Aluminum extrusions are an essential part of our homes, although many people do not even notice them. They are usually part of window or door systems, but the application does not stop there. Aluminum bars have countless applications in building and manufacturing industries, therefore the quality of each product must be impeccable.
Impol is the largest European supplier of aluminum extruded bars for forging and one of the largest suppliers of drawn bars in Europe and the US. In our manufacturing process, which is trusted by all the largest European automotive companies and the European aviation industry, we apply the best possible production practices which we continuously improve. Read on to find out why this process is crucial for so many industries and why Impol is the best answer when it comes to quality extrusion rods, tubes, profiles
Extrusion is a modern process in which aluminum billets are heated and pushed through a shaped die opening. The opening can be modified to create different shapes and sizes to fulfill a users specific needs.
Depending on the required aluminum bar type, we use different steel dies.
You can read more about the differences in the extrusion process and the created products on our website.
The extrusion process is carried out in direct or indirect extrusion presses with different power levels (at Impol, those are between 12.5 and 55-MN). The basic process can be broken down into six distinct steps, although they can be modified or expanded upon depending on the customers specific requirements.
But even before the extrusion process begins, the cast aluminum rods needs to be cut into smaller pieces. These short pieces are called billets. The pre-cut billets ensure that the length of each extruded bar will be roughly the same and there will be no material wastage.
While the above-described steps of the extrusion process may seem fairly simple and automatized, they are anything but. In truth, extrusion is a very complex process which is dependent on the correlation between numerous parameters that need to be adapted during the process. Those parameters are called TST parameters and refer to the temperature, speed and time.
In essence, before, during and after extrusion, the following factors must be closely monitored:
These parameters must be closely controlled and monitored. The most important among them is temperature, which needs to be adapted depending on the extruded material and the desired final shape of the product. In general, the aluminum alloy billets need to be heated to between 300 and 595°C.
Another very important part of the extrusion process is quenching. As seen above, the extruded profiles are quenched immediately after exiting the die. In this stage it is essential that every part of the aluminum bar is covered by the right amount of water for the right amount of time. Meaning that they cool down from the extrusion temperature to room temperature as quickly as possible. Only then can the extruded bars/tubes/profiles be cooled uniformly and reach the highest mechanical and technological properties. The fastest quenching rate will achieve the best combination of strength, toughness and microstructure. This process is commonly used in producing extruded shapes of the 6xxx Al series e.g the T66 temper.
After the extrusion and quenching process is completed successfully, the following parameters need to be monitored closely:
In comparison to other products, aluminum extrusions are the preferential option due to their unique combination of lightness and toughness. From the industry viewpoint, aluminum extrusion has additional advantages:
Despite the numerous advantages, there is also an important disadvantage to aluminum extrusions in comparison to casting. And that is their size. Aluminum extrusions are limited by the size of both the billet and the capacity of the steel container on the extrusion press.
In hot extrusion, there are to different extrusion processes:
Direct extrusion is the simplest production mode. This method is most commonly used to produce aluminum extrusions. In it, the die is stationary while the ram forces the billet through the die opening. The action of the billet and ram moving forward in the same direction has led to this method being called the forward or direct aluminum extrusion process.
Indirect extrusion is a process in which the billet remains stationary, but the assembly on the end of the ram moves against the billet. This creates the pressure necessary for metal to flow through the die.
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This is the main advantage of the indirect press as it enables the pressing of harder alloys (2xxx, 7xxx) and products with smaller cross-sections due to the smaller extrusion pressures. Lower pressures also allow for lower pressing temperatures and consequently greater extrusion speed. This of course increases productivity.
Extrusion is a part of so many industries that it is not possible to create a complete list of every one of its types. There are limitless possibilities regarding shapes which are available in a wide range of configurations and sizes. The main categories are:
Especially in large and complex industries, the extruded bars are sometimes not suitable to be used as finished products due to their wider tolerances, worse straightness and greater surface roughness. For such demanding industries, drawn products are more suitable, as the tolerances are significantly more rigorous and the surface is smoother. Drawn products allow customers to achieve greater productivity, less work operations and a smaller scrap share.
