Aluminum Extrusion manufacturer: A Step by Step Extrusion Process

 

In recent times, there has been an increased demand for Aluminium Extrusion  in product manufacturing and design. This led to an increase in the demand for a professional and reliable Aluminium Extrusion manufacturer. Technavia presented a report showing that there would be an annual growth rate of almost 4%.

In case, you are unaware of this manufacturing process, you are in the right place. In the course of this article, we will talk about Aluminium Extrusion in detail. So, without any further delay, let us get started!

A Guide on Aluminium Extrusion

What is Aluminium Extrusion?

It is a process that forces an aluminum alloy material through a die while using some specific cross-sectional profile. The manufacturer uses a powerful ram to pus the aluminum through the die. Due to the intense pressure, the aluminum comes out of the die opening.

When the aluminum comes out of the die’s front, it has the same shape as that of the die.  A runout table then pulls out the aluminum. Aluminium Extrusion is easy to understand the process, especially at the fundamental level.

You can link the force applied to push the aluminum via the die’s front as to that of squeezing a tube to get the ingredient out. The substance present inside the tube would take the same shape as the opening of the tube after you apply pressure to it.

Таким образом, это означает, что алюминиевый профиль будет зависеть от открытия матрицы. Для круглой формы вам потребуется круглое отверстие, для квадратного, квадратного отверстия и так далее.

Формы для выдавливания

Вы подразделяете выдавленные формы на три разные категории.

1.  Твердый

Твердые формы не имеют закрытых отверстий или пустот. Угол, балка или стержень - общие примеры, которые подпадают под эту конкретную категорию.

2.   Hollow

Hallow обычно имеет одну или несколько пустот. Например, прямоугольная или квадратная труба.

3.   Semi-hallow

Эти формы обычно имеют пустоту, которая частично закрыта. Например, канал «С», имеющий узкую щель.

Extrusion is popular among numerous industries including the energy, aerospace, electronics, automotive, architecture, and several other industries. You can achieve even extremely complex shapes by using multiple extrusion processes.

The Aluminium Extrusion Process

Below, we have explained the Aluminium Extrusion process in ten steps.

Step 1: Preparing and Moving the Extrusion Die

For starters, an Aluminium Extrusion manufacturer would use H13 steel for the machining a round-shape die. Of course, some manufacturers would already have the desired shape. In that case, they would simply pull it out from their warehouse.

The die needs to be preheated between 450 to 500 degrees Celsius. This would not only help maximize the lifespan of the die but at the same it, it would make sure that the metal flows evenly. Once you preheat the die, you can load it into the extrusion press.

Step 2: Heating Aluminum Billet Before Extrusion

The next step is heating the aluminum billet. It is basically a cylindrical solid block of aluminum alloy. Manufacturers extract the billet form a longer log of aluminum alloy material. You should have to preheat this in an oven. The temperature needs to be between 400 to 500 degrees Celsius.

Heating the billet would not melt it completely. However, it would make it malleable enough to yield to the extrusion process.

Step 3: Transferring Extrusion to the Billet Press

Once you heat the billet as required, it would mechanically be transferred to the extrusion press. However, applying a release agent or a lubricant onto the billet is important. This step needs to take place before the loading of the billet into the press.

Also, it is important to apply the same release agent to the extrusion ram. Doing so would ensure that the ram and the billet do not stick together.

Step 4: Pushing the Billet in the Container

After transferring the billet to the extrusion press, it is time for the apply the pressure. The ram would apply around 15,000 tons of pressure to the malleable billet. The application of the pressure forces the billet into the extrusion press’ container.

The material than would expand and gradually fill the container walls.

Step 5: Extruded Material Coming Out of the Die

Даже после того, как материал заполнит контейнер, гидроцилиндр все еще оказывает давление. Это означает, что теперь материал прижимается к экструзионной головке. Из-за постоянного давления алюминиевый материал будет проходить через отверстие матрицы.

