Types of Aluminum Extrusions
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Introduction
This article takes an in-depth look at aluminum extrusions.
You will learn:
- What are Aluminum Extrusions?
- Types of Extrusions
- Aluminum Profiles
- Heatsinks
- And much more …
Chapter One: What are Aluminum Extrusions?
Aluminum extrusions are solid, semi-hollow, and hollow common and custom designed linear shapes are produced by the extrusion process that forces an aluminum billet through an extruder profile. The three forms of extrusion are hot, warm, and cold, each of which is used to produce strong and lightweight angles, beams, channels, and different sizes of tubing. Complex profiles are produced with exceptional tolerances to interlock with channels and other aluminum structures.
The industrial use of aluminum extrusions is rapidly growing as new and innovative ways have been found to use them. The wide use of aluminum extrusions is due to aluminum’s exceptional weight to strength ratio and its many positive properties. Additionally, there is an endless number of aluminum alloys, which makes it possible to choose the right alloy for any application.
The main characteristic of aluminum extrusions that has made them the component of choice for so many projects is aluminum’s lightweight combined with its toughness. Extrusions are an economical choice especially when dealing with complex and intricate applications. In the majority of cases, regardless of the extrusion process, aluminum extrusions have a smooth surface with a pleasing appearance.
Chapter Two: The Aluminum Extrusion Process
Aluminum extrusion can be hot, warm, or cold. The selection of the extrusion process depends on how the fabricated piece will be used and the type of product. Of the three processes, hot extrusion is used the most because final products have greater strength and tolerance. Warm extrusion is performed at above room temperature while cold extrusion is done at room temperature or slightly below.
The essence of aluminum extrusion is shaping a billet using a die or profile in the form of the cross section of the item to be extruded. Dies are thick, circular disks with one or several openings that have the shape and dimensions of the item being produced. They are made from steel that is heat treated to withstand the pressure and temperature of hot aluminum. When raw aluminum is forced through the die, it takes 100,000 to 125,000 psi to push it through. All dies are solid, semi-hollow, or hollow. Solid dies produce shapes with no openings in the middle while hollow dies have one or many openings and semi-hollow dies are nearly hollow.
The life of an aluminum die depends on its original design since the buildup of pressure and heat can produce a great deal of wear. Dies need to be able to withstand uneven pressure and control the amount of heat. Although dies wear out, the low cost of the extruding process makes up for the expense of replacing them. Profile design, tolerance settings, and adjustments for the types of alloys can significantly help in extending a die’s life.
The feedstock for the extrusion process is referred to as a billet or log, which can be square or circular. It is forged by taking pure aluminum and combining it with other metals to form an alloy. The combined metals are smelted to remove impurities. The molten mixture is poured into a form where it is placed under high pressure to remove any air or gases and to align the molecules. The final result is a solid block of aluminum.
During extrusion, the billet is heated to temperatures of 800°F to 925°F (426.7°C up to 496°C) above the recrystallization temperature to keep it from hardening, which makes it easier to push through the die. Once the billet is heated, it is moved to the loader where a thin film of lubricant, which can be oil or graphite for cool extrusions and glass powder for hot ones, is added to keep it from sticking to the equipment before being placed in the cradle.
The ram pushes the billet crushing it against the die. As the molten aluminum is forced through, liquid nitrogen cools it, which helps to increase the life of the die. As the extrusion exits the die, it is pushed to the lead out table and puller, which guides it down the table. As the extrusion is pulled, it cools. At the desired length, the extrusion is cut and placed on the cooling table. After it cools, it is stretched to increase its hardness. The final step of the process is to cut the fully processed extrusion to the desired length. In some cases, there may be a need for extra finishing, buffing, or trimming. Those processes depend on the requirements of the final product.
In cold extrusion, the part is formed by moving the aluminum through the die at room temperature. The necessary force to move it through the die has to exceed the strength of the aluminum to ensure proper deformation. Cold extrusion produces parts with close tolerance, high strength, and requires minimal finishing. Though there are several methods of cold extrusion, for most manufacturers, there are three basic types – forward or direct, backward or indirect, and upsetting.
