This article takes an in-depth look at aluminum extrusions.
You will learn:
Aluminum extrusions are crafted into solid, semi-hollow, and hollow configurations, both standard and custom, through a process that presses an aluminum billet through an extrusion die. The extrusion techniques—hot, warm, and cold—produce sturdy yet lightweight configurations such as angles, beams, and channels, along with various tubing dimensions. Intricate profiles with precise tolerances are developed to seamlessly integrate with channels and other aluminum frameworks.
The demand for aluminum extrusions is on the rise in industrial sectors, as innovative applications are perpetually discovered. This growth is fueled by aluminum's remarkable strength-to-weight ratio and versatile properties. Additionally, a wide selection of aluminum alloys allows for the optimal alloy selection tailored for specific applications.
The defining advantage of aluminum extrusions as components for a multitude of projects is their lightweight nature combined with high durability. They prove to be highly economical, particularly in complex and detailed projects. Furthermore, despite the extrusion method employed, aluminum extrusions generally have a smooth finish with an attractive look.
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 lies in shaping a billet by forcing it through a die or profile that mirrors the cross-section of the desired product. These dies are thick, circular disks with one or more openings, precisely shaped to match the dimensions of the item being produced. Made from heat-treated steel, they are designed to withstand the immense pressure and high temperatures involved in extruding hot aluminum. It typically requires between 100,000 to 125,000 psi to push raw aluminum through the die. Dies are classified as solid, semi-hollow, or hollow: solid dies produce shapes without any openings, hollow dies create forms with one or more openings, and semi-hollow dies produce shapes that 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.
In warm extrusion, the billet is heated to temperatures between 800°F and 1800°F, with the optimal range being 1000°F to 1330°F. These temperatures are below the recrystallization point, which increases the billet's ductility while maintaining its solid state. As a result, less force is needed to push the billet through the die during the extrusion process.
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.
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 categorized into standard, commonly used profiles such as corners, ducts, square and round shapes, as well as T, U, and Z profiles. These profiles are typically readily available from extrusion manufacturers, who either stock them or have the necessary dies to produce them. They are offered in a variety of sizes and lengths to suit different applications.
The second group of aluminum profiles consists of complex and intricate shapes that necessitate specialized dies and tooling. These profiles can include designs with screw attachments, specialty corner profiles, handles, handrails, and transition strips with shanks. Unlike standard aluminum profiles, these complex profiles are custom-ordered and often require the engineering of a unique die to meet the specific requirements of the profile.
Complex profiles are commonly used as accents in architectural structures and decorative pieces to enhance the features of a project. The versatility of the extrusion process allows for the creation of custom shapes and profiles that meet the specific needs of any application, offering both functionality and aesthetic appeal.
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 ideal for producing angles because of its high strength-to-weight ratio and excellent corrosion resistance. Aluminum angles come in two main types: those with equal or unequal leg lengths, each forming sharp right-angle corners. Some aluminum angles feature angles less than 90°, resulting in more open leg configurations.
To ensure sufficient strength, aluminum angles undergo heat treatment to achieve the desired temper, typically T5 or T6. Although aluminum naturally has a layer of corrosion protection, many manufacturers further enhance durability by applying an anodizing finish. This process involves placing the angles in a chemical bath to create a robust outer coating.
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 known for its weather resistance, non-corrosive properties, ability to withstand both high and low temperatures, and resistance to rust. Aluminum beams are durable and come in various shapes, including unequal or equal I-beams (the most commonly used), unrounded channels, C-shaped channels, H-beams, and T-beams.
The two types of aluminum beams are Aluminum Association and American Standard, distinguished by the thickness and shape of their flanges. American Standard beams feature tapered flanges with rounded edges, while Aluminum Association beams have thicker, straight flanges without tapering.
While there are various beam profiles, I-beams are the most commonly used. The primary distinguishing factors among I-beams are their sizes and the ratio between the horizontal flanges and the vertical web. H-beams, which resemble I-beams, are heavier and feature a thicker web, making them more robust.
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 shape of aluminum channels is determined by the profile of the die used during extrusion, resulting in various forms such as angles, T-shaped profiles, I-beams, C-channels, Zee bars, tubing, or bars. Aluminum channels possess all the advantageous properties of aluminum, including being 100% recyclable. They are cost-effective, versatile, and widely used by architects and designers as both structural elements and accents for highlighting special features in buildings.
