2024 Aluminum Extrusion Tech & Special Profiles Overview

Introduction

Revolutionizing materials usage, aluminum extrusion profiles are soaring in popularity, swiftly supplanting traditional materials like wood, plastic, steel, and stainless steel. Boasting a wide array of unparalleled advantages, they've found ubiquitous application across industries. With a surge in demand for innovative product design and manufacturing, aluminum extrusion has emerged as a game-changer.

According to Technavio's latest report, the global aluminum extrusion market will grow at a staggering 4% CAGR between 2019 and 2023, indicating that its influence is everywhere. You may have already been exposed to this manufacturing technology and are eager to learn more about it. In that case, I believe this article can help you.

The article will look at topics such as:

1. Extrusion Process: How It Works
2. Kinds of  aluminum extrusion profile
3. Things to consider when selecting Aluminum Extrusion Profile
4. What are special aluminum extrusion profiles?

Extrusion Process: How It Works

The technique of forcing aluminum alloy material through a die with a certain cross-sectional profile is called extrusion (Fig. 1).

Fig. 1 Extrusion

Aluminum is forced into the die by a strong ram, and it comes out through the die aperture. It is then pulled out along a runout table and emerges in the same shape as the die. Aluminum extrusion is a fairly easy technique to comprehend at a fundamental level. Applying pressure to a toothpaste tube with your fingers is similar to the force used here. When you squeeze, toothpaste comes out in the shape of the opening in the tube. This is the principle of the production process of aluminum extrusion profiles.

Fig. 2 Aluminum extruded shapes

Shapes That Can Be Extruded, Fig. 2: Extruded shapes fall into three major categories:

1. Solid, devoid of any enclosed spaces or openings (such as an angle, beam, or rod).
2. Hollow, including one or more voids (such as a rectangle or square tube).
3. Semi-hollow, featuring a thin gap in the middle of a partially contained void (similar to a "C" channel).

Numerous industries, such as the architectural, automotive, electronics, aerospace, energy, and other sectors, use extrusion in one way or another.

Now that you have a better understanding of the fundamentals of aluminum extrusion profiles, let's examine the specifics of the procedure. The Ten Steps of the Aluminum Extrusion Process are as follow:

Step #1: Setting Up and Transferring the Extrusion Die to the Extrusion Press

First, H13 steel is machined into the shape of a circular die. If one is already accessible, it is taken out of a warehouse. To prolong its life and guarantee uniform metal flow, the die must be warmed to 450–500 degrees Celsius before extrusion. The die can be placed into the extrusion press after it has been preheated.

Step #2: Before extrusion, an aluminum billet is heated

After that, a lengthier log of alloy material is carved into a solid, cylindrical block known as a billet of aluminum alloy. This oven is prepared at 400–500 degrees Celsius. This keeps it from becoming molten but makes it sufficiently pliable for the extrusion process.

Step #3: The Billet is Transferred to the Extrusion Press

After preheating, the billet is fed into the extrusion press via a mechanism. It is lubricated (also known as release agent) before being loaded onto the press. To stop the ram and billet from adhering to one another, the release agent is also applied to the extrusion ram.

Step #4: The Billet Material is Propelled Into the Container by the Ram

The hydraulic ram in the extrusion press now presses up to 15,000 tons of pressure onto the malleable billet. The billet material is forced into the extrusion press's container by the pressure exerted by the ram. The substance grows to fill the container's walls.

Step #5: The Material Extruded Through the Die

The alloy material is now being forced up against the extrusion die as it fills the container. The aluminum substance has nowhere to go but out the die's opening(s) when pressure is applied continuously. It appears as a fully-formed profile that emerges from the die's opening.

Step #6: Quenching and Guiding Extrusions Along the Runout Table

Once it emerges, the extrusion is guided down the runout table at a speed commensurate with its exit from the press by a puller such as this one that you are currently viewing. The profile is "quenched," or consistently cooled, as it travels along the runout table by fans above the table or by a water bath.

Step #7: Shearing Extrusions to Table Length

An extrusion is separated from the extrusion process by being sheared by a hot saw once it has reached the entire length of the table. Temperature is a key factor in every stage of the process. The extrusion has not cooled completely even though it was quenched after coming out of the press.

Step #8: Extrusions are Cooled to Room Temperature

Table-length extrusions are mechanically moved from the runout table to a cooling table, such as this one, following shearing. Until the profiles come to room temperature, they will stay in that location. They'll need to be stretched once they do.

Step #9: Extrusions are transferred to a stretcher and stretched to achieve alignment

The profiles need to be adjusted because they have some natural twisting. They are transferred to a stretcher in order to remedy this. Every profile is pushed into specification and made completely straight by means of a mechanical grasp on both ends.

Step #10: Extrusions are Moved to the Finish Saw and Cut to Length

The table-length extrusions are moved to the saw table when they have straightened and completely hardened. They are sawed here to predetermined lengths, usually ranging from eight to twenty-one feet. The extrusions' characteristics now match the T4 temper. They can be aged to the T5 or T6 temper by placing them in an aging oven after being sawed.

