminum billet: This step involves loading the extrusion press with the flexible billet and subjecting it to increased pressure generated from the hydraulic ram. Then, the pressed aluminum billet material moves toward its final destination when ram pressure is applied. The product gradually fills the container’s walls.
The extruded material is driven through the die: This step requires that the material is forced against the die while filling the container. The aluminum substance is then released via die openings with the exertion of constant pressure. It comes in the appearance of a wholly formed shape from the die’s entrance.
Guiding and quenching extrusions along with the run-out table: After coming from the press, the extrusion is grabbed by a puller, which leads it down the run-out table at the same speed as it exited the press. A water bath is used to uniformly excellent the “shape” as it descends the run-out table.
Snipping aluminum extrusions: Once an extrusion achieves its optimum table length, it is sheared using a hot saw. It helps separate extrusions from the extrusion process. Here, temperature plays a crucial influence in every phase of the process.
Thus, even if the aluminum extrusion is cooled after passing the press, it is still not assured of achieving its maximum cooling temperature.
Cooling extrusions to room temperatures: After they have been sheared, the extrusions are mechanically transported from the run-out table to a cooling aluminum extrusion table. The aluminum extrusions will be kept on the cold table until they reach room temperature.
Stretching extrusions into alignment: Some profiles may have been bent, which requires fixing. To fix this, they are put on a stretcher. Mechanical grips on both sides of each shape pull one to precise straightness.
Extrusions must be transported to the finish saw after straightening and fully work-hardened.
8. Aluminum Extrusion Part Surface Finish
Surface treatments for aluminum may be divided into mechanical finishing anodizing, powder painting, and chemical paint. Anodizing is the most common surface treatment for aluminum. Surface treatments like mechanical finishing, pretreatment, and sublimation are available; however, they are not widespread.
Mechanical aluminum extrusion finish: Aluminum may be mechanically finished in the same way other metals are and, in most cases, use the same types of equipment. Because they all employ abrasion to remove the metal, polishing, buffing, and blasting may all be used to achieve a smooth surface.
Anodized aluminum extrusion finish: This electrochemical procedure, which has been in use for an extended period, is one of the most extensively utilized finishing processes available. Thickening the existing oxide layer to form a dense film is required for anodizing to be effective; the longer the aluminum is kept in the anodizing solution, the thicker the coating.
It is long-lasting and offers an additional layer of protection by increasing corrosion resistance and regular wear and tear. Anodized aluminum also provides excellent UV protection, perfect for outdoor applications.
Powder painting: The powder paint finish is painted without the need for a solvent to adhere to the surface. It’s a resin and pigment combination sprayed with a spray gun to provide a durable finish.
One of the most significant benefits of powder paint is its uniformity and consistency. It means that powder-coated aluminum placed at the initiation phase will appear precisely the same as powder-coated aluminum put after the project.
It is also available in a wide variety of colors, with the option of metallic or textured treatments; it is pretty adaptable.
It has a higher likelihood of fading, and if applied poorly, it may result in an undesirable look – which is why the aluminum must be prepared before application. However, since it is frequently simpler to fix than other kinds of finishes, you will be able to get more use out of it over time.
It is simple to keep clean daily and feasible to dye it to give a variety of colors.
Chemical paint finish: There are a variety of applications for which aluminum may be treated chemically. Cleaning with chemicals may remove dirt from the surface, while chemical brightening can provide a reflecting surface, and etching can produce a matt appearance.
9. How To Cut Aluminum Extrusion
We advise that aluminum extrusion can be cut using a saw. The following six steps can be used to cut the aluminum extrusion.
Putting the saw in place. On the saw, install the non-Ferris cutting blade. Set up the saw in a clean, open location with enough room to maneuver it around freely. It would help if you took precautions not to connect the saw to the power source.
Figure 3: Setting Up The Saw
You are making a dust collector. It is messy cutting aluminum metal. It won’t help much if you connect a vacuum to the miter saw exhaust port. The chips will end up all over the place. Making a dust collector from scratch will make your life simpler. It may be made out of anything.
You can tarps a few feet away from the saw for significant tasks. You can make a temporary cage surrounding the saw with plywood slanted to drive the chips downwards at the foot of the saw for smaller jobs.
Figure 4: Improvised Dust Collector On The Saw
Make a cut line. When you get to the point to cut the aluminum extrusion, measure the effectiveness and mark them using sharp pencils. Then use a machinist’s or speed square to cut the aluminum extrusion at the marks.
Figure 5: Marking Cut Lines Using A Pencil
You are putting the Work Piece in the Clamps. The tooth of the blade is arranged in a zig-zag pattern. For this reason, you will need to locate the cutter and align the tooth with the cut line on the aluminum extrusion. Take care to secure the workpiece to the tabletop.
Again, make sure it is in line with the tooth. The longest tooth on the blade used to align it should be used as a guide when you move it.
