Aluminum Extrusion
What is Aluminum Extrusion ?
Aluminum profiles, also known as aluminum extrusion profiles, are generated via a process known as extrusion. This involves pushing a heated aluminum billet through a die with a specific cross-sectional shape under applied pressure. The resulting profiles are lightweight, sturdy, and resist corrosion due to the die shaping. Typically, the die is crafted from hard steel or carbide.
Two prevalent methods of aluminum extrusion exist: direct (or forward) extrusion, and indirect (or reverse) extrusion. There is a variety of ways to classify aluminum profiles. If we categorize them by the constituent aluminum material, we can have 1100 aluminum profiles, 6061 aluminum profiles, and 6063 aluminum profiles. Alternatively, if we classify them based on their usage, they can be segmented into architectural aluminum profiles and industrial aluminum profiles, among others
The Process of Extrusion :
Step 1: Raw Material Selection The production of industrial aluminum profiles begins with the selection of raw materials, which are obtained by melting and casting aluminum ingots. This material directly influences the performance quality of the final product.
Step 2: Aluminum Rod Heating The aluminum rods’ heating treatment needs strict temperature control as temperatures too high or low affect the hardness of the final product. Thus, the temperature should be meticulously managed during the heating and cooling process.
Step 3: Die Design The die, which is a tool with high-precision designs crafted according to specific needs, is vital for extruding the desired specifications and cross-sections of the industrial aluminum profile.
Step 4: Industrial Aluminum Profiles Extrusion During the extrusion production phase, the control of extrusion temperature is a fundamental and critical process factor. Careful control of the extrusion speed is also required.
Step 5: Straightening and Adjusting Industrial Aluminum Profiles The straightness of the aluminum profile, which dictates whether it can be used on mechanical equipment, is a key quality standard. Generally, extruded profiles need straightening.
Step 6: Manual Ageing Freshly extruded aluminum profiles are low in hardness and therefore require post-production age hardening to enhance their strength.
Step 7: Sandblasting Post-extrusion, industrial aluminum profiles typically bear visible stretch marks, and their surface micropores can be large and rough. These need to be smoothed out via sandblasting.
Step 8: Surface Oxidation Treatment After cooling, the surface of aluminum profiles is usually treated with anodized silver white for an elegant, aesthetically pleasing, and corrosion-resistant finish.
Step 9: Packaging The final product’s packaging must adhere to strict standards due to the high-quality and aesthetic requirements of industrial aluminum profiles.
Finalizing the Aluminum Profile Processing Procedure
Step 1: Cutting
The standard length of an aluminum profile is typically around 6.01 meters. Fine cutting of this profile, based on the design specifications, is the initial procedure, generally maintaining an error margin less, or equal, to 0.5mm. Apart from regular length cutting, the profiles may also require diagonal and bevel cuts.
Step 2: Drilling and Tapping
When internal connections are required within the aluminum profiles, drilling and tapping are often necessary. Given that different aluminum profile specifications demand varying drill sizes, the drilling and tapping processes serve as critical tests for the practical processing capabilities of an aluminum profile.
Step 3: Aluminum Profile Securing
Once the aluminum profiles have undergone the cutting, drilling, and tapping processes, they need to be connected utilizing specialized aluminum profile connectors. As long as the installation is executed following the precise design blueprints, the desired aluminum profile frames, equipment hoods, assembly line workbenches, and other configurations, can be achieved