Extrusion

Aluminium Extrusion

Aluminium extrusion is a widely used manufacturing method in which aluminium is pressed through a die to form complex and finished aluminium profiles. This process allows customer-specific profiles to be produced for an infinite number of applications.

How does it work? Advantages

What is aluminium extrusion?

Aluminium profiles are extruded. In this extrusion process, part of an aluminium billet is pressed through a die with great force; this is also known as pressing. The desired aluminium profile is created based on the openings incorporated into the die. Enclosed chambers in an aluminium profile are created using cores in the die.

The manufacturability and price of your aluminium profile mainly depend on these factors:

The size of the profile (see our press diagram)
The number of enclosed chambers in the profile
The chosen aluminium alloy
The desired surface treatment
The desired profile tolerances
The quantity per order and per year

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How are aluminium profiles extruded?

Raw material: the process begins with the base material: aluminium in the form of a solid billet. This aluminium is pre-mixed in the furnace to produce the desired alloy (e.g. EN AW-6060). The billet is first heated so that it can be more easily shaped. Note: the W in EN AW stands for “wrought”, meaning malleable.
Extrusion: the heated aluminium is pressed under pressure through a die which has the desired shape of the final extrusion profile. This process is known as extrusion. The die can have various complex shapes, ranging from simple rods to intricate structures.
Cooling: after extrusion, the formed aluminium profile is cooled. This ensures that it retains its final strength and shape.
Stretching: the extruded profiles are then stretched so that they become straight and within tolerance.
Cutting: the stretched aluminium profiles are cut to the desired length. This length can vary depending on the final application.
Hardening: after sawing, the profiles are automatically placed on steel racks and hardened in an oven to obtain the desired mechanical properties.

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Advantages of aluminium extrusion

Aluminium extrusion, as an advanced production method within the metal industry, offers several advantages that contribute to its versatile applications. Let us take a closer look at the advantages of aluminium extrusion:

Shape complexity: the process makes it possible to create complex shapes.
Lightweight and strong: aluminium profiles are lightweight and offer an excellent strength-to-weight ratio.
Sustainable and corrosion-resistant: aluminium is 100% recyclable without any loss of properties! It is therefore highly sustainable, but also corrosion-resistant (after surface treatment), which extends the service life of products.
Efficient use of material: the process results in minimal material waste, which promotes sustainability.
Low processing costs: the efficient production method reduces processing costs, enabling cost-effective solutions.

The aluminium extrusion process is a smart and affordable way to create shaped aluminium profiles that meet specific design requirements.

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Applications of aluminium extrusion

Aluminium extrusion is incredibly versatile and is used in various sectors. The flexibility and strength of aluminium extrusion are important in all kinds of industries. It can adapt to different situations while remaining malleable and durable. Below are the various applications of aluminium extrusion:

Construction: for the manufacture of windows, doors, and architectural structures.
Transport: in the production of car parts, train components, and aviation materials.
Electronics: for housings of electronic devices and heat sinks.
Industrial: in various industrial applications such as machine parts and profiles for transport systems.

References

Contact ALUDEX

Are you interested in having your aluminium profiles custom-made? And are you looking for support in areas such as profile design, the most suitable alloy, permissible tolerances, surface treatment, mechanical processing, the assembly of your semi-finished product, or do you have a logistical challenge? ALUDEX is happy to help! Please feel free to contact us: