Aluminum Profile Extrusion Manufacturing Process

Extrusion is defined as the process of forming a material by forcing it, such as aluminum, through forming an opening in a die. The extruded material is an elongated piece with the same profile as the die opening. The advantages of aluminum extrusion include its lightweight, versatility, and strength. It is 100% recyclable and resistant to rust and corrosion. It is also malleable and conducts heat beautifully. It weighs only a third of that of steel, making it a great choice for lightweight, extra-strength structures. Different die designs allow for a variety of shapes and profiles. In addition, aluminium is a 100% recyclable material and can be recycled multiple times. Generally speaking, the aluminum extrusion has four features as follows.

Die design

Die design in aluminium profile manufacturing process ensures an even distribution of velocity throughout the final product, which plays an important role in the quality of the finished product. The velocity relative difference can be calculated by examining the relationship between node speeds and the average speed of the product, as shown in Equation. The smaller the VRD value, the better the flow distribution and quality of the end product. A traditional flat die has a smaller contact area with the material and a longer bearing length in the exit region. This creates increased heat transfer, and the highest temperature occurs in the middle of the product. The minimum temperature is located at the left and right edges of the profile. The region near the center of the finished product is most likely to experience severe deformation. Typical temperatures of a traditional flat die are 497.5°C, while those for a pocket die and spread die are 500.6°C and 496°C respectively.

    

                           
 

Port Area and Total Area of ports in the die are important variables to evaluate. The size of each port should correspond to the required profile size, while the distance between each port and the center of the die port determines the direct exposure to aluminium flow. In addition to evaluating the port area, the designer must consider the die’s weight and a variety of other parameters.  A computer simulation of the extrusion process can be used to help determine the shape of an aluminium die. The model used in this simulation uses the rigid-plastic modeling method to determine the distribution of metal particles in the container and to calculate the strain, stress, and temperature of the metal. The software then automatically generates the meshing process for the die. The billet area receives a rough mesh size, which gradually decreases as it moves through the pocket and spread chambers. 

Temperature Control

The aluminum extrusion process relies on precise temperature control. Temperatures are adjusted at different points during the extrusion process to achieve the desired mechanical properties. These properties are important for the finished product, including strength and hardness. Temperature control is important during this process to avoid the burning of energy. The process of aluminium extrusion requires constant measurement of billet temperature. During the process, the billet temperature must be monitored several times to ensure the desired rate of cooling. Once the billet is extruded, it is transferred to a cooling table and is mechanically stretched to achieve the desired profile.

 

Several temperature measurement methods are available. These include contact temperature measurements, which require prodding the aluminium, which may damage the surface. Another option is to use noncontact temperature measurement sensors. These temperature sensors do not touch the aluminium and provide continuous monitoring of the metal temperature. An infrared pyrometer is an infrared device that uses radiated energy to measure temperature. Temperature measurements are crucial for quality control and to ensure product consistency.

 

The mechanical properties of the metal depending on the temperature history. Moreover, the pressing speed of aluminum is determined by the temperature. In order to obtain a high-quality pressed product, the processing speed must be high. The cooling rate after extruding the matrix is also important for the strength properties of the extruded profiles. The temperature-control method is used for the manufacturing of aluminum profiles. This process involves careful monitoring of temperature, press speed, and quality.

 

Aluminum extrusion is a complicated process, and accurate temperature control is essential to ensure that the final product is as good as it can be. Extrusion requires precise temperature control of the billet and its exit temperature, which determines the final shape and dimensions of the finished product. Excessively high temperatures can cause the profile to crack or leave defects. This can reduce the production rate, which reduces the quality of the end product.

Precision

If you are looking for a high-quality supplier for your aluminum extrusion needs, you have come to the right place. Listed below are three reasons you should choose a supplier for your aluminium component needs. First of all, precision is a crucial requirement for aluminium components. Although the variance in physical properties and dimensional control is inherent in virtually any manufacturing process, precision is essential for the understanding of all parties involved.

