How We Modernize Machined Projects By Aluminum Extrusion
Aluminum extrusion is a metal machined process we use in shaping aluminum by forcefully pushing it through a die with the desired shape. The extruded aluminum emerges on the other end as an elongated metal piece with the same shape as the die opening. Standard extruded aluminum shapes make fabrication constructs easier and quicker. Hence, It is a flexible process that enables us to Creatingway satisfy our clients’ specifications.
The features of extruded aluminum
Aluminum is an extremely versatile metal that is lighter than steel but almost of similar strength. It does not easily corrode except for really extreme environmental conditions. It also readily conducts electricity and heat enabling its application in various industries. Furthermore, Its most acclaimed quality in the manufacturing industry is that by using it in extruded section forms, so that you can simplify and cut the cost of your designs. This is possible while still ensuring strength and improving its surface quality.
The process of manufacturing
We prefer the standard extrusion of a section of aluminum is when it comes to manufacturing magnificent and functional aluminum parts. The process entails forcing aluminum through an aperture that has a specific shape. The shape can be of any variety, whether it’s: rectangle, square, circular or polygonal. It can also be a hollow which is useful for light but strong parts. The extruded shapes must have perfect symmetry. The symmetrical shapes are fewer distortions than asymmetrical shapes. This translates to lesser bending or twists along the extruded length of aluminum.
The aluminum undergoing extrusion is usually in molten form and we subject to high pressure. Since aluminum is highly flexible, there are several techniques for performing it. They include continuous or semi-continuous and hot or cold. We heat aluminum billets to between 700- and 900-degrees Fahrenheit to turns it into a soft molten form. We then feed this through the die.
A hydraulic press or mechanical power facilitates the extrusion process. If the extruder is continuous, then the hydraulic press forces out the aluminum as a long continuous section until it is complete. When it is a semi-continuous extrusion process then the press cuts off calibrated sections of the metal as it passes through the die.
The tooling process
Lead Times
In comparison to injection molding, the tools we use in the extrusion process is less complicated. One simple metal section can take several days to complete producing while the more complex variation may require several weeks. This directly correlates to a higher cost.
Fancy custom extrusions do add the finishing touch to the final product. However, we recommend to our clients that there is a need in having to incur the cost accompanying wait time.
Adding value to aluminum extrusion
In addition to the production of aluminum extrusion, the parts can further undergo processes that add utility to them. These additional processes include
- Drilling of holes and slots in them
- Bend them within the normal limits
- Cutting them to any length including bevel lengths
- Welding
- Anodizing the pieces as a surface finishing process
Finishing techniques we use on Aluminum extrusion
We also prioritize on enhancing the appearance and surface quality of extruded aluminum. The importance of treating aluminum surfaces improved include
- Its color
- The lectrical insulation
- The esistance to wear and tear
- Reflectivity
Surface finishing techniques include:
- Mechanical Surface treatment.
The entails several processes such as grinding, polishing and tumbling. These processes provide a glossy surface finishing which is normally followed up by other finishing methods.
- Anodizing
This is a common process that increases the translucent film of the aluminum oxide that is already naturally present on the extruded aluminum surface. It essentially improves its corrosion resistance, adds a decorative touch and is dirt repellent.
The paint we use can either be chrome-free or chrome-based. It delivers a good adhesion and increases its resistance to corrosion
- Powder coating
It provides a limitless choice of colors as it does not require the use of solvents. We preferably use it over wet paint in some in some instances to avoid wastage as we lose wet paint via evaporation. Up to 98% of the powder is in use. The technique is highly repeatable, and it has no risk of running or blistering.
Advantages of extrusion
This technique uniquely helps in producing parts that need to be uniform in cross-sectional area. The applications of structural aluminum have several benefits which include
- Cost-effective to use
- Very high strength to weight ratio
- Easily adapts to temperature variation
- Excellent electrical and thermal conductivity
- Ability to produce various shapes and sizes
- Resistant to corrosion
We outfit the press with various dies hence can invest in its long-term use. Our loyal customers can, therefore, seek out their previous customizations and new variations without much delay. The final product may be used alone or interlocked with other symmetrical metal parts. Aluminum has a natural oxide coating that helps in preventing its corrosion. Aluminum can further tolerate high temperatures without producing toxic fumes. It is worth noting that the different aluminum alloys available differ in properties and benefits.
Applications of Aluminum Extrusion
In the transport industry, aluminum is critical in maximizing the key element of strength to weight ratio. The parts we manufacture using it include engine blocks, transmission housings, chassis, panels, roof rails, and the vehicle’s body.
Extruded aluminum tubing houses coaxial cables and wires since it is non-magnetic. So that it is thus important for high-voltage applications and anywhere magnetic fields come up.
In construction, they are resistant to corrosion and distortion that is a result of weather and building movement. Also, they maintain shape through their strength and malleability upon impact from shock.
Its highly reflective property is important in shielding appliances or areas from radio waves, light waves or infrared radiation. Therefore, This guideline will help you understand the enthusiasm surrounding aluminum profiles, with specific emphasis on its extrusion.
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