In comparison to extrusion, drawing is a cold manufacturing process that forms aluminum bars by reducing their cross-section. This is accomplished by pulling the bar/tube through a smaller die. Although the process is similar to extrusion, the direction of the applied force is different. In extrusion, the billet is pushed through the die opening, where in drawing it is pulled through.
The drawing process has many important factors that affect the quality and precision of formed bars or tubes, such as die angle, drawing speed, lubrication condition and pass reduction ratio.
For cases of extremely complex final products or thinner products, the extruded products are replaced by rolled products or by mechanical processing or forging simpler extruded products (flat, square or hexagonal bar). This is how we can ensure products of more challenging shapes or with more precise dimensions.
If you have any additional questions about our services or processes, you can visit our website for more information or contact us.
Author: M.Sc. Ervin Rošer, process engineer
Ever wondered how the sleek frames of modern automotive or aerospace structures come to life? The answer is aluminum extrusion: a process that molds aluminum alloy into defined shapes to be used in endless industrial applications. Aluminums high corrosion resistance and strength-to-weight ratio make its extrusion process a cornerstone in manufacturing.
The applications of aluminum extrusions are vast and varied, stretching across automotive, aerospace, electronics, and beyond. From creating sturdy frames and enclosures to designing efficient heat sinks and workstations, aluminum extrusions fulfill structural needs and drive innovation in product design. The customizability of aluminum profiles, achieved through machining and anodizing processes, further amplifies its utility and appeal across many industry sectors.
In this guide to aluminum extrusions, well go through all the basics and technical aspects as well as its almost limitless industrial applications. Youll learn why extruded profiles are important tools for todays product designers and manufacturers. By the end, youll know whether you should make aluminum extrusions a part of your next project.
Read on to learn all about aluminum extrusions and find out if its the solution to your manufacturing needs.
To get started, heres a look at what the aluminum extrusion process entails:
The diversity in aluminum extrusion types is a testament to aluminums adaptability. Each type serves distinct purposes, catering to a myriad of industrial applications. Lets look at how each type works and what theyre often used for.
Also known as forward extrusion, direct extrusion is the most common type wherein the billet is pushed through the die by a hydraulic press. Its straightforwardness makes it a popular choice for creating solid and hollow tubes for automotive frames or construction purposes.
In the indirect extrusion process, the extrusion die remains stationary while the billet and container are the only parts that move. This reduces friction, allowing for more complex and precise profiles. Its ideal for aerospace applications where tighter tolerances are required.
Impact extrusion sets itself apart with a high-velocity punch that forces the billet through the die. This method does a great job of creating hollow objects like cans, round tubes, and other container shapes, which is why its often used in the product and food packaging sector.
With hydrostatic extrusion, the billet is submerged in fluid within a pressurized container in order to extrude it through the die. This method allows for higher extrusion speeds and tighter tolerances, making it suitable for high-precision automotive and aerospace components.
Like the Swiss Army knife of manufacturing, aluminum extrusion caters to many different industrial needs. Lets explore the advantages of aluminum extrusion and how they make it ideal for certain applications.
While aluminum extrusion clearly offers many advantages, it does come with a few challenges as well. Next, well address the most common issues and offer the best solutions.
A notable challenge in aluminum extrusion is material wastage, especially during the die preparation and cutting phases. Any discrepancy in die design or the extrusion process can lead to overproduction of scrap material.
Using precise computer-aided design (CAD) software and advanced cutting technologies for die can help. Plus, recycling the scrap aluminum can offset the cost and environmental impact of any wasted material.
Aluminum extrusion is energy-intensive, especially during the billet heating phase. This can escalate operational costs and carbon emissions. However, energy-efficient heating systems and recovering heat from the extrusion process can cut down your energy use. Using renewable energy sources can also reduce your environmental impact.