 

Tolerances are the limits on which a profile can differ from its design. They are used to ensuring that the part is functional without compromising the design. Tolerances are defined by engineering professionals, and it has developed them in response to the complexity of aluminum profile extrusion. Tolerances are an integral part of an aluminium component, as they determine its suitability for the intended application. Tolerances can vary considerably, and you should know these limitations to make sure you are getting the exact results you need.

 

For cutting aluminum extrusion profiles, precision is paramount. There are many types of saws, each varying in its blade size, toleration, and cut angle values. With precision miter cutting, you’ll be able to produce aluminum profiles that meet the specifications of your project with minimal defects. In addition, you’ll be able to benefit from automatic devices that clamp profiles. Aside from precision miter cutting, precision aluminum extrusion also ensures cleaner, more accurate results.

 

Aluminum extrusion is also an excellent solution for custom shapes. Compared to other fabrication methods, it’s more cost-effective than other methods. The process can be used to consolidate parts and eliminate secondary joining processes. And since aluminum extrusion is made of several different materials, you can make any shape you need. You can even customize the extruded product according to your specifications. So, you can’t go wrong with a precision aluminium extrusion.

Customization

The process of aluminum extrusion allows for a great deal of customization. The process can produce complex shapes and uniform designs over the entire length of the material. It is also possible to produce aluminum extrusions in a variety of finishes and grades and can be fabricated with close tolerances. A custom extrusion can be used for both hollow and solid products. Read on to learn more about the benefits of this process and how it can benefit your business. Firstly, aluminum is a malleable material. It is one of the most easily worked metals in the heavy industry. Its surface is protected by an oxide layer, which will repair any damage to it. This means that aluminum is more suitable for use in marine environments, where other metals are prone to corrosion. Custom extrusion can help you achieve exactly what you need. You can even customize the dimensions of the product.

  

When custom extrusion is performed, the material is pushed through a pre-made mold in order to produce the desired shape. This process is very similar to pushing toothpaste through the end of a tube. However, in this process, only compressive and shear stresses are applied to the material. This allows for complex cross-sections and the use of brittle materials. Custom extrusion is a cost-effective option for manufacturers who need products in a specific shape or size. Because of the advantages of custom aluminum dies, the metal is an attractive option. Aluminum is abundant on Earth, making it an attractive material to use. Custom dies reduce the amount of material used, resulting in significant weight and fabrication savings. Additionally, manufacturers can easily recycle aluminum, making it a more environmentally friendly choice. The benefits of aluminum extrusion go far beyond weight savings. The versatility of this material makes it an ideal material for any business.

   

 

Through the aluminum extrusion process, aluminum extrusion manufacturers produce a wide range of aluminum extrusions from bar, sheet and coil, benefiting several industries. For example, extruded gaskets are used by the automotive, aerospace and aerospace industries, among others. The most common extruded profiles that use aluminum as a workpiece include channels, rectangular tubes, and angles. With these three alone, manufacturers can manufacture components for industries such as appliances, construction, computers, and construction.

  

Standard Aluminum Extrusions Shapes

Aluminum profiles are the shapes of extruded aluminum products, including decorative covers, rods, angles, bars and channels, which represent only a small fraction of the wide range of configurations and sizes in which aluminum profiles can enter. The profile can be hot, cold or lukewarm and extruded through a die having the shape of the profile. There are standard profile designs that are commonly used, or profiles can be custom designed for special applications. The most common alloys used to make profiles are aluminum 6061, 6063, and 1100. Profiles play a key role in the extrusion process. A billet or log forced through a die emerges in a shape called a profile. The outline design is created during the design phase which determines its size and shape. Over the many years of using extrusion, various hollow, solid, or semi-hollow profiles have been developed. The profiles are carefully selected according to their application before production. Its shape is forged in a die to precisely match its design requirements. Once the profile is approved and die-cast, it is applied to the application process and the product or part is manufactured.

