How to extrud aluminum profiles and types of extrusion

What are aluminum extrusion profiles

Extruded aluminium profiles are produced through the aluminium extrusion process. This process involves passing a high-temperature aluminium alloy billet through a specialised extrusion die. Under substantial pressure from the extruder, the aluminium alloy is pushed through the die cavity at a controlled speed, producing profiles with the desired shape, size, and mechanical properties. These profiles are suitable for various applications.

The features of extruded aluminium profiles are as follows:

• Lightweight and high-strength: Aluminium has a low density of about 2.7 g/cm³ and considerable strength, typically ranging from 80 to 265 MPa. Specifically, industrial pure aluminium has a tensile strength of 80 to 100 MPa, while common alloys like rust-resistant 5A50 reach 265 MPa. Additionally, aluminium panels have compressive strengths typically between 4 and 20 MPa, with tensile strength reaching 20 MPa. This makes them highly suitable for structures that require lightweight properties.
• Good corrosion resistance: A natural oxide film forms on the surface of aluminium, protecting it from oxidation and corrosion.

Specific reasons for corrosion resistance:

1. Dense oxide film: Aluminium readily oxidises in air, forming a dense aluminium oxide film (Al₂O₃). This oxide layer is exceptionally hard and effectively prevents further reactions between aluminium and elements such as oxygen or moisture in the air, providing protection.
2. Anodising treatment: To enhance the corrosion resistance of aluminium profiles, anodising is typically applied. This method forms a thicker and denser oxide film on the aluminium surface, significantly improving its resistance to corrosion.

• Easy to process: Aluminium extrusions can undergo various secondary processes, such as cutting, welding, CNC machining, and surface treatments, meeting a wide range of application requirements.

CNC machining center： The CNC machining center is a precision machining facility controlled by computer numerical systems, automating machining by managing the movement and processes of the machine tool. Conco owns multiple fully-automated CNC machines, including five 4-metre CNC machining units and one fully-automated gantry milling machine, meeting all customer processing requirements.

Surface treatment versatility: Aluminium profiles can undergo various chemical and physical treatments, such as anodising, spraying, electrophoresis, and baking paint, allowing for attractive surface finishes and a range of colours to meet diverse requirements. Conco has many years of experience in surface treatment processes. The company possesses multiple surface brushing and polishing machines, as well as a large fully automated sandblasting machine. Additionally, Conco offers a variety of anodising tanks for different colours, significantly meeting customer demands while also saving on costs and time.

• Diverse applications: Aluminium is widely used in various fields, including construction, transportation, electronics, and machinery, for items such as window frames, door frames, and aluminium alloy vehicle bodies.
• Recyclability: Aluminium materials can be recycled multiple times, making them environmentally friendly.

What is the process of Aluminum Extrusion

The process flow for Conco aluminium extrusion primarily includes the following steps: heating the aluminium billet, extrusion, cooling and quenching, stretching and straightening, sawing, inspection, artificial ageing, inspection, and storage.

1）Raw material preparation: Suitable aluminium alloy materials are selected, typically in the form of aluminium ingots or billets, and inspected to ensure their quality meets standards. Generally, we classify aluminium billets into the 1xxx to 8xxx series.

• The 1xxx series is known as industrial pure aluminium, characterised by a high aluminium content, with a purity of up to 99.00% or more. The common models are 1100 and 1199. The aluminium content of model 1100 is approximately 99.0%, and it is widely used in conductive and heat exchange equipment. On the other hand, model 1199 has an aluminium content of up to 99.99% and is primarily used in electrical applications where excellent conductivity is required. The general application scenarios commonly involve the use of extruded coils and hoses in the food, chemical, and brewing industries.
• The 2 series is known as aluminium-copper alloys, characterised by their high hardness, and are commonly used in the aerospace sector. Common models include 2024, 2014, and 2219. Model 2024 contains aluminium, copper, and magnesium, with a small amount of manganese, and is one of the most widely used alloys in the 2 series. Model 2014 consists of aluminium, copper, silicon, and magnesium, and is typically suited for high-temperature applications. Model 2219 contains aluminium, copper, and vanadium, and is known for its excellent high-temperature strength and weldability.They are also primarily used in the aerospace sector, such as in aircraft structural components, rivets, and so on.
• The 3 series is known as aluminum-manganese alloys. They are characterized by their excellent rust resistance and are commonly used in applications where corrosion resistance is required.Common models include 3003, 3004, and 3015. Model 3003 is the most commonly used, containing approximately 1.2% manganese. Model 3004 has a higher content of manganese and magnesium than 3003, making it commonly used in the production of cans. Model 3015 contains small amounts of additional manganese and magnesium, and is also commonly used in the manufacture of building materials and vehicle components. Other application scenarios include those requiring rust resistance, such as in chemical equipment, kitchen appliances, and so on.
• The 4 series is known as aluminum-silicon alloys, characterized by their high silicon content, as well as their heat and wear resistance. They are commonly used in construction and mechanical components.Common models include 4043 and 4032. Model 4043 has a silicon content of about 5% and is one of the most commonly used welding alloys. Model 4032 contains as much as 12% silicon and is used in the manufacture of high-performance pistons and other mechanical components.