Surface Finishing: Improving Protection against Corrosion and Appearance There are numerous finishing processes that aluminum extrusion  profiles can go through.

Fig. 3 Surface finishing

These should be taken into consideration primarily because they can improve the aluminum's corrosion resistance and look. There are, however, additional advantages. For instance, anodization deepens the naturally occurring oxide layer on the metal, increasing its resistance to corrosion, wear, and surface emissivity while also creating a porous surface that can take in various colored dyes. Additional finishing techniques include painting, powder coating, sandblasting, and sublimation (which creates a wood-like appearance).

Kinds of aluminum extrusion profile

Aluminum extrusions are produced using a metal extrusion method, with the varieties varying based on the needs and uses. A billet of aluminum is passed through a die having cross sections in the extrusion process. There are two possible outcomes: condensed versions or expanded ones. A variety of aluminum extrusion profiles, Fig. 4,  are available in various thicknesses, shapes, and sizes, which facilitates easy construction of robust industrial fixtures. Because aluminum has so many properties that can be combined to make profiles that are strong, durable, and efficient, it's an affordable option. It is possible to shape different types of aluminum extrusion profiles at different thicknesses. Depending on the usage, these extrusion profiles of aluminum might have distinct and complex empty spaces.

Fig. 4 Aluminum extrusion profiles

Different aluminum extrusion profiles of different complexity can be produced in different thicknesses. Depending on the required applications, these aluminum extrusion profiles can usually feature a variety of intricate void areas. To support different automation applications and meet particular performance weight requirements, a variety of internal void assortments are produced. The hollow beam profiles, which are a square profile variant, are the most widely used aluminum extrusion profile kinds. Additionally, several aluminum extrusion profiles exist, such as triangular, L-shaped, and single radius profiles.

Here are the common types of aluminum extrusion profiles:

1. Square Profile
2. Hollow Beam
3. SD aluminum extrusion profile
4. Door Section
5. RCW Profile
6. T-Section
7. Louver Profile

1- Square Profile

This is a distinctive aluminum extrusion profile, Fig. 4,  associated with hollow-beam choices. The capacity to ensure greater stability is the primary difference between hollow beams and square aluminum components, which meet comparable criteria. These profiles come in wall load special bearing, column, and support pillar varieties. Depending on how they are manufactured, square beams can be made smoothly or not. In addition to taking a while, the production procedure is quite simple. Actually, all that needs to be done is flatten metal sheets and integrate the corners to create standard squares. In addition, piercing points with high pressure are sent through the central portion of them to get the best smoothness possible.

Fig. 4 Square profile

2-Hollow Beam

A hollow beam profile, as the name implies, is simply an aluminum beam that is hollow and lacks a defined cross-section. Modular installations often include hollow beams, especially in the building design. Hollow beams come in a variety of shapes, each with its own sub classifications. Usually, they come in a variety of shapes and sizes, such as square, rectangular, or hollow tops and bottoms. Typically, the result is a set of unique beams that can be utilized for various industrial applications such as bridge construction and building support frameworks. When providing horizontal support, hollow beams are incredibly helpful, especially when large loads are involved.

3-SD Aluminum Extrusion Profile

Aluminum extrusion profiles are used in a variety of minor and large-scale project applications; window framing is one such application. Aluminum's corrosion resistance, combined with its flexibility and low weight, is one of the main reasons it is used so often to make sturdy window frames. For premium sliding window frames, use an aluminum SD profile, Fig. 5. Strong window frames are necessary since windows are constantly exposed to external factors including dust, rain, and extreme heat. In light of this, SD aluminum accomplishes just that; it is an excellent option because of its exceptional stiffness, sliding capability, and resistance to various weathering forms.

Fig. 5 SD aluminum extrusion profile

4-Door Section

Often referred to as the ED section, the door section profile is an aluminum extrusion profile used in heavy-duty glass building doors, Fig. 6. ED sections often work as a whole system and are a component of the entire push door application mechanism. In many business settings, glass doors with push mechanisms are common. Aluminum door pieces have a distinctively traditional design that emphasizes both form and function in their whole. Aluminum ED pieces offer a novel way to fasten glass materials so they don't topple over or fall unexpectedly.

Fig. 6 Door section

5-RCW Profile

One of the most commonly used aluminum extrusion profiles for conventional high-rise structures nowadays is the RCW profile. Usually, they are used on curtain walls or mullions. RCW profiles are ideally employed as a strong barrier to assist keep environmental components out of structures rather than for their structural function. Curtain walls, Fig. 7,  typically have an aluminum frame and come in a variety of sizes. These profiles must contain the components required to provide adequate sealing, preventing undesired objects from penetrating the inside of a building area. This is one of the main explanations for the regular installation of additional standard materials in RCW aluminum extrusion profiles, which aid in preventing leaks.

Fig. 7 Aluminum Curtain Wall Profile

6-T-Section

The t-section aluminum extrusion profiles are, as the name implies, t-shaped extrusion items made of aluminum that provide support in several dimensions. There are spans, horizontal flanges, and vertical webs in these aluminum extrusion profile constructions. In addition to being a component of truss networks, T-section structures are frequently encountered in corners. These aluminum extrusion profiles can be readily connected to common profiles such as hollow beam and square beam profiles. Fittings can also be added to the T-section profiles to increase support and durability.

