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Aluminum is a very commonly specified material for use in extrusions and shape profiles because it possesses mechanical characteristics that make it ideally suited for the shaping and forming metal billet sections.
The aluminum extrusion (also known by “aluminum frames”) forming process is a bulk plastic deformation process. First, a billet of aluminum is preheated to a specified temperature that is still comfortably below the material melting point in order to facilitate the plastic flow of the material. The heated billet is then forced through a tooling die that is designed to shape and form the billet into the corresponding profile cross section.
Aluminum is a very commonly specified material for use in extrusions and shape profiles because it possesses mechanical characteristics that make it ideally suited for the shaping and forming metal billet sections.
The high malleability of aluminum means that the metal can be readily shaped into a variety of sections without expending significant energy on the tooling or forming process, and the melting point of aluminum is also generally on the order of half that of ordinary steel. Both of these facts mean that the aluminum extrusion process has a relatively low energy footprint translating into low tooling and manufacturing costs. Finally, aluminum also possesses a high strength to weight ratio, making it an excellent choice for industrial applications.
Aluminum profiles are most commonly used across industrial automation applications such as automated motion applications on process lines and industries throughout manufacturing. They are strong and yet light enough that they yet can be easily man-handled and built into various configurations as necessitated by the automation structure.
Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation.
Factors Affecting Extrusion
Shape is a determining factor in the part’s cost and ease with which it can be extruded. In extrusion a wide variety of shapes can be extruded, but there are limiting factors to be considered. These include size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, factor, and scrap ratio. If a part is beyond the limits of these factors, it cannot be extruded successfully.
The size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap ratio are interrelated in the extrusion process as are extrusion speed, temperature of the billet, extrusion pressure and the alloy being extruded.
In general, extrusion speed varies directly with metal temperature and pressure developed within the container. Temperature and pressure are limited by the alloy used and the shape being extruded. For example, lower extrusion temperatures will usually produce shapes with better quality surfaces and more accurate dimensions. Lower temperatures require higher pressures. Sometimes, because of pressure limitations, a point is reached where it is impossible to extrude a shape through a given press.
The preferred billet temperature is that which provides acceptable surface and tolerance conditions and, at the same time, allows the shortest possible cycle time. The ideal is billet extrusion at the lowest temperature which the process will permit. An exception to this is the so-called press-quench alloys, most of which are in the 6000 series. With these alloys, solution heat-treat temperatures within a range of 498-525° C must be attained at the die exit to develop optimum mechanical properties.
At excessively high billet temperatures and extrusion speeds, metal flow becomes more fluid. The metal, seeking the path of least resistance, tends to fill the larger voids in the die face, and resists entry into constricted areas. Under those conditions, shape dimensions tend to fall below allowable tolerances, particularly those of thin projections or ribs.
An alloy’s higher mechanical properties mean a lower extrusion rate. Greater friction between the billet and the liner wall results in a longer time required to start the billet extruding. The extrusion ratio of a shape is a clear indication of the amount of mechanical working that will occur as the shape is extruded.
Extrusion Ratio = area of billet/area of shape.
When the extrusion ratio of a section is low, portions of the shape involving the largest mass of metal will have little mechanical work performed on it.
Advantages of the extrusion process:
There are several advantages of the modern extrusion process
• A variety of shapes are possible, especially with hot extrusion.
• Grain structure and strength properties are enhanced in cold and warm extrusion.
• Fairly close tolerances are possible, especially in cold extrusion.
• Little or no wasted material is created. However, a limitation is that the cross section of the extruded part must be uniform throughout its length.
Types of Extruded Profiles
An extruded profile is defined as a product that is long in relation to its cross section other than extruded rod, wire, bar, tube, or pipe. Many custom or complex cross-sectional designs are possible with aluminum extrusion and, as such, three broad categories of profiles have been established:
? Solid profiles: Extruded cross sections that do not incorporate enclosed or partially enclosed voids (Some examples of solid profiles are I-beams or C-channels; refer to Table 4 and related information to discern solid from semi hollow profiles.)
? Hollow profiles: Extruded cross sections that contain one or more completely enclosed voids in one or more portions of its overall shape geometry
? Semi hollow profiles: Extruded cross sections that contain one or more partially enclosed voids in one or more portions of its overall shape geometry
The global sales of aluminum extrusion is expected to garner a market value of US$ 89 Billion in 2022 and is expected to register a CAGR of 7% by accumulating a market value of US$ 175 Billion through the assessment period 2022-2032.
It is intended to prepare a Feasibility Report to install 5 TPD Aluminium Extrusion production facilities as a Green Field Project near Angul, Odisha