• The 5 series is known as aluminium-magnesium alloys, characterised by their low density and high tensile strength. They are commonly used in general industrial applications.Common models include 5052, 5083, and 5754. Model 5052 contains approximately 2.5% magnesium and is widely used in the manufacture of shipbuilding and vehicle components. Model 5083 has a magnesium content ranging from 4.0% to 4.9% and is one of the strongest non-heat-treated aluminium alloys, commonly used in shipbuilding and other high-strength applications.The general models are also widely used in industries such as shipbuilding, automotive manufacturing, and so on.
• The 6 series is known as aluminum-magnesium-silicon alloys, characterized by moderate strength and excellent corrosion resistance. They are commonly used in industries such as construction and automotive. These alloys offer good corrosion resistance and machinability.Common models include 6061, 6063, and 6082. Model 6061 is one of the most commonly used alloys in the 6 series, containing approximately 1.0% magnesium and 0.6% silicon, and is widely used in structural applications. Model 6063 contains around 0.45%-0.9% magnesium and 0.2%-0.6% silicon, and is commonly used in building materials and window frames. Model 6082 has a magnesium content ranging from 0.6% to 1.2% and a silicon content between 0.7% and 1.3%. Compared to 6061, it contains more magnesium and silicon, and is typically used in applications requiring higher strength.
• The 7 series is known as aluminium-zinc alloys, characterised by their ultra-high strength, and are commonly used in the aerospace sector.Common models include 7075, 7068, and 7050. Model 7075 is the most well-known aluminium alloy, widely used for its excellent overall properties. It contains approximately 5.6% zinc, 2.5% magnesium, and 1.2% copper. Model 7068 is considered the strongest commercial aluminium alloy, containing around 8.4% zinc, 2.85% magnesium, and 1.2% copper, offering higher strength and better wear resistance. Model 7050 contains approximately 6.2% zinc, 2.3% magnesium, and 2.3% copper, and is primarily used in the aerospace sector.It has excellent resistance to stress-corrosion cracking. It is also used in aircraft structural components, missile parts, and other applications.
• The 8 series is known as other alloys, characterized by their less frequent use. The main models are primarily used in specific fields, such as in the production of aluminum foil.

2）Heating: The aluminum billet is placed in a hot alkaline furnace and heated to approximately 480 degrees Celsius (generally between 400°C and 500°C), with a hold time of one hour. This ensures the billet reaches the desired processing temperature, making it more malleable and facilitating subsequent extrusion.

3）Extrusion: The heated aluminum billet is placed in the extruder, where it is forced through an extrusion die to form the desired profile. The extrusion process can be either direct or indirect. Conco primarily uses presses with capacities of 1200T, 2500T, and 4000T for the extrusion process.

4）Cooling: The extruded aluminum profiles undergo cooling, typically achieved through water cooling or air cooling methods, to rapidly reduce their temperature and maintain the stability and dimensional accuracy of the profiles.

5）Cutting: The cooled aluminum profiles are cut to the required lengths as specified.

6）Inspection: The cut profiles undergo quality inspection to ensure they meet the design specifications.

7）Artificial ageing: The inspected and approved profiles are placed in an ageing furnace for artificial ageing treatment, which helps to eliminate internal stresses and improve the mechanical properties of the material.

8）Final inspection: After the aging treatment, a quality check is conducted once again to ensure the profiles meet the desired specifications for their intended use.

9）Storage: The inspected and approved profiles are framed and then stored, completing the entire processing cycle.

Advantages and disadvantages of aluminum extrusion:

Advantages:

1. High strength and lightweight: Aluminium extrusions offer good strength, making them suitable for applications that require lightweight properties.
2. Complex shapes: Aluminium extrusion can produce intricate cross-sectional shapes to meet a variety of design requirements.
3. Good corrosion resistance: Aluminium has strong corrosion resistance, making it suitable for outdoor and harsh environments.
4. Easy to process and weld: Aluminium extrusions are easy to machine, cut, drill, and weld, facilitating subsequent manufacturing processes.
5. Recyclability: Aluminium is 100% recyclable, resulting in a lower environmental impact.