The wall thickness of aluminum channels, ranging from 0.0625 inches to 0.25 inches (0.16 cm to 0.635 cm), plays a crucial role in determining their suitability for various applications. The main appeal of aluminum channels lies in their customizability, allowing them to be tailored to meet specific shape and size requirements for different uses.
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 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 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.
Aluminum tubing is favored for its lightweight and durable qualities, making it suitable for a variety of applications, particularly those needing corrosion resistance. The main types of aluminum tubing include extruded, seamless, welded, and drawn. Each type is defined by its manufacturing method, with seamless and extruded tubing being quite similar in appearance and application.
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 produced through an extrusion process that involves piercing. First, the billet is heated to the appropriate processing temperature, and a hole is punched into one end. Rotary piercing, a rolling process where the billet is passed between rollers, is then applied. As the billet rolls, tensile stress at the center causes the material to flow along the roll, resulting in a seamless, unwelded aluminum tube.
Drawn aluminum tubing is produced through a cold drawing process, where a cleaned and lubricated billet is pulled through a series of progressively smaller die cavities. This process causes plastic deformation as the billet is cold-worked at room temperature, reshaping it into the desired tube form. The result is aluminum tubing with exceptional precision and surface quality.
Welded tubing is created using flat strips of aluminum, which are joined along their edges through high-frequency welding. The seams of these strips are heated and welded together along their longitudinal axis. Unlike drawn, seamless, or extruded tubing, welded tubing allows for the combination of multiple layers of different aluminum alloys, offering enhanced versatility and performance.
In metalworking, secondary operations are often required to prepare workpieces for specific applications or additional treatments. For aluminum extrusions, these secondary processes may include cutting, CNC machining, mitering, punching, notching, drilling, and further cutting. Before undergoing these fabricating processes, the extrusions are typically allowed to age, ensuring they are properly prepared for the subsequent operations.
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 improve both the appearance and corrosion resistance of aluminum profiles. Common finishes include anodizing, painting, and blasting. Anodizing enhances wear resistance, strengthens the surface, and provides a porous layer that helps paint adhere better. While extruded aluminum naturally has a bright surface, painting is often applied to extend the profile's lifespan, reduce maintenance costs, and offer additional corrosion protection.
Blasting is a process used to remove residue and scale from extrusions that have undergone heat treatment. It helps add texture, eliminates contaminants, and prepares the extrusion for further processing such as machining, painting, or achieving a matte finish.
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.
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.
Despite the name, T-slot extrusions can feature a single slot, multiple slots, or no slots at all, and come in various cross-sectional sizes. These versatile profiles facilitate rapid assembly, allowing structures or enclosures to be quickly erected, disassembled, and relocated. Common T-slot profiles include 20x20, 30x30, and 40x40, with weight capacities exceeding 3000 lbs (1360.8 kg). They are easily connected using plates or corner brackets secured with T-bolts and nuts.
Aluminum trim consists of long, thin, narrow extrusions used in a variety of applications, including automotive design, decorative architecture, screen printing, indoor and outdoor lighting, and construction projects. It is weather-resistant, unaffected by extreme temperatures, and resistant to corrosion and rust.
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 its lightweight and cost-effective nature, aluminum trim is flexible and can be extruded into various shapes, finished, and maintains its shine. Interior vehicle trim often features small, detailed surface patterns or textures. With the appropriate finish, aluminum trim can achieve a luxurious appearance while helping manufacturers reduce 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.
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 favored for its many beneficial properties, including flexibility, recyclability, durability, high structural strength, and low weight. These characteristics make aluminum cost-effective to ship and ideal for weight-restricted applications. Additionally, aluminum extrusions maintain their strength across a range of temperatures where other metals might become brittle and break. They are also non-toxic, non-magnetic, and conduct electricity.
Cold extrusion is conducted at or near room temperature, where a billet or slug is pushed through a die profile using compressive force. The billets, cut from bars of aluminum, are placed in the extruder's barrel. The critical aspect of cold extrusion is maintaining the billet at room temperature or slightly above. A screw, plunger, or ram applies pressure to force the billet through the die profile. In forward cold extrusion, the billet is pushed forward through the die, while in reverse cold extrusion, the die is pushed toward the billet by the ram.
In hot or direct extrusion, the billet is heated to a carefully controlled and monitored temperature. Similar to cold extrusion, the billet is lubricated before being placed in the extrusion chamber or barrel. To minimize die wear, the die is also heated. A ram, plunger, or slug then pushes the heated billet through the barrel to the die, where it is shaped into the desired profile. The elevated temperature facilitates easier deformation and enhances the formability of the billet.