For forward or direct cold extrusion, the ram forces the billet through the die. The billet is placed in a heavily walled container for the ram to force it forward. With backward or indirect cold extrusion, the metal moves upward into the descending die, which requires greater pressure. Upsetting cold extrusion is normally a part of backward or forward cold extrusion and performed at right angles to the workpiece or billet.
With warm extruding, the billet is heated to temperatures ranging between 800°F to 1800°F. The ideal range is 1000°F to 1330°F. In either case, these temperatures are below the recrystallization temperature, which enhances the ductility of the billet while keeping it solid. Less force is required with warm extruding to move the billet through the die.
A crucial part of the extrusion process is the maintenance of the temperature for both the billet and the die. Controlling the billet feed and exit temperature improves the quality of the final product. In many situations, the operator is responsible for ensuring the temperature is correct and determining the quality of the finished product. With closed looped systems, the control of the profile temperature is electronically controlled to keep it consistent and increase extrusion speed.
Chapter Three: Types of Aluminum Extrusions
There is an extensive list of the many types of aluminum extrusions, which range from simple angles to multiple intertwined complex components and tubing. Manufacturer’s websites provide a complete and comprehensive list of the many varieties and types of aluminum extrusions. Although there are standard aluminum extrusions, the types, shapes, and configurations of extrusions is constantly changing as new innovative uses for them are being introduced.
Aluminum extrusion profiles can be divided into standard common profiles such as corners, duct, square and round, T, U, and Z. All extrusion manufacturers have these profiles on hand and immediately available or dies to form them. They come in a wide range of sizes and lengths.
The second group of aluminum profiles are complex and intricate shapes that require special dies and tooling. These can include profiles with screw attachments, specialty corner profiles, handles, handrails, and transition strips with shanks. Unlike the standard aluminum profiles, complex profiles are special ordered and may require the engineering of a die to match the requirements of the profile.
A common use of complex profiles is as accents for architectural structures and decorative pieces to highlight the features of a project. The beauty of the extrusion process is the ability to produce shapes and profiles that fulfill the needs of any application.
Aluminum Angles
The standard extruded aluminum angle has sharp, square corners and are made from series 6061, 6063, and other aluminum alloys with a T6 temper. The two extensions of an aluminum angle are referred to as legs since they are similar to the structure of a right angle even though certain angles do not have a 90° angle. Although they are lightweight, aluminum angle extrusions have sufficient strength to support structural projects and are ideal for aesthetic appearance. Of the many varieties of aluminum angles, L shaped angles are used the most for framing and braces.
Aluminum is used to produce aluminum angles due to its high strength-to-weight ratio and corrosion resistance. The legs of aluminum angles are equal or unequal in length with sharp right angle corners. Of the various types of aluminum angles, there are ones that are less than 90° that leaves the legs more open.
In order for aluminum angles to achieve sufficient strength, they are tempered using a heat treatment. In most cases, the heat treatment is applied to reach T5 or T6 tempered levels. Regardless of aluminums layer of corrosion protection, many manufacturers apply an anodizing finish where the angles are placed in a chemical bath to create a durable outer coating.
Aluminum Beams
Aluminum beams are large, oblong pieces of metal, constructed from aluminum alloys, and are used as horizontal support in building construction. Aluminum beams are a preferred alternative to steel, which is stronger but heavier, and wood which is lighter but weaker. Structural Aluminum is used for beams because of its light weight, which makes it easy to install.
Structural aluminum is weather resistant, doesn't corrode, is able to withstand high and low temperatures, and doesn't rust. Aluminum beams last longer and come in different shapes including unequal or equal I beams, the most commonly used, unrounded, and C-shaped channels, H beams, and T beams.
The two types of aluminum beams are aluminum association and American standard, which are differentiated by the thickness of their flanges. American standard beams have traditional tapering of their flanges with rounded edges. Aluminum association beams have thicker flanges and are straight and not tapered.
Although there are several different beam profiles, I beam profiles are the most used. The factors that separates I beams are their sizes and the relationship between the horizontal flange and vertical web. H beams, which look like I beams are heavier and have a thicker web, the vertical part of the beam.