7-Louver Profile

Louvers, Fig. 8, are special configurations of aluminum extrusion profiles in which slats are linked at a specific angle and at regular horizontal intervals. Because of its structural design, louvers—which include window blinds and door shutters—are mostly employed for ventilation and the flow of natural light. Furthermore, louver profiles prevent debris from entering a structure. Different designs of aluminum louvers can be produced based on different construction specifications. These structures may successfully let in cooling and ventilation from the inside while also keeping water out because of the aluminum component in them. Furthermore, because the angled slats greatly restrict view, the louver profiles give building spaces more seclusion.

Fig. 8 Louver Profile

Things to consider when selecting Aluminum Extrusion Profile

Extrusions Profiles Provider

There are many things to take into account when choosing an aluminum extrusion profile supplier. Here are a few important things to remember:

1. Quality of Products

The quality of a supplier's products should always come first, regardless of other qualities. In addition to possessing the necessary certificates, the supplier must follow stringent quality control guidelines. By doing this, you can be sure that the extrusions you receive are of the best caliber and have successfully completed extensive testing.

2. Supplier's Experience

Experience is a powerful indicator of a supplier's competence, effectiveness, and market understanding. A knowledgeable provider will be better able to comprehend your requirements, offer advice on the best kind of extrusion, create bespoke designs, and recommend the most efficient manufacturing procedure.

3. Production Capacity

The production capability of the supplier must be taken into account. Whether you require high- or low-volume purchases, they should be able to accommodate your demand. A reputable supplier maintains strong inventory control and is dependable in keeping to delivery dates.

4. Customer Service

A reputable supplier offers excellent customer service and cherishes its clients. They should walk you through the process and quickly answer any queries you have, communicating in an open and responsive manner.

5. Cost

Effectiveness on a budget is essential for any organization. It is imperative that you assess the costs offered by different vendors in light of your requirements. To ensure that you don't sacrifice quality in favor of a cheaper component, keep an eye on the total cost of ownership.

6. Location of the Supplier

Delivery times and shipping prices may be impacted by the supplier's location. Business processes can run more smoothly and you can save a lot of time by using a supplier who is in the same area or time zone.

7. Additional Services

Your company might gain value from suppliers who provide extra services like anodizing, customization, and after-sale support.

8. Supplier's Track Record

The track record of a provider can offer crucial information about the dependability and caliber of their goods. Seek feedback and get references to find out more about their experience.

What are special aluminum extrusion profiles?

Special profiles, Fig. 9, are intricate shapes that are mostly utilized in the furniture and building, automotive, and transportation industries. Among the unique profiles we create on a daily basis are aluminum borders with screw attachments, water deflectors and drainers, glass extrusions, picture frames, vehicle trim profiles, corner components with unique sections, aluminum handles, and handrails.

Specialist aluminum extrusion profiles provide adaptable solutions for a range of uses, including specialist industrial projects and intricate architecture. They are made of premium aluminum, offer customized strength and durability, and may be used both indoors and outdoors. These profiles are perfect for applications with special geometric requirements because of their variability in shape and dimension. Unlock the creative potential of unique aluminum extrusion profiles to produce eye-catching and useful designs. These profiles provide the essential modifications to satisfy even the most exacting project requirements, whether they be curved shapes, specific angles, or special structural requirements. Use aluminum extrusion profiles to maximize your building or design—they offer both performance and beauty.

Aluminum can be machined or extruded into special shapes in addition to basic profiles, depending on the needs of the project. Extrusions for awning, shutter, and blind components are a few examples. Industrial equipment's structural framing is made of hollow and solid rectangular, circular, or triangular parts. Electronic heat sinks are made of intricate hollow parts. Bicycles, ladders, and scaffolding are among the items that use thin-walled tubing. Aluminum may be carved into complex 3D geometries for molds, architectural features, and other precision parts thanks to CNC machining. Aluminum can be shaped into nearly any shape that is needed because of the flexibility of the extrusion and machining processes. Numerous specialized applications can benefit from its formability, strength, and resistance to corrosion.

Fig. 9 Special aluminum extrusion profiles

Conclusions

To summarize, extruded, rolled, sheets, composite panels, diamond plate, and tread plate are the primary forms of aluminum extrusion profile. The strongest and most popular portions for curtain walls, doors, windows, and structural framing are extruded sections. Less expensive options are rolled shapes. For cladding and non-load-bearing purposes, sheets and composite panels are employed. Slip resistance is provided by special finishes like diamond plate. Because of their strength, formability, corrosion resistance, and lightweight, aluminum extrusion profiles are continually being designed for a larger range of industrial and construction applications. Aluminum is an environmentally favorable material due to its sustainability.

Offering a vast array of aluminum extrusion alloys and assisting you in choosing the ideal one for your particular requirements, JLCMC is the top manufacturer of aluminum extrusion. Get in touch with us right now to find out more!