Extruded Aluminum Shapes

Extruding aluminum is a metal forming process that uses compression and a pre-cut die to shape aluminum billets into long, uniform parts, such as rods, beams, tubes, or channels. Depending on the shape of the die, extruded aluminum components can be solid, hollow, or semi-hollow. The process is highly temperature intensive and requires specialized equipment and expert handling to ensure optimal strength and accuracy.

A typical aluminum extrusion process involves the following steps:

1. Creating the die. Before the extrusion process can begin, a design must be created and manufactured to meet the desired product’s shape and size specifications. Aluminum extrusion dies are typically made from durable steel to ensure they can withstand repeated use.
2. Preparing the die. Once an appropriate die is attained, it is preheated and attached to the extrusion press as part of the setup for the extrusion operation.
3. Preparing the billet. Another key step in the preparation stage is preheating the raw aluminum material (also known as the billet) to between 750° to 930° F. This softens the metal without melting it. The preheated aluminum billet is then loaded onto the extrusion press.
4. Extruding the material. Once the die and billet are properly prepared, a hydraulic ram forces the aluminum through the heated die, extruding it into the desired shape.
5. Initial cooling and cutting of the extruded pieces. The aluminum extrusion then exits the die, is cut at the desired length, and guided across a cooing table. The table uses a water bath, spray, mists, or air to cool the extrusion. At the end of the table, a hot saw separates the extrusion from the rest of the material for further processing.
6. Finishing the extrusion. Throughout the extrusion process, the material may experience twisting and turning, which can be corrected by stretching the extrusion back into the proper alignment. Once the extrusion is fully straight, it is cut into the desired lengths and, if needed, aged, quenched, heat treated, coated, painted, or otherwise finished.