Aluminum Channels
One of many extruded aluminum shapes is aluminum channels, which are a special type of aluminum extrusion that is smooth, linear, and narrow. They provide support for framing for roll formed products and are ideal for engineering and structural applications such as light building frames, frame extensions, light poles, lighting fixtures, window frames, car bumpers, hardware joints and boat dock ladders.
Aluminum channels have high electrical conductivity and are good heat conductors and reflectors, which makes them ideal for heat transfer and heat shields. Industries that use aluminum channels include construction, industrial manufacturing, shipping, automotive, aerospace, medical and automotive.
The profile of the die for aluminum channels determines its shape, which can be an angle, T, I beam, C, zee bar, tubing, or bar. Aluminum channels have all of the positive properties and characteristics of aluminum and are 100% recyclable. They are an inexpensive extrusion that are flexible and widely diverse. Architects and designers use aluminum channels as structural elements and highlights for special features of buildings.
As with many types of extrusions, the wall thickness of aluminum channels determines how they can be used with thicknesses that range from 0.0625 in up to 0.25 in (0.16 cm up to 0.635 cm). The main reason for the popularity of aluminum channels is the ability to customize them to fit the requirements of shape and size for an application.
Aluminum Extruded Tubing
Aluminum extruded tubing is a hollow linear aluminum product that is typically cylindrical, however aluminum square tubing and aluminum rectangular tubing is also manufactured for specialty applications such as aluminum downspouts and building supplies. Aluminum tubing may also have rectangular, square or round cross-sections. Formed during extrusion processes, aluminum tubing may be hot extruded, cold extruded or warm extruded, all of which extrude aluminum through a die, although at various temperatures.
Aluminum Shapes
Aluminum shapes are linear aluminum products highly valued in a wide spectrum of structural applications due to aluminum's high strength-to-weight ratio and the cost effectiveness of the metal extrusion process. Aluminum is one of the most recent metals to be used in industrial manufacturing processes with just over a hundred years of usage in industrial and commercial applications. However, aluminum shapes have a far longer service life than most metal extruded shapes and are therefore embraced. Standard aluminum shapes include beams, trim caps, rods, angles, bars and channels, all of which are available in a wide range of configurations and sizes.
Aluminum Tubing
Aluminum extruded tubing is a hollow linear cylindrical, square, round, or rectangular tubing manufactured for uses such as downspouts and building supplies. It is formed using hot, cold, or warm extrusion methods. The wide use of extruded aluminum tubing is due to its flexibility and versatility. It is used with mining equipment, hardware joints, fluid and gas transport, light building frames, structural applications, lighting fixtures and light poles. Aluminum extruded tubing is an excellent heat conductor or reflector, is flexible, and has a high strength-to-weight ratio.
Extruded aluminum produces rods, profiles, tubing, channels, trim and angles that are used by a wide range of industries including architecture, aerospace, commercial furniture, marine vehicle manufacturing, public transportation, structure, mining, medicine, and the military. It is found in every aspect of society and is one of the most reliable and resilient products on the market with properties and characteristics that have made it one of the most dependable manufacturing processes.
Extruded Aluminum Tubing
The lightweight and durability of aluminum tubing makes it ideal for a wide range of applications, especially those that require corrosion resistance. The types of aluminum tubing take several forms and include extruded, seamless, welded, and drawn. Each type is distinguished by the method used to produce it with seamless and extruded being similar.
Extruded aluminum tubes are produced by forcing aluminum rods, under pressure, through a deformation die. The process improves the microstructure and mechanical properties of the aluminum. Once the aluminum rod has been shaped, it is quenched and age treated, which further improves its properties. The many positive properties of aluminum tubing makes it ideal for a wide range of applications. Since it is a good heat conductor and reflector, aluminum tubing is widely used in heat transfer and heat shield applications.
Seamless tubing is the product of an extrusion process that involves piercing. After the billet is heated to the processing temperature, a hole is punched in one end of it. Rotary piercing is then applied, which is a rolling process where the billet is rolled between rollers. As the billet rolls, tensile stress takes place at the center of the billet and piercing causes the material to flow along the roll. The final product is a seamless unwelded aluminum tube.