Недостатки：

1. Higher costs: The investment in equipment and dies for aluminium extrusion can be substantial, potentially leading to production costs that are higher than those of other materials.
2. Temperature sensitivity: The strength of aluminum decreases at elevated temperatures, limiting its use in high-temperature environments.
3. Susceptibility to deformation: In certain cases, aluminum profiles may deform due to uneven stress distribution.
4. Poor wear resistance: Compared to steel, aluminum has lower wear resistance and is not suitable for applications that experience high abrasion.
5. Thermal conductivity: Although aluminum has good thermal conductivity, it may not meet the requirements for certain specialized applications.

How can you tell different aluminum channel

The distinction between different aluminium profiles can primarily be made based on the following aspects:

• Types: Aluminium profiles are mainly divided into two types: U-shaped channels and flat sealing strips. U-shaped channels are primarily used for the installation of hardware components, while flat sealing strips are mainly used for decorative purposes and cushioning.

• Material: U-shaped channels and flat sealing strips are typically made of PVC, available in various colors such as black, white, and yellow. Flat sealing strips are primarily used for decorative purposes, while U-shaped channels are used for cushioning and protection.

• Usage: U-shaped channels are primarily used for the installation of hardware components, while flat sealing strips are used for decorative purposes and cushioning. They help maintain the cleanliness of the profile surface and prevent dust and debris from entering the grooves of the profile.
• Installation method: U-shaped channels are connected to hardware components using self-tapping screws, while flat sealing strips are simply inserted directly into the grooves of the profile.
• Design differences: The design of U-shaped channels is primarily intended for the installation of hardware components, using self-tapping screws for connection. In contrast, flat sealing strips are designed for decorative purposes and cushioning, with differences in both material and function.

By distinguishing between the above aspects, one can better understand and utilise the different types of aluminium profiles. In addition to the above aluminium profiles, Conco also offers T-slot aluminium and C-channel aluminium profiles.

T-slot aluminium is primarily used for:

• Construction: T-slot aluminum is widely used in the construction sector, primarily for connecting and securing structural elements, providing stable support and connection functions.

• Machinery and tools: In machinery and tool manufacturing, T-slot aluminum serves as a reference plane used for machine tool inspection and measurement benchmarks, checking the dimensional accuracy or behavior deviations of parts, and precision marking. It is an indispensable basic tool in mechanical manufacturing.
• Automobiles: T-slot aluminum also has significant applications in automotive manufacturing, primarily for connecting and securing automotive components, ensuring the stability and safety of the vehicle structure.
• Electronics: In the manufacturing of electronic products, T-slot aluminum is used for the assembly and securing of electronic devices, ensuring their stability and reliability.
• Other industrial applications: T-slot aluminum is also widely used in shipbuilding, power generation, metallurgy, mining, oil, chemical, and petrochemical industries, as well as in educational institutions, research institutes, and scientific organizations. It is employed for inspection, marking, measurement, assembly, welding, riveting, and testing in maintenance and repair equipment.

C-channel aluminium is primarily used for:C-channel aluminium is primarily used in the aluminium alloy door and window market as well as in home decoration.

C-channel aluminium, also known as C-slot or 15-20mm slot, is a European standard dedicated hardware slot for aluminium alloys, widely applied in aluminium alloy doors and windows. This slot design ensures the secure installation of hardware components, relying on the clamping force of stainless steel nails and machine screws with stainless steel spacers to guarantee stable installation of the hardware.

How do you custom aluminum extrusion

1. Send us your drawings (CAD or 3D), or provide a proposal for us to design the drawings.
2. Conco receives the drawings to confirm the dimensions and provides suggestions for modifications. After several iterations of confirmation, the next step in the process is carried out.
3. Both parties confirm the mould production plan and the associated costs. Once everything is verified, the next step is initiated.
4. The mould is produced, and then subjected to the corresponding extrusion pressure for initial testing and extrusion.
5. Once the accuracy and dimensions are confirmed, the mould is extruded again to produce samples, which are then compared with the initial extruded samples. The samples are sent to the customer for confirmation or further modifications.
6. Both parties agree on the signing of the contract, including the quantity, delivery date, and packaging details.
7. Commence mass production, followed by any additional processing or packaging for shipment.

Summary:

The widespread use and properties of aluminum make it one of the essential materials in modern industry. As technology advances and the demand for material performance increases, the research and application of aluminum profiles will continue to deepen, constantly expanding their range of applications across various fields.

Conco Company uses high-quality materials and advanced technology to solve aluminum-related issues for customers. We also offer a range of processes, including further processing of aluminum profiles, surface treatment, and anodizing.