Aluminum Extrusion Process Explained in 10 Simple Steps

There's a notable increase in the adoption of an aluminum extrusion both in the manufacturing and designs of products.  In recent times, reports across the globe have shown that there's more to come concerning the Aluminum extrusion market. Those interested need to key in now as the market is moving at a geometric rate. The compound annual growth rate is pegged at about 4% yearly. Before outlining the process involved in the aluminum extrusion process, you would be provided with all the information that has to do with it.

Aluminum Extrusion Process Definition

The aluminum extrusion process is the steps taken in which aluminium alloy material is put through a die. It is all about a strong ram pushing the aluminum via the die and it comes out from the die opening. This forceful entry is to enable the aluminum to have the exact shape just like the die. The pullout will happen along a runout table. So the whole essence of the aluminum extrusion process is for the aluminum to come out with the needed extruded angles, shapes, or roundness.

The Extruded Shapes of Aluminum Extrusion

When it comes to aluminum extrusion it can be extruded into different shapes which can be relatively simple and even more complex. The extruded shapes can come in simple solid, hollow, or semi-hollow shapes. Aluminum extrusion can be used in different industries which include the energy, arch liberal, automotive, and even the architectural industries.

The Aluminum Extrusion Process Explained in 10 Simple Ways

The Aluminum extrusion process can be done in about 10 steps. You can use the below process steps to get it right.

First step: preparing the extrusion die before transferring it to the extrusion press

To start the aluminum extrusion, the first step will be to preheat the die. You would have to use between 450-500 degrees Celsius, this will aid in maximizing its life.  When the die is preheated, it will be time to transfer it into the extrusion press.

Second step:  Preheat the aluminum billet before extrusion

This step is about sawing the billet (This is a solid oval block of Aluminum alloy) taken out of a long log material of alloy. Then you would have to heat it in the oven using 400-500 degrees Celsius heat. This whole process will aid make the aluminum soft enough for the extrusion.

Third step:  transferring the billet to the extrusion press

This is a stage where the preheat billet is mechanically loaded to the extrusion press. For ease of transfer, a lubricant is applied to the press. The same lubricant would be used on the extrusion ram to prevent sticking together of both the ram and the billet.

Fourth step:  the pushing in of the billet material by the ram into the container

This is the next step to take after transferring the billet to the press. Now the ram will apply pressure to the billet. This will enable the billet material to be easily pushed into the extrusion press. Now the billet will then expands to accommodate the walls of the container

Fifth step: the introduction of the straightened material via the die

There will be a force against the die as the vessel is filled with alloy material. Then with consistent pressure applied, the aluminum materials will not escape and move along the opening of the die. By now, it will come via the die opening in the shape of a completely formed profile.

Sixth step: directing the extrusion  through the suppressed runout table

When the extrusion is out on the opening, it will be gripped by a puller. The puller will then direct the extrusion along the runout table. It will be at a speed that fit the exit of it from the press. Now as it pushes through the runout table, there will be a suppression of the profile. Making it chill will be done by either a fan that will be above it or by water.

Seventh step:  shearing of extrusions to table length

This step will be to shear the extrusion as it has gotten to its full table length. The shearing will be done by the use of a hot saw to separate it from the extrusion process. With this step, the temperature will be needed. Though the different steps above still need good (cool)  temperature. Though in the previous step there was quenching of the exiting press but the cooling wasn't fully done.

Eighth step:  The cooling of the extrusions to room temperature

This is the stage where the shearing table length extrusions are left to cool and moved from the runout table to the cooling table. This simply means that the profiles will be kept open to cool till they get to room temperature. The stretching will begin when the profiles are fully cooled.

Ninth step:  moving the extrusions to the stretcher

The moving of the extrusions to the stretcher stage is when something natural might have gone wrong with the profiles. This is mostly natural twisting that will need some correcting before stretching the profiles into alignment. So to correct any twisting, you first, transfer to a stretcher. Then grip one profile on both ends of the stretcher. Go ahead, to pull it until it is straight out and you have stretched it into the specification you want.

Tenth step: transferring of extrusions to be cut to length with the use of a finish saw

After straightening and fully work-hardened the table-length extrusions, it's time to load it on the saw table. You would cut them to their pre-specified lengths. The ideal length size is always 8-21 feet long.  By now, the extrusion properties should have aligned with the T4 temper.  You can move them to the aging oven after sawing. They would be aged now into the T5 OR T6 temper.

Conclusion

The need for aluminum extrusion can't be overemphasized as it is one important manufacturing process. It is about producing parts with the use of specific cross-sectional profiles via forcing heated alloy material through a die. The good thing about the extrusion process is that it can be manufactured, heated, and completed to customer specifications.

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