Drawn aluminum tubing is made by cold drawing, which involves pulling a billet that has been cleaned and coated with a lubricant through die cavities. The plastic deformation occurs as the billet is pulled through a series of dies that get progressively smaller in diameter. The movement through the dies cold works the aluminum at room temperature, reshaping it into the desired tube form. Drawn aluminum tubing has exceptional precision and surface quality.
Welded tubing involves the use of flat strips of aluminum that have their edges joined by high frequency welding. The heated seams of the flat strips are welded and joined along their longitudinal axis. The difference between welded tubing and drawn, seamless, or extruded tubing is that welded tubing makes it possible to have multiple layers of different aluminum alloys
Fabricated Aluminum Extrusions
In most metal working processes, there are secondary operations that are performed on workpieces to prepare them for an application or further treatment. With aluminum extrusions, those secondary functions include fabrications from a number of different functions such as cutting, CNC machining, mitering, punching, notching, drilling, and further cutting. Prior to submitting an extrusion to a fabricating process, it is allowed to age such that it is sufficiently prepared.
Fabricated aluminum extrusions refers to the processes that aluminum extrusions undergo after being extruded. Fabrication and finishing processes make extrusions functional components for an application. The first step in the process is generally cutting, where the extruded piece is cut to the proper length for dimension correction.
Surface finishes help enhance the appearance and corrosion resistance of profiles and include anodizing, painting, and blasting. Anodizing makes an extrusion resistant to wear, strengthens its surface, and creates a porous surface for the application of paint. Although extruded aluminum has a bright surface, manufacturers will paint extrusions to increase their longevity, reduce the cost of maintenance, and provide extra corrosion protection.
The process of blasting removes residue and scale on extrusions that have received a heat treatment. Blasting helps to add texture to an extrusion and removes contaminants. It is a method for preparing an extrusion for machining, painting, or giving it a matte finish.
Structural Aluminum
Structural aluminum goes through post forming treatments to make it light weight, durable, and corrosion resistant for high-strength applications. Since pure aluminum is too soft for structural applications, it has to be alloyed with magnesium, silicon, zinc, copper, zirconium, chromium, or manganese. The most common aluminum alloy is 6061-T6, which is a combination of aluminum, manganese and silicone.
Structural aluminum is more costly to produce but has a faster manufacturing process and low labor costs. Other benefits of structural aluminum are its cleanness and aesthetically pleasing appearance that can be painted or finishing. It is commonly used by marine, automotive, engineering and construction industries to produce machine bases, building framing, cryogenic vessels, piping, bridges, and industrial machinery. Regardless of its strength, it can be easily formed into several shapes such as castings, forgings, wire, rod, bar, and flat rolled sheets or plates.
T-Slot Aluminum Extrusion
A T-slot aluminum extrusion has the shape of a square, rectangle, or curved radius with a long slot on one of its edges in the shape of a T. The shape of T-slot extrusions make it possible to connect accessories that fit into the T-slot. It is a solid, strong, and sturdy type of framing that is used for 3D printer frames and the manufacture of workbenches and enclosures. The popularity of T-slot extrusions is due to its durability, versatility, and low cost. T-slot extrusions make it possible to connect structural framing without the need of welding, drilling, or bolting and allow for easy customization of designs and applications.
Regardless of its name, T-slot extrusions can be made with a single slot, multiple slots, or no slots with the sizes of cross sections being available in several varieties. The many types of T-slot extrusions allow for rapid assembly such that an enclosure or structure can be erected quickly and just as quickly be torn down and moved. Common profiles of T-slot extrusions are 20x20, 30x30, and 40x40 with profiles having a weight capacity of over 3000 lbs (1360.8 kg). T-slot extrusions are quickly connected using plates or corner brackets, which are anchored by T-bolts and nuts.
Aluminum Trim
Aluminum trim is long, thin, narrow extrusions used for automotive designs, decorative architecture, screen printing, indoor and outdoor lighting, and construction and engineering projects. It is weather resistant, impervious to high and low temperatures, and corrosion and rust resistant.