In the indirect extrusion method, the ram moves the die towards the stationary billet and applies pressure by forcing the die against it. The completed extrusion exits through the ram, and since the billet remains immobile, there is no barrel friction affecting it. This results in a constant force applied from the front to the rear of the billet, leading to consistent extruded parts with minimal temperature variations. Dimensions, grain structure, and mechanical properties are uniform throughout the process. For optimal results and high-quality products, the billet must have any surface materials removed that could impact the extrusion.
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 that shape the desired profile. Made from heat-treated H-13 steel, these dies are designed to endure the high pressure and temperature of the extrusion process. Despite the small size of the dies and the relatively soft nature of aluminum, it requires between 100,000 psi and 125,000 psi to push an aluminum billet through the extrusion profile.
The three forms of aluminum extrusion profiles are solid, hollow, and semi-hollow. Each type is tailored to produce different shapes, ranging from simple angles to highly intricate designs for specialized applications. The die profile dictates the final shape of the extrusion, with the key difference between the profiles being the presence or absence of openings or voids.
Solid dies or profiles produce shapes without voids or openings, such as beams, angles, and rods. They are generally the least expensive and easiest to manufacture. A solid die comprises a stack that includes a feeder plate, die plate, backer plate, and bolster. Among these, the die plate defines the shape or profile of the extrusion.
Hollow dies are used to produce extrusions with voids and openings, such as tubing or intricate profiles. They feature a mandrel with two or more portholes to form the internal features of the profile. As the billet is extruded, it separates at each port and then rejoins later in the process. The die cap shapes the profile and is supported by the bolster, which also provides support for the mandrel.
Semi-hollow dies are akin to hollow dies, featuring a mandrel, die cap, and bolster. The mandrel includes portholes but lacks cores for creating voids. The die cap defines the profile's shape, while the bolster supports both the mandrel and the die cap.
All extrusion companies provide standard profiles, typically made from aluminum alloy series 6061, 6063, and 1100. These profiles are designed to meet various application, operational, assembly, or process requirements and are categorized into five line types: 5, 6, 8, 10, and 12. Each line type is defined by three geometric characteristics: modular dimensions, groove dimensions, and bore diameter.
Standard profiles are readily available and include basic types such as corner profiles, duct and double-duct profiles, square and round tubes and pipes, T-tracks, U channels, Z profiles, and flat, round, and square bars. Manufacturers keep these profiles on hand, ensuring quick availability.
Complex profiles are utilized for their strength and durability in construction, automotive production, and manufacturing. Unlike standard profiles, which feature simpler shapes like angles and circles, complex profiles incorporate multiple design elements. Examples include borders with attachments, water deflectors, and automobile trim.
The key difference between complex profiles and custom profiles lies in the dimensions and tolerances. Custom profiles can be extremely small and feature very tight dimensional tolerances. They are crafted from a combination of aluminum alloys and tailored for specific, unique applications, whereas complex profiles are designed with multiple elements for strength and durability.
The wall thickness of an aluminum profile influences its load-bearing capacity and the range of applications for which it can be used. It affects the extrusion force required, dimensional tolerance, and surface finish. Additionally, wall thickness is a key factor in selecting the appropriate alloy grade; higher alloy grades offer improved dimensional tolerance and produce stronger products with better mechanical properties.
In addition to strength and mechanical properties, the wall thickness of a profile impacts its ability to be shaped, welded, bent, and formed. With profiles having varying wall thicknesses, it's crucial to match the thickness of adjoining walls to prevent weakening the extrusion. Typically, a 2:1 thickness ratio between adjoining walls is not recommended, as it may compromise the profile's integrity.
Hollow beam profiles come in various cross-sectional shapes and subclassifications. Single radius profiles, or SD profiles, feature a curved back with straight segments forming quarter circles. These profiles can be solid, semi-solid, or hollow. L-shaped profiles are among the simplest and are versatile for many applications. T-slot profiles are designed to accommodate connections and are ideal for assembling and reassembling structures.
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.
What industries use aluminum extruded heatsinks, and how do their designs vary? Extruded heatsinks are crucial for applications needing efficient heat dissipation, such as in electronics, military, medical equipment, industrial manufacturing, appliances, and LED lighting. They come in various designs, including differences in length, width, height, style, weight, noise level, and speed. In contrast, non-extruded heatsinks, like stamped, bonded, or folded types, generally incur 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.