Examine the workpiece to verify it is parallel to the blade. Any material that is left on the level has the potential to distort the workpiece.
Figure 6: Aligning Blade To The Cut Line On Aluminum Extrusion
It is cutting the aluminum extrusion. Lower the saw blade to the aluminum extrusion and verify that nothing moved. Then hook the saw in. Slowly cut, allowing the edge to do the job. Don’t yank the blade down; a little touch is all that is required. Remove the saw from the outlet.
Remove the piece from the clamps and take measurements. Ensure the chip remains clean because a single metal chip might throw off the orientation of the cut; this is a wise practice to do between each amount.
Figure 7: Cutting The Aluminum Extrusion
Remove the Clutter in the working area and clean the saw. After the cutting process is over, sweep everything up with a broom. On the miter saw, vacuum every nook and corner. Vacuum the saw on the other side. Please clean up the area surrounding the saw and anything you used to support it.
10. Where Is Aluminum Extrusion Used?
Aluminum extrusion is a process that turns aluminum alloy into a wide range of consumer and industrial goods.
Our aluminum extrusions are used in a variety of sectors, including electronics, automotive, mass transportation (Trailers and recreational vehicles are all examples of transportation that use aluminum extrusion), bridge decks, renewable energy, and telecommunications, among other applications like industries where workbenches, inspection tables, and trolleys are examples of industrial usage.
Figure 8: Aluminum Extrusion Applications
11. Aluminum Extrusion Defects And Remedies
Aluminum material breaking will develop in structural fractures if the tension rises too high is one of the aluminum extrusion defects. The choice of die angle would significantly influence avoiding center cracking in production. In a metal extrusion, high die angles encourage center breaking greater than low die angles.
Melt fracture is another defect in aluminum extrusion. We recommend that it can be corrected by optimizing the die flow channel, lowering shear stress in the surface area, utilizing a processing assist, adding die-land heaters, and functioning above the vital shear force.
Internal flaws in hollow extrusions result from friction existing between the mandrel and the internal billet interface, causing considerable distortion at the interior surface. Consequently, the inside cover is blotchy and damaged, and the material fused to the spindle is hard to extract. A remedy for this defect is applying a lubricant.
12. How Much Does Aluminum Extrusion Cost?
Extrusion presses may cost nearly $100,000, while dies can cost as much as $2000. Geometry, intricacy, alloys, and whether it’s solid or hollow determine the price of a die. Raw material costs often account for over half of a company’s operational expenditures in the aluminum extrusions processing industry. Controlling these expenses will have a significant effect on the bottom line.
The cost of aluminum extrusion per kilogram may range from $3.79-to $4.39. This aluminum extrusion price varies with the company. If you need, you can contact us through our official website.
13. Why Is Aluminum Extrusion So Expensive?
Usually, the cost of the die makes aluminum extrusion expensive. It is determined by the profile’s intricacy and size, including whether it is a solid shape or one with an enclosed hollow or hollows. Open dies are more costly because they must include more pieces. So, consider if a hollow die is required while creating your section.
Also, more friction equals more force, requiring larger presses, more die wear, and more expenses overall. Therefore, allow for a one-time payment for making the aluminum extrusion die.
You can always reach out to us for more information about prices.
14. How Much Is Aluminum Extrusion Per Pound?
Aluminum extrusion may cost approximately $2.50 per pound. For scrap aluminum material, it can cost about $0.50 per pound.
If you are in need, feel free to contact us via our website
15. Where To Buy Aluminum Extrusion
We provide aluminum extrusion in ample supplies across the world. We guarantee you the suitable aluminum extrusion profiles that will suit your needs. JITA Company is one of the leading aluminum extrusion manufacturers specializing in mass production and customization of high-quality profiles per customer requirements.
Our aluminum extrusion profiles are made strict procedure to comply with the international standards. We also offer reasonable prices and deals with audited and reputable suppliers highly recommended by clients. If you need, visit our website or contact us any time of the day at your comfort.
16. Where To Find Aluminum Extrusion Manufacturers
If you are looking for high-quality aluminum extrusion, you can contact Homii Bottles Company because we provide durable products in bulk at flexible prices. You can browse through our websites and find contact details such as telephone, email address, Facebook page, Twitter, and Instagram.
Alternatively, you can reach us via reliable, professional suppliers and distributors that deal with our products worldwide.
17. What Does Aluminum Extrusion Machine Have?
The machine that completes the aluminum extrusion process is known as an extruder. The machine heats the product and drives it through the aluminum extrusion die to generate the required shape using a series of barrels and cylinders.
The components of the aluminum extrusion machine include ram, main cylinder, hydraulic pressure chamber, butt shear, long shear, log oven, die oven, die lock, die, holder, billet, die assembly, platen pressure ring, container, dummy block, tie rods, canister, press lead-out table, run-out table, front press platen, and cradle.
Figure 9: Aluminum Extrusion Machine
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