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About Aluminum Extrusions

During the aluminum extruding process, the application of pressure forces heated aluminum billets or logs through a metal die. The die is an opening in the press shaped to resemble the final aluminum part needed. The result is similar to the effect created when squeezing toothpaste through a tube. The extruded aluminum part reflects the die shape, just as the squeezed toothpaste reflects the shape of the tube opening. Two methods of aluminum extruding are direct extrusion and indirect extrusion. In the former process, the die remains stationary while the ram forces the aluminum alloy through the die opening. In the indirect extrusion process, the hollow ram houses the die. The ram moves into the stationary billet from one end, forcing the metal to flow into the ram and shaping the alloy with the die. An almost infinite variety of shapes can be produced at very close tolerances by the aluminum extruding process.
 
Extrusion dies can be either solid (flat) or hollow. Solid dies produce solid shapes and may have one or more orifices through which the softened alloy is forced. Hollow dies produce hollow or semi-hollow shapes. A single die may produce shapes that have solid, semi-hollow and hollow sections. The bearing length of the die is a critical characteristic of extrusion dies because it controls the metal flow through the die. The longer the bearing length, the greater the resistance to the flow of aluminum, and vice versa. All parts of the profile must emerge from the die at the same speed. A well-designed die will slow the profile through the thinner parts with shorter bearings in order to match the speed of the profile through the longer bearings.
 
Aluminum is the best all-around extrusion metal due to its unique combination properties. Although aluminum is one-third the weight of copper, brass or steel, the extrusion process results in a very strong part because it can distribute the metal to where it is needed. Aluminum is self-protected from corrosion by its own thin transparent oxide film. Aluminum alloys can be easily joined by welding, brazing and soldering. Conventional equipment can readily form or bend aluminum extrusions. Aluminum also has high electrical conductivity and is a good heat conductor and reflector, making it ideal for heat transfer and heat shield applications.
 
Extruded aluminum parts remain quite abundant and include aluminum tubing, vehicle components, computer parts, window and doorway frames and kitchen and other domestic appliances. Aluminum extruded products are often used as feedstock for aluminum wire, drawn aluminum tubing and rod and bar products. Aluminum extrusions range in size from one-millimeter parts weighing a few ounces to parts several meters in length weighing one ton or more. In addition to standard aluminum parts available in stock sizes and shapes, aluminum extrusions meet specific customer needs in the construction, automotive, medical, aerospace and telecommunications industries.

Image Provided by Fab Masters Company, Inc.	Image Provided by Nothern States Metals Corp.

Featured Articles

"Why Aluminum Extrusion?"
http://www.midstal.com/content/default.asp?id=48

“ The Advantages of Aluminum Extrusions”
http://www.extrusions.com/005issue/htmls/ExtrusionAdvantages.htm
 
“Designing for Aluminum Extrusions”
http://www.temroc.com/extrusion.asp

"Why Use Extruded Aluminum?"
http://www.psiextrusions.com/facts.html

Image Provided by Talan Products, Inc.	Image Provided by GSH Industries

Types of Aluminum Extrusions

• Aluminum extruded shapes can be customized for almost any application. Standard shapes include angles, channels and tubing.
  
• Extruded aluminum is molded with dies into specific shapes.
  
• Extruded aluminum channels provide clean, straight installation of anything from boat dock ladders to doorframes.
  
• Extruded aluminum profiles are lightweight, have high rigidity and often have anodized surfaces. Extruded aluminum profiles are used for applications such as floor frames and tracks along which machinery runs.
  
• Extruded aluminum tubing is heavy-duty and very strong but still flexible enough to withstand windy conditions.
  
• Metal extrusions are created using hot extrusion or cold forming, and commonly made of semi-soft metals, such as lead, tin, aluminum alloys, copper, titanium, etc., which are less expensive to extrude then high-strength alloys.
  
• T-slotted aluminum extrusions can be used in building most anything but are commonly seen in enclosures, cabinets, shelving, machine guarding systems, industrial workstations, office partitions, computer server racks, trade show exhibits, material handling and robotics.