 

There are a large number of extruded aluminum shapes and sizes to choose from. In addition to rectangular tubes, angles, and channels (including F, H, J, and Z), there are also rods, sliding T-tracks, splitter rods, H-beams and I-beams, pipes, slotted square tubes, corner extrusions, even decorated with mirror trim. With so many standard profile options, you should be able to easily find what you’re looking for, whether it’s armrest accessories, auto parts, inverted edging, or more. If you’re looking for standard aluminum extrusion shapes, the best place to start is a reputable manufacturer. Top aluminum extrusion manufacturers produce a wide variety of shapes and sizes. You can find rectangular tubing, angles, channels, and other shapes that can be used across multiple industries. These products can be millimeters or several feet in length. The following is a breakdown of the most common shapes. 

Customized aluminum extrusions shapes

The manufacturing process of aluminum extrusions allows manufacturers to create complex designs with tight tolerances. Additionally, they can produce aluminum extrusions in a wide variety of finishes and grades. These extrusions are commonly used for products in the healthcare industry and can be used to produce both simple and complex designs. Here are some of the benefits of custom aluminum extrusions for your next project. You will be glad you took the time to learn about them! Using custom aluminum extrusions in your industrial applications is a smart way to reduce cost and waste. These materials are highly durable and are resistant to corrosion. Additionally, they can be used in a wide range of environments, including hot and cold temperatures. Lastly, these products can be recycled without degrading their properties. Customized aluminum extrusions are an excellent option for industrial applications. However, they must be sourced carefully.

  

The versatility of aluminum allows for many different applications. In addition to being lightweight and strong, aluminum is also resistant to corrosion and can accept a greater range of coatings. Finishes are important because they affect the overall look of aluminum extrusions. The process of extruding aluminum also allows manufacturers to produce complex shapes from a single piece. This allows manufacturers to minimize the waste of metal and make more custom products. Aluminum extrusion shapes can be customized with a variety of finishes, including powder coating and anodizing. These coatings can add a beautiful, durable finish to aluminum extrusions. Anodized aluminum is resistant to rust and stain. In addition, these extrusions are lightweight and low-density, making them an ideal choice for various applications. Furthermore, aluminum is an environmentally friendly metal and is recyclable.

  

Since aluminum is one of the most abundant metals on earth, it is a highly desirable material for manufacturers. The custom extrusion process allows manufacturers to save weight and money on fabrication, which is another key benefit. In addition to this, custom extrusions can save money on tooling and dies. Customized aluminum extrusions shape industrial aluminum profile factories to provide a reliable and quick service. The company provides state-of-the-art. ShiJunHongMao is the company to turn to for your next aluminum extrusions project.

Dimensions of custom aluminum extrusions shapes

Custom aluminum extrusions can be manufactured in nearly any shape you can imagine. They can be engineered to simplify assembly, reduce machining and welding operations, and reduce other processes. Hollow shapes are typically referred to as Class 3 hollows and can be made to fit any specific shape. For more information on these types of shapes, please contact your aluminum extrusion supplier. This is a list of common shapes made from aluminum extrusions.

 

After aluminum extrusions are finished, they are transported to the cooling table, where they are allowed to cool to room temperature. In addition to cooling the aluminum extrusions, the process also involves a stretching step. This stretcher pulls the aluminum extrusion from both ends of the length until it becomes straight. Next, the extrusions are cut to size and aged in an oven until they reach the desired hardness. After that, they undergo a finishing process that deburrs and softens the sharp edges.

 

Custom aluminum extrusions can be made of various types of aluminum and are easy to use. Using them in your manufacturing process will simplify the process and reduce the overall costs. In addition to being affordable, they are also easier to assemble, with fewer steps and tooling. With the right tools, you can create your own custom aluminum extrusions in any shape you like. To learn more about how custom extruded aluminum profiles can be used and their characteristics, Please contact ShiJunHongMao aluminum extrusion manufacturer for more information.

