Metal extrusion forces raw metal material through a shaped die to create an elongated final shape. The shape of this die defines the profile of the extruded piece, which can be altered to suit many desired geometries. Due to their physical characteristics, aluminum alloys hold up particularly well to extrusion, and aluminum extrusion as a distinct process is popular for creating diverse components and products across industries.
Compared to alternatives such as die casting, extrusion promises a cost-effective, versatile method of manufacturing high-quality aluminum components.
The aluminum extrusion process occurs in multiple steps:
The exact method used to create an aluminum extrusion varies depending on a number of factors. Direct and indirect extrusion methods broadly represent the subcategories of the technique, and each poses a unique set of advantages suitable for certain manufacturing environments.
In direct extrusion—or forward extrusion—a motorized ram forces the billet through the die to achieve the final shape. While more common than other methods, direct extrusion is more energy-intensive due to the force required to release the billet from the machinery.
The main difference between direct and indirect extrusion lies in which component of the machinery moves. With indirect extrusion, the ram remains stationary and the die itself is what moves to direct the billet. This mechanism reduces friction, making indirect extrusion quicker and more energy-efficient than the alternative.
In the extrusion process, care must be taken to control a range of factors that can affect the finished product. Changing the materials or procedures used alters the final component’s physical characteristics, which is part of why extrusion can be beneficial for such diverse applications.
Some controllable factors that alter the results may include:
Aluminum extrusion is a highly desirable manufacturing technique for industries ranging from construction to energy and telecommunications. The experts at Tri-State Aluminum will work with you to determine the appropriate extrusion process for your individual specifications, ensuring that your finished pieces are precise, consistent, and of the highest quality.
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