What is Aluminium Extrusion? The Process in 10 Steps.

Aluminium extrusion is a proceeding in which aluminium is coerced to drift all over a die to create profiles or shapes. The process usually starts with an ingot of the aluminium heated until molten. 

The molten aluminium is then forced through a shaped opening in a die, where it cools and solidifies into the desired shape.

The demand for aluminium extrusion products has grown in recent years due to the many advantages that aluminium offers over other materials. 

Aluminium extrusion is a versatile process that can produce various products, including window and door frames, automotive parts, structural components, and more.

Custom aluminium extrusions can be tailored to meet each customer's specific needs, and they are often more affordable than products made from other materials.

Aluminium extrusion is a highly scalable process to produce small or large products.

This article will examine the aluminium extrusion process and explore the steps involved in making an extruded product.

What is Aluminium Extrusion? 

Aluminium extrusion transforms aluminium alloy into shapes by forcing it through a shaped die. 

It is one of the most versatile and standard manufacturing processes used in various automotive and construction industries. 

The profile can then be used for various purposes, such as windows, door frames or curtain walls.

The process begins by heating the aluminium until it is in liquid form. It is then poured into the die forced through a small opening. This creates the profile, which is then cooled and trimmed to size.

The Extrusion Process:

Breaking down the process into its steps is helpful. The following is a brief overview of the ten steps involved in manufacturing an extruded product:

Step One: Extrusion Die Is Prepared

The die is machined to the exact shape and dimensions of the desired part. The inside of the die is then polished to a mirror finish so that the aluminium can flow smoothly through it.

Step Two: Aluminium Is Melted

Aluminium is melted in an induction furnace until it reaches approximately 1400 degrees Celsius.

Step Three: Molten Aluminium Is Poured Into Die

Molten aluminium is poured into the top of the extrusion die, filling it.

Step Four: Pressure Is Applied

A hydraulic ram applies tremendous pressure to the molten aluminium, forcing it to squeeze through the small opening in the die.

This process forces out any impurities in the metal and creates a long, thin tube called a billet.

Step Five: Billet Is Cooled

The newly extruded billet is cooled by air or water, depending on the extruded alloy type.

Step Six: Billet Is Cut Into Lengths

The cooled billet is then cut into short lengths for further processing.

Step Seven: End Faces Are Trimmed

The end faces of the billets are trimmed to remove any excess metal and create a smooth finish.

Step Eight: Annealing Is Performed

Annealing is performed to soften the metal and improve its machinability. 

The billets are heated to a very high temperature and then slowly cooled in an oven. 

This process alters the metal's internal structure, making it easier to work with.

Step Nine: Billets Are Machined

The billets are machined into the desired shape and dimensions using various cutting tools.

Step Ten: Finished Parts Are Inspected

A final inspection is performed to ensure that the parts meet all quality standards. 

The components are now ready for shipment, and they are packaged carefully so that no damage to the parts occurs during transportation.

What Kinds of Shapes Can be Extruded?

There are a variety of shapes that can be extruded from aluminium, including angles, channels, bars, tubes and custom profiles. 

The most common shape is the angle, creating frames and enclosures. 

Channels are often used for structural applications, while bars and tubes can be machined into finished parts or used as raw material in other manufacturing processes. 

Custom profiles can be made to fit specific needs or designs.

Aluminium extrusion companies can impart diversity of different forms and sizes. 

Some shapes, such as angles and channels, are common and can be found in stock. Other forms may need to be made to order.

What are Aluminium Extrusions Used For?

Aluminium extrusions are used in various industries, including construction, transportation and manufacturing. Some typical applications include:

Construction industry:

In the construction industry, aluminium extrusions are used for window and door frames, curtain walls, sunshades, louvres and signage.

Transportation industry: 

In the transportation industry, aluminium extrusions are used to manufacture railway vehicles, trams, trolleybuses, aircraft fuselages and automotive body panels.

Manufacturing industry: 

In the manufacturing industry, aluminium extrusion is widely used to produce kitchen cabinets, furniture components, architectural features and engineering products.

Aluminium extrusion is an essential process because it allows the manufacture of a wide range of products in small quantities and with high precision.

 It also offers considerable design flexibility, making it possible to create products that are not possible using other manufacturing methods.

Benefits of Aluminium Extrusion

Aluminium extrusion has several benefits over other contriving processes that include:

Ease of fabrication: 

Shapes can be easily machined into finished parts using standard tools.

 It can also be readily joined to other components using screws, rivets or welding. Aluminium Extrusion is also solid and lightweight.

Strength and stiffness: 

Aluminium extrusion produces high-strength parts with excellent rigidity. This makes it ideal for those implementations where weight is a top priority.

The ability to extrude complex shapes also contributes to the durability of the consummate part.

Versatility: 

Aluminium extrusion can create parts with a wide range of shapes and sizes. 

It is also possible to add holes, slots or grooves during the extrusion process.

Low manufacturing costs: 

Aluminium extrusion is a relatively low-cost manufacturing process. 

The high degree of automation makes the process possible. This makes it a cost-effective option for large-scale production runs.

Customizable profiles: 

Profiles can be customized to encounter the particular entails of a peculiar application. 

This allows for maximum flexibility when designing parts and assemblies.

 In customisable profiles, aluminium extrusion can be anodised to produce a range of colors and finishes.

Environmental friendliness: 

Aluminium extrusion is a metal fabrication process that does not generate significant waste or pollution. 

This makes it friendly to the environment and aids in conserving resources.

Wide range of finishes and coatings: 

Aluminium can be finished in various ways to suit the application. It can be painted, anodised, powder-coated or polished to a high gloss. 

In addition, a wide range of coatings and sealants are available to protect against corrosion and other forms of degradation.

About Ares Prototype:

The Ares Company specializes in creating prototypes and small runs of plastic and metal goods.

The company has a wide range of equipment, including three and five-axis CNC mills, injection moulding machines, and metal stamping presses. 

This allows Ares to create prototypes. Ares also offers engineering services, helping its customer's design products that can be manufactured efficiently and cost-effectively. 

In addition, The Ares Company is a top-notch supplier for rapid prototyping and small production runs.

 We have tremendous types of equipment and expertise team. Please contact us if you need an aluminium extrusion, or a CNC machined part.