  

 

Characteristics of Industrial Aluminium Profile Extrusions

Hardness:

Due to the nature of aluminum, many customers worry about the hardness of the material when purchasing industrial aluminum profiles. The hardening of aluminum profiles is achieved by “heat treatment” as opposed to flat rolled products which are usually achieved by cold working/rolling processes for greater hardness or strength. It is important to note that the hardness of an aluminum profile is directly related to the chemical composition of the alloy. The 7 series of alloys have the highest hardness, followed by alloys 2, 4, 6, 5, 3, and 1. 

Corrosion Resistance:

The corrosion resistance of industrial aluminum profiles includes chemical corrosion and stress corrosion. Generally speaking, pure aluminum alloy 1 series corrosion resistance is the best, alloy 5 series performs well, alloy 3 series and alloy 6 series are second, and alloy series 2 and alloy series 7 are poor. The type of corrosion resistance must also be determined depending on the application of the profile. Various anti-corrosion composite materials must be used in conjunction with high-strength alloys used in highly corrosive environments.

Machinability:

Machinability refers to the ease with which the profile can be machined by drilling, cutting, etc. Since the formability of the extrusion is related to the quenched state, the strength range of the different quenched states should be considered after the selection of the aluminum alloy grade, most often not, the high-strength alloy is not so easy to form, but easy to process. The reverse is true for easily formable alloys, which are generally less easy to machine. The formability of annealed material is generally the best, while the formability of heat-treated material is the worst. In contrast, low-strength aluminum alloys have poor machinability.

Weldability:

The “weldability” of most aluminum alloys is generally not an issue, especially 5 series alloys which are designed for welding. It is important to note that welding aluminum generally affects the strength and temporality of the alloy and should only be performed by experienced aluminum welders.

Decorative Applicability:

When industrial aluminum profiles are used for decoration, the surface is usually anodized, polished or powder coated. In order to achieve the appropriate color and surface texture, the decorative nature of the application must be considered. Generally speaking, alloys with good corrosion resistance have good anodizing, surface preparation and coating properties.

 

Last, The Benefits of Aluminum Extrusion

The aluminum extrusion process has its advantages and when combined with the properties of aluminum can produce products with unique qualities. These qualities are beneficial to both the manufacturer and the end user. The extrusion process is mainly used to produce parts with complex sections. Additionally, it can handle brittle materials that are difficult to handle with other forming processes. Easy to create complex cross sections. Complex parts can be made as long as they have the same cross-section along their entire length. The increase in operating costs to produce more complex parts is minimal compared to other forming processes.

Glass Wall Rail Cross Section

Ability to Form Brittle Materials: Extrusion produces parts free of tears and cracks due to the favorable configuration of the metal for plastic flow. This is due to the high compressive stress on the cavity and the die due to the forces acting on the blank.

High dimensional accuracy: Compared to casting and rolling, aluminum profiles can be produced with tight tolerances. Metal flow can now be modeled using computer numerical simulations to predict extrusion dimensions and profiles.

Seamless hollow parts can be formed: Hollow sections can be extruded from aluminum using a combination of die and mandrel. These profiles do not require mechanical joints or welds, which are potential weak points of the product.

Extruded Aluminum Hollow Profile

Solid profiles: Solid profiles are created without a closed cavity, but with one or more holes. They have a simple design, attractive appearance, and extraordinary strength.

Operational flexibility: When changing from one extruded profile to another, only minor adjustments to process parameters are required with little or no downtime in production.

Good surface condition: Secondary operations can be easily integrated to create various finishes. The surface of the product can be polished or polished for a mirror finish or brushed for a matte finish. In addition to polishing, aluminum profiles can also be anodized, painted, powder coated, galvanized, or laminated. The standard finish is a ground finish where the product is deburred and cleaned and is ready for anodizing, powder coating, or any other secondary surface finish. Sandblasting is a common surface treatment performed before anodizing. Types of anodized finishes include clear and black, which are the most common anodized finishes, and custom colors are also available.