The aluminum alloy extrusion process involves forcing the aluminum alloy through a die. Since the demand has been increasing over the years, it is useful for product design and manufacturing. There are many applications for products made from this process. Industries benefiting include automotive, aerospace, electronics, and construction.
What is the aluminum alloy extrusion process?
Preparation of extrusion dies
First of all, we use H13 steel to process the round mold. Or, if there is already a mold that suits your specifications, we can use it. This can even save the preparation time required to manufacture one. Then before extrusion, we preheat the mold to about 450 to 500 degrees. This will help extend the life of the mold and keep the metal flowing evenly. After preheating, we load the extruder and get ready to start.
Preheating of aluminum billets
A billet is a cylindrical solid aluminum alloy block. We cut it from a long section of alloy logs. We preheat it in the oven to 400 to 500 degrees Celsius. This gives it enough ductility for extrusion. However, we did not reach a melted state to protect the equipment.
Extrusion is transferred to the blank
We mechanically transfer the preheated blanks to the extruder. This is after the use of a release agent or lubricant. It prevents the plunger and blank from sticking together.
Stamping pushes the blank into the container
Once loaded into the press, the hydraulic cylinders push the malleable billet. It does this by applying a pressure of up to 15000 tons. This forces the material to expand and fit into the container walls.
The emergence of extrusion of materials through molds
When filling the container, the material is pressed against the extrusion die. The constant pressure forces the aluminum material through the mold opening. This is because it has no other escape routes. Therefore, it will appear after the opening shape of the mold has been fully formed.
Together with the quenching runout table, the extrusion is guided
Aluminum alloy extrusions
Once the aluminum extrusion comes out of the mold, a puller grabs it and guides it along the runout table. However, the speed must match the exit speed of the press. The ratio depends on the profile difficulty, wall thickness, part weight and aluminum alloy selection. As the extrusion moves along the table, we quench it evenly using a water bath or fan.
Table length shear extrusion
We cut the extrusion after reaching the full length of the table. Hot saws do this to separate it from the extrusion process. However, even after quenching, the extrusion is not cool enough for further processing. This requires an additional step.
Cool extrusion at room temperature
We transfer the cut part to the cooling table. Here, the profile is cooled to room temperature. This will allow the extrusion to be stretched later.
Move and stretch the extrusion alignment
The extrusion process can sometimes lead to natural distortion of the profile. This must be corrected as it may affect the functionality of the product. We use stretchers for this task. We mechanically grasp both ends of the profile and pull it until it is completely straight. We do this to meet the norm.
Move the profile to complete the sawing length
This is the final step after achieving table length extrusion. At Vemet, we see pre-specified lengths. It is usually between 7 and 22 feet long. The extrusions at this stage are matched to the T4 tempering. However, we can age them in the oven to reach a temperature of T5 or T6.
Surface treatment of extruded aluminum products
heat treatment
This occurs after the extrusion is completed. We use it to enhance the properties of extruded materials. Yield stress and tensile strength belong to these profiles. The oven accelerates the aging process so that the aluminum material reaches a T5 or T6 state.
Surface treatment
This step is mainly to enhance the appearance and corrosion resistance of aluminum. Other finishes such as anodizing thicken the oxide layer of the metal. It makes the metal more wear-resistant, improves surface emissivity, and provides a porous surface that is more receptive to dyes.
fabricate
This step helps to achieve the final dimensions of the profile. We can drill, machine, CNC machine, stamp, or cut extruded products to meet your specifications. For example, securing screw holes into structural products.