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Everything you need to know about aluminum extrusion:Aluminum extrusions are an essential part of our homes, although many people do not even notice them. They are usually part of window or door systems, but the application does not stop there. Aluminum bars have countless applications in building and manufacturing industries, therefore the quality of each product must be impeccable.Shanyi is one of the largest European supplier of aluminum extruded bars for forging and one of the largest suppliers of drawn bars in Europe and the US. In our manufacturing process, which is trusted by all the largest European automotive companies and the European aviation industry, we apply the best possible production practices which we continuously improve.The 6 Steps of Aluminum ExtrusionThe extrusion process is carried out in direct or indirect extrusion presses with different power levels. The basic process can be broken down into six distinct steps, although they can be modified or expanded upon depending on the customer's specific requirements.But even before the extrusion process begins, the cast aluminum rods needs to be cut into smaller pieces. These short pieces are called billets. The pre-cut billets ensure that the length of each extruded bar will be roughly the same and there will be no material wastage.Step 1: Preheating the aluminum billet and steel die to a specified temperatureThe billets are heated in induction or gas furnaces from room temperature to the extrusion The temperature varies depending on the alloy and the final temper.The heated billets need to be malleable enough to take on the required shape, but still firm enough to retain their shape during transportation.The push bat starts applying pressure into the heated billet and pushes it towards the die opening.Step 2: Loading the billet into the steel extrusion press containerTo prevent heat loss, the billets are quickly transported from the furnace into the press. They are loaded into the recipient and are ready to be extruded.The ram starts applying pressure into the heated billet and pushes it towards the die opening.Step 3: ExtrusionThe heated aluminum billet is pushed through the openings in the tool. Those openings can be modified to create different shapes and sizes. The process is similar to a cookie press, where the different shaped discs create different cookie designs.When the bars exit the press, they are already extruded to their required shape.Step 4: Controlled coolingThe extrusion process is followed by quick cooling of the extruded bars/tubes/profileWhen exiting the press, the fully formed bars/profiles are pushed through a water bath which guarantees uniform quenching of the heated aluminum.The quenching process is necessary to ensure the required mechanical properties and adequate material micro structure.To prevent any material deformation, the cooling process must be carried out without delays immediately after the extrusion process.Step 5: StretchingImmediately after quenching, the extruded bars are cut into the prescribed inter phase length.The cut bars are then grabbed by a puller, which lays them over the run out table. This allows them to further cool down.In this phase, the extruded bars are run through a strengthening process, which stretches the bars and ensures their mechanical properties by removing the internal tension within the bars.Step 6: Cutting and final packagingThe quenched and straightened bars are cut to the length specified by the customer.At this stage, the aluminum bars have the properties of the T1/T4 temper. To ensure better mechanical properties of the T5/T6/T66 temper, the bars are artificially aged.The aging process further strengthens the extruded profiles and ensures they fulfill the mechanical properties specified for individual alloys.Advantages of Aluminum ExtrusionIn comparison to other products, aluminum extrusions are the preferential option due to their unique combination of lightness and toughness. From the industry viewpoint, aluminum extrusion has additional advantages:They are generally a competitive and economical production option especially when dealing with very complex cross-sections.They are stronger and toughThe surface finish of extruded products is impeccable and in general, those products are stronger when compared to aluminum castings.Despite the numerous advantages, there is also an important disadvantage to aluminum extrusions in comparison to casting. And that is their size. Aluminum extrusions are limited by the size of both the billet and the capacity of the steel container on the extrusion press.Aluminum extrusion is great to meet a range of your product development needs. Here are some of the benefits of aluminum extrusion:Lower tooling cost.Fast tooling delivery time.Minimize material waste.Highly accurate and repeatable.Highly production speed and capacity.Low investment in tooling and preparation costs.Economical.Fast turnaround.  /* January 22, 2024 19:08:37 */!fun