Aluminum Extrusions: Streamline Strength for Modern Applications

In recent decades, the use of Aluminum Extrusions in product design and manufacturing has significantly increased. A recent Technavio report predicts a 4% CAGR in the global Aluminium extrusion market between 2019 and 2023. Aluminium extrusions can be solid, semi-hollow, or hollow and are used in everyday products, from home appliances to automobiles.

What are Aluminium extrusions?

Customers appreciate aluminum extrusions for their strength, stability, corrosion resistance, and lightweight properties. These extrusions enhance consumer products like patio furniture and speedboats, making them lighter, while also increasing the durability of items such as sports equipment. Additionally, the extrusion process involves several steps to ensure successful manufacturing.

The Process of Aluminum Extrusions 

1. Heating of billets to 800-925° F.
2. Transfer of billet to the loader for lubrication.
3. Transfer of billet to cradle for pressure application.
4. Crushing of billet against die, creating an inert atmosphere.
5. Extrusion of soft metal through the die opening
6. Use of True Temperature Technology (3T) instrument to record exit temperature.
7. Extrusions pushed out of the die to lead out the table and puller.
8. Fans cooled Extrusions along the run-out and cooling table.
9. The remaining butt (oxides) sheared off and welded to a previously loaded billet.
10. Extrusion cut with profile saw or shear.
11. Metal was transferred to the cooling table.
12. Aluminium cooled and moved to a stretcher for ‘work hardening’.
13. Extrusions cut to specific lengths.
14. Parts are loaded on transportation devices and moved into age ovens for heat-treating or artificial ageing.

The pieces are placed into ageing ovens after being cut and put into a vehicle. Heat-treating or artificial ageing hardens the metal by accelerating the ageing process in a temperature-controlled setting for a predetermined period.

What are the Different Aluminum Extrusion Shapes?

The Aluminium  Association highlights various factors in the extrusion process, such as die type, layout, design, billet length, alloy type, temperature, die and tooling temperature, and extrusion speed. These adjustable factors, combined with inexpensive tooling, offer limitless design possibilities. The extrusion process produces components ranging from millimeters to several feet long. Aluminum’s lightweight and malleable properties allow for complex shapes, including hollow and multi-chamber designs. The aluminum extrusion molding apparatus resembles a cake decorating kit, with hydraulic presses enabling the creation of nearly any shape.

 Aluminium Extrusion Shapes

• Aluminium angles: L-shaped parts with two legs intersecting to form a 90-degree angle.
• Aluminium beams: Structural and support components in building construction.
• Aluminium channels: Are smooth, linear, and narrow structures that provide a supportive frame for roll-formed products.
• Aluminium extruded tubing: A hollow, linear Aluminium product, typically cylindrical, square, or rectangular.
• Aluminium frames: Components of modular framing systems.
• Aluminium trim: Long, thin, narrow, custom-made for specific purposes.
• T-slotted aluminium extrusions: Are used in enclosures, cabinets, shelving, machine guarding systems, industrial workstations, office partitions, computer server racks, trade show exhibits, material handling, and robotics.

What Are the Benefits of Aluminum Extrusions?

Metal has evolved into a sturdy and versatile material for various designs. Specifically, aluminum extrusions find applications in architectural millwork, OEM, marine industries, RVs and trailers, as well as in restaurants and hospitality. Additionally, they are used for symbols, speciality vehicles, store fixtures, displays, and custom applications.

Aluminium is the preferred material for structural and construction applications due to its strength, resistance to rust and corrosion, ease of fabrication, and 100% recyclable nature. Aluminium’s malleability makes it simple to mould, process, and cast. Utilized in several applications. Aluminium is an economical and adaptable material.

What Are the Advantages of Aluminum Extrusions?

Aluminium  Advantages and Applications

• Affordable and cost-effective material.
• Attractive finishes like anodizing, polishing, and buffing.
• Good conductor of electricity.
• Corrosion-resistant.
• Customization is preferred in product solutions.
• Large coefficient of linear expansion.
• Highly reflective for visible light and finish options.
• Heat-conductive for heat shielding applications.
• Lightweight, about one-third the weight of steel, iron, brass, and copper.
• Low maintenance, naturally resistant to corrosion.
• Simple to machine into intricate forms and to form and extrude.
• Non-toxic, paramagnetic, precise, and quality.
• 100% recyclable, strong, and time-to-market.

What factors should be considered in aluminium extrusions?

Aluminium extrusion is a bulk-forming process that significantly alters the surface-to-volume ratio of the shaped metal. This process applies compressive forces to the billet using rams, punches, tools and dies. We use the principles of plasticity to create the desired profile with a consistent grain structure, which controls the metal’s plastic deformation.

Extrusion pressure is one of the main factors that significantly influences the properties of the final product. In addition, other parameters such as temperature, extrusion ratio, and extrusion speed also play crucial roles. Furthermore, the two major categories of aluminum extrusion—direct and indirect—each have their own advantages and disadvantages.

Extrusion Pressure: Extrusion pressure ranges from 800 MPa to 1200 MPa, while friction between the billet and die or chamber and die occurs in indirect extrusion.

Die Type and Design: Die type and design determine the mechanical properties of the metal during extrusion.

Lubrication: Extruding high-strength aluminium alloys requires lubrication.

Types of Aluminium  Alloys: We designate aluminum alloys by series and classify them according to their primary alloying element.

Temperature: Elevated temperatures enhance metal flow and reduce defects in aluminum hot extrusion, but also speed up oxidation.

Extrusion Ratio: We define the extrusion ratio as the ratio between the billet and die-opening cross-sectional areas.

Extrusion Speed: Higher extrusion speeds result in higher exit temperatures.

Length of Billet: The length of the billet also influences the length, profile, and extrusion ratio of the extrudate. In fact, longer billets require higher extrusion pressure. Overall, aluminum extrusions are complex and critical processes that necessitate careful consideration of various factors to achieve the desired results.

How to Customize Aluminum Extrusions?

Custom dies can be designed to meet a customer’s specific needs. Moreover, aluminum extrusions can be fabricated with holes and features to support their unique manufacturing processes. Additionally, these extrusions are compatible with various aluminum grades and finishes, ensuring uniformity across complex designs.

Texas Technology is a leading aluminium extrusion producer known for delivering high-quality, precision-engineered products. Specializing in custom aluminum profiles, they serve the construction, automotive, and electronics industries. With advanced manufacturing processes and a commitment to innovation, Texas Technology offers durable, lightweight, and cost-effective aluminum solutions. Moreover, their focus on sustainability and customer satisfaction has established them as a trusted partner for businesses seeking reliable aluminum extrusion services.