Когда он выходит из отверстия матрицы, он имеет точную форму, что и отверстие матрицы. Это означает, что вы уже достигли желаемой формы.

Шаг 6: Таблица закалки и биения

Когда экструзия выходит из передней части матрицы, съемник удерживает ее. Этот съемник затем отвечает за его ведение вместе с выходным столом. Скорость стола будет соответствовать скорости, с которой экструзия выходит из пресса.

With the run-out table movement, the profile is quenched. To ensure its sturdiness, it needs to be cooled uniformly. алюминиевой экструзии either uses fans located above the table or they rely on water baths.

Step 7: Extrusion Shearing

After the extrusion has reached its full table length, it is not time to sheared it away from the extrusion process. For this particular purpose, manufacturers use a hot saw. The saw would separate the particular extrusion from the extrusion process.

NOTE: Temperature is an extremely important aspect of the extrusion process. You need to keep a close check on it at every stage of the extrusion process.

Even though you quench the extrusion after it leaves the press, it still requires time to fully cool down.

Step 8: Extrusion Cooling at Room Temperature

After the shearing takes place, it is time to transfer the extrusion from the run-out table to the cooling table. This process would take place mechanically. Now the manufacturer would wait for the profile to reach room temperature before shifting it to some other place.

After they cool down, it is important to let them stretch.

Step 9: Moving Extrusion to Stretcher

Sometimes, there is a certain twisting that occurs in the profile. As a professional Aluminium Extrusion manufacturer, you would have to work on it. In order to correct the problem, you move the table length extrusion on to a stretcher.

Every profile is gripped from both sides. It would mechanically be pulled until it reaches the desired specifications.

Step 10: Sawed According to Specifications  

Now that the table length extrusions are fully cooled and they are straight as well, it is time to transfer them to the saw table.

Here, these extrusions are sawed according to the length. In general, the length ranges from eight to twenty-one feet.

NOTE: The properties of extrusion at this particular stage are similar to that of the T4 temper. After sawing, it is possible to age the extrusion to T5 or T6. In order to do so, you would have to move them to an aging oven.

 

The Final Touches

After the completion of extrusion, it is possible to enhance the properties of the profiles by giving them heat treatments. To enhance the finished look of the extrusions, Aluminium Extrusion manufacturer uses different finish types.

However, these finishes need to be done the heat treatments. To bring the extrusion to their final dimensions, they need to go through different fabrication operations.

Improving Mechanical Properties

It is possible to enhance the tensile strength and stress taking ability of alloys in the 7000, 6000, and 2000 series. In order to get these enhancements, it is important to put the profiles into ovens. These heating treatments would bring the alloys to T5 or the T6 tempers.

Surface Enhancement

There are numerous finishing operations that aluminum profiles would undergo. Surface enhancements not only improve the overall appearance of the aluminum but at the same time, it also improves it corrosion properties.

For instance, when you anodize the aluminum, it would result in the natural occurrence of the oxide layer. Thus, resulting in the thickening of the metal. Also, the process would enhance the corrosion resistance of the profile. In addition, the metal would become more resistant to wear.

Likewise, it would result in a porous surface, it means that the surface would accept different colors. The surface emissivity would be enhanced as well.

There are some other finishing processes available as well. Some of them are listed below:

1. Sandblasting
2. Порошковое покрытие
3. Painting
4. Sublimation

Резюме

Aluminium Extrusion is a process that manufacturers use to create components and parts having certain cross-sectional profiles. To enhance both the properties and appearance of the aluminum, the manufacturer uses different mechanical and surface enhancement processes.

Процесс алюминиевой экструзии также использует определенный производственный процесс для получения окончательных размеров продукта. В конце концов, их цель - получить высококачественные алюминиевые детали.

Если вы ищете поставщика или производителя алюминиевых профилей, вы можете обратиться к нам . Мы предоставим вам все, что вы ищете.