What is Aluminum Extrusion: Ultimate Guide
Aluminum extrusion is used to shape aluminum alloys for different components used in various industries.
If you are looking forward to learning more about what is aluminum extrusion, and its process, the guide below will help you. So let's read.
What is Aluminum Extrusion?
Aluminum extrusion is a process in which the aluminum alloy is shaped by being forced through the die.
It has a ram that is powerful enough to push the aluminum through the die. Then, the opening of the die allows for the emergence of the required aluminum components.
It is a simple process and is used in many industries where aluminum components are manufactured.
Advantages of Aluminum Extrusion
Aluminum extrusion is a process with multiple benefits, and some of these are the following:
Eficiencia de costes
When compared to other processes used for producing componentes de aluminio, the process of aluminum extrusion is cost-efficient. The cost of tooling is low, and the usage of material is controlled, which also helps minimize waste and reduces overall production costs.
Flexibility in Designing
The process of aluminum extrusion allows the creation of complex components and custom aluminum extrusions, which cannot be produced by any other methods. The process of aluminum extrusion is flexible and can cater to various applications.
Offers Scalability
The aluminum extrusion is capable of handling small as well as larger volumes of production. Hence, it offers flexibility in the situation where the business expands and needs to produce a high volume of components.
Optimization of Strength
Aluminum extrusion allows enhancing the mechanical properties of aluminum profiles to strengthen them. The process aligns the structure of aluminum grains, which makes them hard and tough.
Quick Process
Aluminum extrusion is a very quick process that has a faster turnaround time. It even suits the rapid prototyping process, which allows quick testing of designs.
How does Aluminum Extrusion Work?
The process of aluminum extrusion consists of different steps, and these include the following:
1. Preheating Billets and Dies
The billets are heated and melted to a certain temperature where they are malleable enough to take the shape of the die. The melted billets are then transported in the die over which pressure is applied.
2. Transfer to the Furnace
The billets that are loaded into the dies are then transferred to the furnace quickly so that they can be pressed and extruded there. The ram starts to apply pressure on the billets, and they are moved towards the opening of the die.
3. Extrusion
The heated billets of aluminum are pushed towards the opening. These openings are capable of being modified to attain different sizes and shapes and work like a cookie press. When the billets are pressed, and they come out of the opening, the extrusion of aluminum is carried out.
4. Cooling of Components
En process of extrusion immediately gives the profiles of aluminum a water bath once they are extruded so that they can retain their mechanical properties without any deformation.
5. Stretching of Components
Once the aluminum profiles are cooled down, they are then subjected to the stage of strengthening– where they are grabbed by a puller, which helps to strengthen the aluminum profiles.
6. Cutting of Components
The stretched components, which may include aluminum bars and profiles, are then cut to the required lengths as asked by the customers. These profiles are guaranteed to have excellent mechanical properties.
Main Types of Extrusion
There are different types of aluminum extrusions, and the main types are the following:
Direct Extrusion
Direct extrusion is one of the most simple types of process, which consists of a stationary die with a ram that forces the billet into the opening.
The movement of the ram makes the billet move in the same direction, and the aluminum profile comes out of the die opening.
Indirect Extrusion
In the process of indirect extrusion, the billet is stationary. But there is an assembly on one end of the ram, which moves against the billet.
This movement creates pressure, which allows the metal to pass through the die opening.
Hot, Warm, and Cold Extrusion
Hot extrusion is a type of aluminum extrusion which is carried out at a temperature ranging between 350 degree centigrade to 500 degree centigrade.
The warm extrusion is carried out between the recrystallization temperature of the aluminum and room temperature, which is around 200 degrees centigrade to 350 degrees centigrade.
Meanwhile, cold extrusion is performed at room temperature and works without heat application.
What Shapes Can Be Extruded?
The extrusion process can help attain multiple types of shapes for aluminum components, and these are:
- Semi-solid shapes like channels, angles, and other shapes that are partially open.
- Hollow shapes like tubes.
- Solid shapes like rods and bars in different bases, including square, rectangle, and circle.
What Aluminum Alloy Can Be Extruded?
Some of the aluminum alloys that can be extruded include the following:
- 1060 offers high weldability and formability, which makes the components suitable for commercial applications when subject to extrusion.
- 3003 is suitable for cold extrusion and is highly machinable, offering good resistance against chemicals.
- 6042 has high tolerance and consistency, and the aluminum extrusions from this alloy are used in electrical connectors, brake parts, etc.
- 6061 offers great strength and is used in the marine, construction, and automobile industries after the process of extrusion.
- 6063 is an aluminum alloy with a texture of fine gains and can be opted for aluminum extrusion to cater to applications like electrical conductors and architectural components.
Which Factors Affect Extrusion?
Some of the factors that affect aluminum extrusion are the following:
- Different types of aluminum alloys have different applications and properties. Choosing the right alloy is very important to attain the desired characteristics in extruded parts.
- The temperature during the process of extrusion also plays a role in the quality of the component. Hence, the temperature must be very carefully controlled to ensure that aluminum profiles are neither too brittle nor too soft.
- The design of the die, which is used in the process of extrusion, also plays a vital role in the shaping of the component.
- Lubrication of the die is important to reduce friction and prevent the molten aluminum from sticking in the die.
- The speed of extrusion impacts the finishing of the component. An extrusion that is too quick causes a lack of accuracy in the dimensions of the aluminum profiles.
- The rate at which the extruded profiles of aluminum cool down impacts the properties of these profiles.
Applications of Aluminum Extrusion
The applications of aluminum extrusion can be seen in many industries, and some of these are the following:
Industria del automóvil
The automobile industry uses aluminum extrusion in the parts of vehicles like chassis and frames. The main structural components of a car are also made using aluminum extrusions.
Industria de la construcción
The construction industry also needs various aluminum profiles. The extruded aluminum is used in curtain walls, door frames, windows, and other structural supports.
Industria electrónica
Aluminum extrusions are common in electronic applications, such as connectors, enclosures, and heat sinks of different electronic devices.
Industria aeroespacial
The aerospace industry uses aluminum because of its lightweight properties. Aluminum extruded profiles are therefore used for aircraft structural components.
Conclusión
Aluminum extrusions are quite versatile. If you are looking to have a custom aluminum extrusion manufacturer for your applications, DEK should be your go-to choice. We offer high-quality aluminum extrusions in various shapes to cater to a wide range of applications.
Preguntas frecuentes
What are the disadvantages of aluminum extrusion?
The process of aluminum extrusion has some limitations, which consist of a high initial cost of investment and limitations on products because, at one time, only one type of shape can be achieved.
What is extruded aluminum used for?
Aluminum extrusions are used to manufacture engine blocks, chassis of vehicles, panels, and housings for transmission.
Is extruded aluminum stronger?
Yes, extruded aluminum shapes are very strong.