Trim manufacturers use all three of the different fabrication methods. Over the past few years, aluminum trim has found wide use in the automotive industry due to its light weight, which helps to lower the overall weight of vehicles to increase gas mileage. Most of the vehicles produced since 2012 have used aluminum trim for interior and exterior accents, instead of heavier, more expensive metals like steel and chrome.
In addition to being lightweight and inexpensive, aluminum trim is flexible and can be extruded in a variety of shapes, have finishes applied, and holds its shine. Interior trim for vehicles is small with detailed surface patterns or textures. With the help of the right finish, aluminum trim can look luxurious while saving manufacturers production costs.
In architecture, aluminum trim is used most often to create exterior accents on both residential and commercial buildings. Trim used in buildings as an aesthetic accent has a secondary processing of powder coating to provide extra water and corrosion resistance. Possible defects in aluminum trim include surface cracking, internal cracking, surface lines, and pipe, which can be prevented during the die design phase.
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Chapter Four: Types of Aluminum Extruders
Aluminum extrusions machines can be categorized based on their structure, function, and transmission mode. The subcategories under each classification are in accordance with the direction of the extrusion, which can be reverse, forward, horizontal, and vertical, and the type of applied pressure. The main types of extrusion machines are cold, hot, hybrid, indirect, and direct.
Aluminum extrusion is a popular process because of aluminum’s many positive properties, which include flexibility, recyclability, durability, high structural strength and low weight that makes it less expensive to ship and perfect for applications with weight restrictions. The wide range of aluminum extrusions retain their strength in varying temperatures where other metals become brittle and break, are non-toxic and non-magnetic, and conduct electricity.
Cold Extrusion Machines
Cold extrusion is performed at room temperature where a billet or slug is forced through a profile using compressive force or push through. Billets are cut from bars of aluminum and placed in the barrel of the extruder. The key to cold extrusion is the temperature of the billet, which is at room temperature or slightly above. A screw, plunger, or ram applies the pressure to force the cold billet through the die profile. With forward cold extrusion equipment, the billet is forced forward through the die. With reverse cold extrusion, the die is forced at the billet by the ram.
Hot Extrusion or Direct Extrusion Machines
With hot or direct extrusion, the billet is heated to a specific temperature that is closely controlled and monitored. As with cold extrusion machines, the billet is lubricated before being placed in the barrel or the extrusion chamber. The die is heated to reduce die wear. A ram, plunger, or slug pushes the heated billet along the barrel to the die through which it is forced to assume the proper profile. The higher temperature makes it possible to deform the billet easier and makes the billet more formable.
Indirect, Reverse, or Backward Extrusion Machines
In the indirect machine method of extrusion, the ram carries the die to the billet and applies pressure by forcing the die against the billet. The completed extrusion exits through the ram. Since the billet remains stationary and immovable, there isn’t any barrel friction applied to the billet. The applied force is constant from the front of the billet to its rear, which makes the extruded parts consistent with less temperature variations. Dimensions, grain structure, and mechanical properties remain the same throughout the process. For the process to be successful and produce quality products, the billet must have any surface materials removed that could affect the extrusion.
Chapter Five: Aluminum Extrusion Profiles
Aluminum profiles are the shapes of extruded aluminum products that are manufactured in different thicknesses, a factor that is important for providing the proper form and function. The numbers and types of profiles are endless, and ever growing, as new and unique applications are being constantly developed. Profiles can be extruded hot, cold, or warm through a die that has the shape of the profile.
Extrusion profiles or dies are thick, circular steel disks with openings of the desired profile. They are made from H-13 steel that is heat treated in order to withstand the pressure and heat of the extrusion process. Although dies are small and aluminum is a soft metal, it takes 100,000 psi up to 125,000 psi to force an aluminum billet through an extrusion profile.
The three forms of aluminum extrusion profiles are solid, hollow, and semi-hollow. Each type of profile is designed to produce different extrusion shapes, which can be very simple angles or extremely complex intricate shapes for special applications. In all cases, the die profile determines the final form of an extrusion. The initial difference between profiles is openings or voids in the profile.
Solid dies or profiles create shapes that do not have voids or openings, such as beams, angles, and rods. They are the less expensive profiles and the easiest to manufacture. A solid die consists of a die stack that includes a feeder plate, die plate, backer plate, and bolster. Of the four parts, the die plate has the shape or profile of the extrusion.