Getting a nice, smooth surface finish can be hard when extruding more complex, intricate profiles. Scratches or die lines can affect the aesthetic and functional quality of the extruded profiles.
One solution to this is using well-designed and well-maintained dies. Surface treatment techniques, like anodizing or powder coating, can also enhance the surface quality of your extruded profiles.
Understanding the properties of different alloys can help you choose the right one for your project requirements. Commonly used alloys include and , known for their good strength-to-weight ratio and corrosion resistance.
Aluminum is often used to fabricate automotive frames because of its strength, weldability, and high corrosion resistance. On the other hand, has a finer surface finish and even higher resistance to corrosion, making it a great choice for window frames.
Aluminum is another choice with a much higher strength-to-weight ratio than that of , making it an ideal candidate for aerospace and military applications. But like , it can be heat treated to further enhance its mechanical properties, offering a spectrum of uses across different sectors.
A fourth popular option, aluminum also referred to as T-slot aluminum extrusion is a good choice for modular framing and structural applications. The term refers to the brand, 80/20 Inc., a leading manufacturer in this field. Comparable to in terms of strength and corrosion resistance, aluminum features a T-slot design for easy assembly, accommodating connectors, fasteners, and other accessories without the need for welding.
The aluminum extrusion process is incredibly versatile. Here are some common shapes that can be extruded:
Solid extrusions are a staple in many industries due to their strength and simplicity. They can take on a variety of cross-sectional profiles, such as squares, rectangles, circles, or any other custom-designed shape.
Hollow extrusions are lighter in weight yet maintain a high level of structural integrity. Common hollow shapes include tubes, pipes, and custom profiles with voids.
Semi-hollow extrusions offer a middle ground between solid and hollow shapes, providing a balance of strength, weight, and cost. They are used in applications that require structural robustness while still benefiting from weight reduction.
Multi-void hollow shapes have complex cross-sections with multiple voids. They are ideal for applications requiring intricate, lightweight, and strong profiles.
The flexibility of the extrusion process allows for the creation of highly complex and custom shapes to meet specific design requirements. These could include a combination of solid, hollow, and semi-hollow sections within a single profile, catering to the sophisticated needs of modern industries.
Extruded aluminum heat sinks are crucial for thermal management in electronics and electrical devices. The extrusion process can create fins and other complex features to maximize heat dissipation.
Channels and angles are basic yet essential shapes extruded for a variety of structural, architectural, and industrial applications. They provide support, framing, and alignment.
The T-slot design allows for easy attachment of connectors and accessories. They enable fast and flexible assembly, facilitating the construction of framing systems, workstations, and other structural applications.
As industries evolve, so does aluminum extrusion. The drive towards lightweight, durable, and sustainable solutions propels the growth in popularity of aluminum extrusion.
Emerging technologies like the advancement in CNC machining and anodizing processes continue to refine the extrusion process, expanding its possibilities. However, challenges like the material waste and energy consumption involved in extrusion processes call for innovative solutions.
The rise of electric vehicles and the increasing demand in aerospace and construction sectors also spell growth opportunities for aluminum extrusion. The development of new alloys with higher strength and better corrosion resistance promises to push the boundaries of what aluminum extrusion can achieve.
With these innovations and expanding applications on the horizon, the future of aluminum extrusion beams with potential and is ready to meet the burgeoning demands of modern industries.
Thanks to its lightweight yet high-strength character, cost-effectiveness, and boundless application across industries, aluminum extrusion holds a key role in modern manufacturing. It enhances functionality, innovates design, and fuels sustainability in each sector it touches. The horizon of aluminum extrusion stretches even further to propel these industries forward.
If this guide has sparked inspiration for your next manufacturing project, learn more about Zetwerks high-quality aluminum extrusions using custom dies.
The path to turning your vision into tangible, high-quality products is within your reach. Take the first stride, and get a manufacturing quote from Zetwerk today!
Contact us to discuss your requirements of aluminium extrusions technology. Our experienced sales team can help you identify the options that best suit your needs.