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.

So, it means that aluminum shape would depend upon the opening of the die. For round shape, you would require round opening, for square, square opening, and so on.

Shapes to be Extruded

You categorize the extruded shapes in three different categories.

1. Solid

Solid shapes do not have enclosed openings or voids. Angle, beam, or the rod are common examples that fall under this particular category.

2.  Hollow

Hallow usually comes with one or more voids. For instance, a rectangular tube or a square tube.

3.  Semi-hallow

These shapes generally have a void that is partially enclosed. For example, the “C” channel having a narrow gap.

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

Even after the material fills the container, the ram is still applying pressure. It means that now the material is pushed against the extrusion die. Due to continuous pressure, the aluminum material would go through the die’s opening.

When it comes out from the opening of the die, it is in the exact shape as that of the die opening. This means, that you have achieved your desired shape so far.

Step 6: Quenching and Runout Table

When the extrusion comes out from the die’s front, a puller holds onto it. This puller is then responsible for guiding it along with the run-out table. The speed of the table would match the speed at which the extrusion is coming out of the press.

With the run-out table movement, the profile is quenched. To ensure its sturdiness, it needs to be cooled uniformly. Aluminium Extrusion manufacturer 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  

ตอนนี้การอัดขึ้นรูปตามความยาวของโต๊ะได้รับการระบายความร้อนอย่างเต็มที่และตรงเช่นกันก็ถึงเวลาที่จะย้ายไปที่โต๊ะเลื่อย

ที่นี่การอัดขึ้นรูปเหล่านี้ถูกเลื่อยตามความยาว โดยทั่วไปมีความยาวตั้งแต่แปดถึงยี่สิบเอ็ดฟุต

หมายเหตุ: คุณสมบัติของการอัดขึ้นรูปในขั้นตอนนี้มีความคล้ายคลึงกับอุณหภูมิ T4 หลังจากเลื่อยแล้วสามารถยืดอายุการอัดขึ้นรูปเป็น T5 หรือ T6 ได้ ในการทำเช่นนั้นคุณจะต้องย้ายไปที่เตาอบที่มีอายุมาก

 

สัมผัสสุดท้าย

หลังจากเสร็จสิ้นการอัดขึ้นรูปเป็นไปได้ที่จะเพิ่มคุณสมบัติของโปรไฟล์โดยการให้ความร้อน เพื่อปรับปรุงรูปลักษณ์ที่เสร็จสิ้นของการอัดขึ้นรูปผู้ผลิตอลูมิเนียมอัดขึ้นรูปจึงใช้ประเภทการขัดผิวที่แตกต่างกัน

อย่างไรก็ตามการเสร็จสิ้นเหล่านี้จำเป็นต้องได้รับการบำบัดด้วยความร้อน ในการนำการอัดขึ้นรูปไปสู่มิติสุดท้ายต้องผ่านกระบวนการผลิตที่แตกต่างกัน

การปรับปรุงคุณสมบัติทางกล

เป็นไปได้ที่จะเพิ่มความต้านทานแรงดึงและความสามารถในการรับความเค้นของโลหะผสมในซีรีส์ 7000, 6000 และ 2000 เพื่อให้ได้รับการปรับปรุงเหล่านี้สิ่งสำคัญคือต้องใส่โปรไฟล์ลงในเตาอบ การให้ความร้อนเหล่านี้จะนำโลหะผสมไปที่อุณหภูมิ T5 หรือ T6

การปรับปรุงพื้นผิว

มีงานตกแต่งจำนวนมากที่โปรไฟล์อลูมิเนียมจะได้รับ การปรับปรุงพื้นผิวไม่เพียง แต่ปรับปรุงลักษณะโดยรวมของอลูมิเนียม แต่ในขณะเดียวกันยังช่วยเพิ่มคุณสมบัติการกัดกร่อนอีกด้วย

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. Powder Coating
3. Painting
4. Sublimation

Summary

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.

The Aluminium Extrusion manufacturer also uses certain fabrication process to acquire the final dimensions of the product. After all, their objective is to achieve high-quality aluminum parts.

In case, you are looking for an Aluminium Extrusion supplier or manufacturer, you can reach out to us. We will provide you with all that you are looking for.