Hollow dies can produce extrusions with voids and openings, such as tubing or complex profiles. They have a mandrel with two or more portholes for the internal features of the profile. During extrusion, the billet separates in each port and rejoins later in the process. The die cap makes the shape of the profile and is supported by the bolster that also supports the mandrel.
Semi-hollow dies are similar to hollow dies and have a mandrel, die cap, and bolster. The mandrel has portholes without cores for making voids. The die cap has the shape of the profile, while the bolster supports the mandrel and die cap.
All extrusion companies offer standard profiles that are generally used and made from aluminum alloy series 6061, 6063 and 1100. The different types of aluminum profiles are designed to meet the requirements of an application, operation, assembly, or process and are divided into five line types, which are 5, 6, 8, 10, and 12. Each line is defined by the three geometric characteristics of modular and groove dimensions and bore diameter.
Standard profiles are readily available and are basic types of profiles that include corner profiles, duct and double-duct profiles, square and round tubes and pipes, T-tracks, U channels and Z profiles, flat, round and square bars. These types of profiles are kept on hand by manufacturers and can be quickly available.
Complex profiles are used for their strength and durability in construction projects, automobile production, and manufacturing. Unlike standard profiles that involve angles and circles, complex profiles have multiple design elements combined. Borders with attachments, water deflectors, and automobile trim are complex profiles.
The distinction between complex profiles and custom profiles are the dimensions of custom profiles that can be extremely small with tiny dimensional tolerances. Custom profiles are made with a combination of aluminum alloys and are specially crafted for unique use and applications.
The wall thickness of an aluminum profile determines its load bearing capabilities and the range of the profiles use. It affects the extrusion force, dimensional tolerance, and the surface finish. Additionally, wall thickness is the determining factor when selecting the alloy grade to be used. Higher alloy grades have increased dimensional tolerance and produce strong products with better mechanical properties.
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Aside from the strength and other mechanical properties of the right alloy grade, the thickness of the walls of a profile enhances its abilities to be shaped, welded, bent, and formed. Since the walls of variance profiles can have different thicknesses, it is important to match the thickness of adjoining walls correctly such that the extrusion will not be weakened. The general rule is that 2 to 1 ratios are unwise and not recommended.
Hollow beam profiles have many types of cross sections and come in a wide range of shapes with each shape having subclassifications. Single radius profiles or SD profiles have a curved back with straight surges that quarter circles. They take all of the forms of profiles including solid, semi-solid, and hollow. The simplest form of profiles are L shaped that are used for a wide range of applications. T slot profiles offer the ability to add connections and are used for assembling and reassembling applications.
Chapter Six: Aluminum Extruded Heatsinks
A heatsink is a metallic device that absorbs thermal energy, or heat, from another object using thermal compounds known as thermally conductive materials. Heat is absorbed from the object at a relatively high temperature and transferred to the heatsink, which has a larger heat capacity. Extruded heatsinks are a thermal energy solution for both low and high volumes and are used in refrigeration, heat engines, cooling medical devices, lasers, and CPUs.
Heatsink applications are used by production processes that require efficient heat dissipation such as the electronic, military, medical equipment, industrial manufacturing, appliance, and LED lighting industries. Extruded heatsinks vary in design by length, noise level, speed, width, style, height, and weight. Other forms of heatsinks, that are not extruded, are stamped, bonded, or folded, which have higher production costs.
Extruded heatsinks are made from aluminum alloys 6061 and 6063. The most common design is a flat aluminum base with vertical radiating fins to increase surface area. Three things are required for the transfer of thermal energy: a heat source, a thermal compound, and a heatsink. Heat sources must have a high temperature and be thermally bonded to the base of the heatsink by a thermal compound for the heat transfer to occur. Thermal compounds are a paste-like substance made of particles of silver, which has a very low thermal resistance. Once bonded, heat transfer brings the heat source into thermal equilibrium as the heatsink lowers its temperature.