How do heatsinks contribute to computer efficiency and protection? In the computer age, heatsinks play a crucial role in maintaining computer performance by managing heat. Computer processors handle multiple operations simultaneously, generating significant heat. Heatsinks transfer this heat away from critical components, preventing overheating and potential damage. Without effective heat dissipation, computers could shut down, leading to costly damage. As a result, every computing device incorporates some form of heatsink to ensure optimal performance and protection.
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 by Bramah’s extrusion process and hydraulic press, Thomas Burr combined the two innovations in 1820 to create a hydraulic press for forcing metal through a die. Burr aimed to improve the speed and reliability of lead pipe production using this new extrusion method, which was then referred to as "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.
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 employed in various processes such as hide tanning, first aid, fabric dyeing, pickling, and canning. This natural substance appears as a salt of either potassium aluminum sulfate or ammonium aluminum sulfate. Even today, alum is still utilized as a supplement in some medicinal applications.
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 surge in aluminum's uses and applications was driven by the introduction of the first extrusion press in the United States, built in Pennsylvania in 1904. This innovation proved to be a significant asset for the burgeoning 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 II, aluminum became crucial to the war effort, being used in numerous items for soldiers and sailors. Campaigns like "Aluminum for the Defense" and "Tinfoil" drives encouraged recycling aluminum for military use. From 1940 until the war's end, over half of the 296,000 aircraft produced 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 was first introduced in 1959 by Coors Brewing Company in Colorado, which launched an all-aluminum, seamless, two-piece can for their beer. Along with this innovation, Coors implemented a recycling program that offered one cent for each returned can. The soft drink industry followed in 1964, with Royal Crown Cola from Columbus, Georgia, adopting aluminum cans for their beverages.
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.
Many manufacturers specialize in aluminum extrusion machines, each perfecting their processes to meet diverse needs. When selecting a company for an extrusion project, it's crucial to consider factors such as the profile's intended use, required quantity, type of aluminum, and other specific requirements. While price is a consideration, it should not be the sole deciding factor; ensuring the desired quality and performance of the extrusion is paramount.
Description: The Series 7 Extrusion Press from Presezzi Extrusion Group is a versatile machine designed to produce a wide range of aluminum profiles. Renowned for its high precision and advanced automation features, this model excels in controlling the extrusion process. It accommodates various alloys, shapes, and sizes with flexibility while ensuring energy efficiency and durable construction.
Description: The SMS SmartExtruder is a cutting-edge extrusion machine designed for producing a diverse array of aluminum profiles. It features intelligent control systems and energy-efficient operation, along with precise temperature management and advanced automation. The SmartExtruder is praised for its versatility, handling various extrusion profiles with consistent quality and high productivity.
Description: UBE Machinery’s UBE Aluminum Extrusion Press is a versatile machine designed for producing a wide range of aluminum profiles. It boasts precision control systems, efficient energy utilization, and high-speed capabilities. This model excels in handling various alloys, sizes, and shapes of extrusions, ensuring both reliability and precision throughout the extrusion process.
Description: HPM (Hamilton Plastic Molding) is a leading manufacturer of industrial machinery, including aluminum extrusion presses. Their HPM Aluminum Extrusion Presses are engineered to produce a diverse array of extruded aluminum profiles. These machines feature advanced control systems, efficient energy consumption, and the capability to handle a wide range of profiles and alloys. HPM presses are recognized for their robust construction, reliability, and versatility.
Description: Nordson Corporation is a specialist in extrusion dies for producing various types of extruded aluminum profiles. Their Xaloy Extrusion Dies are engineered to deliver precise shaping and control throughout the extrusion process. These dies offer customization options for different profile shapes and sizes, ensuring high-quality and consistent results. Nordson Xaloy Extrusion Dies are renowned for their durability, precision, and versatility.
Please note that the availability and specifications of these extrusion machines may change over time. For the most current and detailed information on the models and features available from these manufacturers, please contact them directly or consult their product catalogs and specifications.
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Anodized aluminum is aluminum that has undergone an anodizing process to create an exceptionally durable, corrosion-resistant, and highly aesthetic surface. Anodizing creates a stable aluminum oxide layer fully integrated with...
A wire brush is an abrasive tool that has stiff bristles made from a variety of rigid materials designed to clean and prepare metal surfaces. The filaments of wire brushes are small diameter pieces of inflexible material that are closely spaced...
Aluminum is the most abundant metal on the Earth’s crust, but it rarely exists as an elemental form. Aluminum and its alloys are valued because of their low density and high strength-to-weight ratio, durability, and corrosion resistance...