Aluminum Extrusion Process 2022

Extrusion refers to the process of creating a particular shape in a material for example, aluminum, by the force of forcing it through a specific opening inside a die. The material that is extruded is an elongated piece which has the same profile that it has the die opening.

To aid in understanding the aluminum extrusion process consider an Play-Doh(r) Fun Factory and how it operates. Imagine the Fun Factory as the extrusion press The handle as the shape bar as the ram, the ram as the die and Play-Doh(r) as an aluminum billet. The first step is choosing the desired shape and color. Imagine the shape as the die, and the color as the temper and alloy required. The Play-Doh (r) is then placed into the storage container. Pressure is applied to handle, which is used to push PlayDoh(r) through the shape. In an extrusion presses, pressure is applied to the billet by the ram where the dummy block is stowed to the top of the ram stem. When Play-Doh(r) starts to appear it has been “extruded”. The same methods are applicable to extrusions made of aluminum billets but far more precise and advanced technologies are employed by tamilnadu aluminum company.

Press size determines how large of an extrusion can be made. The size of an extrusion is measured using its largest cross-sectional size, i.e. it’s size within a circumscribing circle. A circumscribed circle is the smallest that will completely enclose the cross-section of an extruded shape.

The most crucial thing to be aware of in the process of extrusion is temperature. The temperature is the most important factor as it allows aluminum to acquire desired characteristics such as hardness and finish.

STEPS OF THE ALUMINUM EXTRUSION System

  1. The temperature of the billets is approximately 800-925 degrees F.
  2. Once a billet has reached the desired temperature and is then transferred to the loader where a thin film of smut or lubricant is poured on the billet as well as to the ram. The smut functions as an agent for separating (lubricant) that prevents both parts from sticking.
  3. The billet then transferred to the cradle.
  4. The ram exerts pressure on the block that is dummy that is pushing the billet into the container.
  5. When the pressure is applied, the billet is crushed against the die, and then becomes shorter and wider until it’s fully in contact with the wall of the container. To cool the aluminum, nitrogen liquid is circulated around the die as it goes through. This increases the life of the die as well as creating an inert air layer that keeps oxides from forming on the surface that is being extruded. Sometimes, nitrogen gas can be substituted for liquid nitrogen. The nitrogen gas doesn’t cool the die but does provide an inert atmosphere.
  6. The billet is compressed due to an increase in pressure and then the hard, solid metal begins to squeeze through the die’s opening.
  7. The temperature of the extrusion as it exits the press is recorded using True Temperature Technology (3T), which is mounted on the platen. The 3T is a device that records the temperature at the exit of the aluminum extrusion. The primary reason for knowing the temperature is to guarantee the maximum speed at which the extrusion can be run. The alloy is what determines the extrusion’s exit temperature. The ideal exit temperature for 6063A/6463A/ 6063A, and 6101, respectively is 930deg F (minimum). The ideal threshold temperature for the alloys 6005A and 6061 is 930deg F (minimum).
  8. Extrusions are pushed out of the die into the table for leadout and then the puller that guides metal across the table during extrusion. The extrusion is cooled using a series fans that run the length of the cooling table as well as run-out. (Note: Alloy 6061 is water quenched as well as air quenched.)
  9. The majority of the billet can be used. The rest (butt) includes oxides formed from the skin of the billet. As the butt is being discarded, another billet is loaded. The the welded billet will then be utilized for extrusion.
  10. When the extrusion reaches the desired length, the extrusion is cut with a profile saw or a shear.
  11. Metal is moved via belts or walking beams, from the run-out to cooling tables.
  12. When the aluminum is cool, it can be moved across the cooling tables and stretched. Stretching straightens extrusions and does ‘work hardening’ (molecular re-alignment which gives aluminum more hardness and increased strength). Aluminium profile manufacturers.
  13. The next step is cutting. After extrusions have stretched they are then transferred to a table saw and cut to the required lengths. The tolerance for cutting on saws is 1/8″ or greater, depending on saw length.

After the pieces have been cut, they’re loaded on a transportation device and moved into age ovens. Heating treatment or artificial aging can harden the material by speeding up the maturing process in a controlled temperature environment for some time.

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