Extruded heat sinks can be passive or active. Active heat sinks use a power source such as integrated fans with directed fins that direct airflow patterns in order to help to increase the surface area of the heatsink. Passive heatsinks do not use any mechanical components. Heat is dissipated through convection or transfer of heat through a liquid or gas caused by molecular motion.
Heatsinks are a major part of the computer age and the most important component for computer efficiency. Computer processors are capable of completing multiple operations rapidly, which generates a great deal of heat. To control the heat, a heatsink transfers keeping the computer from overheating. Without the dispersal of heat by a heatsink, computers would shut down causing thousands of dollars of damage. Every computing device has some form of heatsink for protection and optimal performance.
Chapter Seven: History of Aluminum Extrusion
Aluminum extrusion, or the extrusion process, owes its beginnings to Joseph Bramah, Thomas Burr, and Alexander Dick who advanced and perfected the process so inventors from the first industrial revolution could improve it. Though the goals of these men may not have been to create aluminum extrusion, they did take the first steps in developing the extrusion process.
Joseph Bramah, locksmith, inventor of the hydraulic press, and originator of extrusion, patented the first metal extrusion process in 1797. With Henry Maudslay, an engineering genius, Bramah developed a process for forcing soft metals through a mold using a hand driven plunger. His reason for using the process was to create parts for producing unpickable locks. The initial use of the process led to the creation of other tools, which marked the beginning of metal extrusion.
Impressed with Bramah’s extrusion process and his hydraulic press, Thomas Burr, in 1820, combined the two inventions to develop a hydraulic press to force metal through a die. Burr’s goal was to extrude lead pipe using a faster and more reliable process. At the time, extrusion was named “squirting”.
The present process of hot extrusion dates back to 1894 when Alexander Dick melted non-ferrous metals to be forced through a die. Though there have been many changes over the last hundred years, the design and developments of Dick, Bramah, and Burr remain the foundation for the modern extrusion process.
The Discovery and Early Uses of Aluminum
Aluminum is the perfect metal for the extrusion process since it can be extruded either hot or cold. Its high resistance to chemicals, rust, and corrosion has made it the solution for the manufacture of many of today’s products. Though aluminum is one of the most common metals on earth, it took centuries for a process to be developed to make the production of aluminum practical and affordable.
In ancient times, alum was used for hide tanning, first aid, fabric dying, pickling, canning, and many other processes. In its natural state, alum appears as a salt of either potassium aluminum or ammonium aluminum sulfate. It is still used today as a supplement to medicines.
Alumina, a form of alum, was discovered in 1825 by Danish scientist Hans Christian Oersted. Though it was known to exist, the refining and processing of it was extremely difficult making aluminum more valuable than gold, which continued until 1887. In 1886, Oberlin college student Charles Martin Hall and French engineer Paul Heroult, working in different parts of the world, developed a smelting process for aluminum involving electrolysis. The Hall-Heroult process made aluminum easily accessible and brought the price of it down, opening the door for its mass production. A year after Hall and Heroult’s advancements, in 1887, Karl Josef Bayer discovered a chemical process for extracting aluminum from bauxite. Though the innovations of these three men are over a hundred years old, they are still used for the modern production of aluminum.
The sharp rise in the uses and applications of aluminum was spurred by the first extrusion press in the United States that was built in Pennsylvania in 1904. Its invention became a major asset for the growing airplane and automotive industries.
In a twist of history, a Swiss student, Robert Viktor Neher, developed a method for processing thin sheets of aluminum in 1910. At the time, ballooning was popular, but many balloons lost air due to the thinness of their fabric. Neher came up with the idea of pressing aluminum so thin that it could be placed over the fabric of the balloon to close any holes. His discovery led to today’s aluminum foil.
During World War Two, aluminum became an essential part of the war effort and was used to make several of the items soldiers and sailors used. "Aluminum for the Defense" and "Tinfoil" drives were held for contributions of aluminum for recycling. From 1940 until the end of the war, of the 296,000 aircraft produced, more than half were made with aluminum.
The exploration of space began with a beach ball sized satellite named Sputnik I launched by the Soviet Union in 1957. The outer shell of the satellite was covered in an aluminum alloy that could withstand the heat and friction of launching into space. The use of aluminum for the creation and manufacture of space vehicles increased the need for aluminum production.
The modern aluminum can began in 1959 with the Coors Brewing Company in Colorado. They introduced an all-aluminum, seamless, two piece can for distribution of their beer. In conjunction with the new can, Coors instituted a recycling program where every can returned to the brewery was worth one cent. The soft drink industry began using aluminum cans in 1964 when Royal Crown Cola, from Columbus, Georgia, introduced them.
Since its beginnings in the late 19th Century, aluminum has become a vital necessity to many industries from household products to airplanes and cars. It is hard to imagine modern society without it.
Chapter Eight: Top Aluminum Extrusion Machines
There are many manufacturers of aluminum extrusion machines who have perfected the process. The choice of a company for the completion of an extrusion is dependent on how a profile is to be used, the required number, type of aluminum, and several other factors. As with all industrial operations, the choice of producer has to be carefully considered in order to machine the desired quality. In most instances, price is relevant but should not be the determining factor.
Model: Presezzi Extrusion Press Series 7
Description: Presezzi Extrusion Group offers the Series 7 Extrusion Press, a versatile machine capable of producing various types of extruded aluminum profiles. This model is known for its high precision, advanced automation features, and excellent control over the extrusion process. It offers flexibility in handling different alloys, shapes, and sizes of extrusions while ensuring energy efficiency and robust construction.
Model: SMS SmartExtruder
Description: The SMS SmartExtruder is a technologically advanced extrusion machine designed to produce a wide range of extruded aluminum profiles. It offers intelligent control systems, energy-efficient operation, precise temperature control, and advanced automation capabilities. The SmartExtruder is known for its versatility in handling various extrusion profiles, enabling consistent quality and high productivity.
Model: UBE Aluminum Extrusion Press
Description: UBE Machinery manufactures the UBE Aluminum Extrusion Press, which is capable of producing various types of extruded aluminum profiles. This model offers precision control systems, efficient energy utilization, and high-speed capabilities. The UBE Extrusion Press provides versatility in handling different alloys, sizes, and shapes of extrusions, ensuring reliability and precision in the extrusion process.
Model: HPM Aluminum Extrusion Press
Description: HPM (Hamilton Plastic Molding) is a renowned manufacturer of industrial machinery, including aluminum extrusion presses. Their HPM Aluminum Extrusion Presses are designed to produce various types of extruded aluminum profiles. These machines offer advanced control systems, efficient energy consumption, and the ability to handle a wide range of extrusion profiles and alloys. HPM presses are known for their robust construction, reliability, and versatility.
Model: Nordson Xaloy Extrusion Dies
Description: Nordson Corporation specializes in extrusion dies used in the production of various types of extruded aluminum profiles. Their Xaloy Extrusion Dies are designed to provide precise shaping and control over the extrusion process. These dies offer customization options for different profile shapes and sizes, ensuring high-quality and consistent extrusions. Nordson Xaloy Extrusion Dies are known for their durability, precision, and versatility.
Please note that the availability of specific models and their features may vary over time. For the most up-to-date and detailed information on the models and features offered by these manufacturers for producing various types of extruded aluminum, I recommend contacting the manufacturers directly or referring to their product catalogs and specifications.
Conclusion
- Aluminum extrusions are solid, semi-hollow, and hollow common and custom designed linear shapes are produced by the extrusion process that forces an aluminum billet through an extruder profile.
- Of the three extrusion processes, hot extrusion is used the most because final products have greater strength and tolerance. Warm extrusion is performed at above room temperature while cold extrusion is completed at room temperature or slightly below.
- The essence of aluminum extrusion is shaping a billet using a die or profile in the form of the cross section of the item to be extruded. Dies are thick, circular disks with one or several openings that have the shape and dimensions of the item being produced.
- There is a very extensive list of the many types of aluminum extrusions, which range from simple angles to multiple intertwined and tubing. Manufacturer’s websites provide a complete and comprehensive list of the many varieties and types of aluminum extrusions.
- Aluminum extrusion, or the extrusion process, owes its beginnings to Joseph Bramah, Thomas Burr, and Alexander Dick who advanced and perfected the process so inventors from the first industrial revolution could improve it.
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