Aluminum Extrusion:

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What is aluminum extrusion ?

Aluminum extrusion is a manufacturing process that shapes heated aluminum alloy billets (400-500°C) into continuous cross-section profiles by forcing them through a die under high pressure. Based on die movement, it is categorized into direct extrusion (billets move while dies remain stationary) and indirect extrusion (dies move while billets remain stationary). The latter reduces friction and enhances surface quality.

Aluminum extrusion machinable materials

Common Aluminum Alloy Grades and Properties

SERIES	TYPICAL MODEL NUMBER	MAIN ALLOY ELEMENTS	CORE CHARACTERISTICS	APPLICATION SCENARIOS
6xxx	6061-T6	Mg, Si	Tensile strength 310MPa, resistant to anodic oxidation	Automotive structural components, bicycle frames
6xxx	6063-T5	Mg, Si	Elongation rate 12%, excellent rationality on surface treatment	Architectural doors and windows, radiators
5xxx	5052-H32	Mg (2.5%)	Corrosion-resistant to seawater, density 2.68g/cm³	Ship decks, fuel tanks
7xxx	7075-T651	Zn, Mg, Cu	Hardness 150HB, strength exceeds some steel materials	Aero-engine blades, racing car suspensions

Surface finishes for aluminum extrusion profile

Machinaal bewerkte afwerking

Het door de bewerkingsmachine bewerkte prototype vertoont sporen van de bewerking met het gereedschap.

Anodiseren

Verbetert de corrosie- en slijtvastheid van metaal; kan worden gekleurd en is geschikt voor beschermende coatings.

Pools

Verbetert de gladheid en het uiterlijk van metalen, keramiek, kunststoffen en PMMA.

Zandstralen

Maakt gebruik van schuurmiddelen onder hoge druk om een schoon, ruw en mat oppervlak te verkrijgen.

Geborstelde afwerking

Voegt structuurpatronen toe aan metalen oppervlakken, waardoor het uiterlijk wordt verbeterd.

Poedercoating

Maakt gebruik van elektrostatische aanbrenging en warmteharding om een dichte laag te vormen, waardoor de corrosiebestendigheid van onderdelen wordt verbeterd.

Galvaniseren afwerking

Brengt een metaallaag aan om de corrosie- en slijtvastheid te verbeteren.

Zwart geoxideerd

Vormt via een eenvoudige chemische oxidatie een goedkope, antireflecterende coating op metalen oppervlakken.

Alodine

Vormt via chemische conversie een corrosiebestendige laag, waardoor de hechting en de geleidbaarheid worden verbeterd.

Warmtebehandeling

Wijzigt de microstructuur van metaal om de hardheid, sterkte, taaiheid en slijtvastheid te verbeteren.

Aluminum extrusion capability:

ARTIKEL	SPECIFICATIE
BILLET SPECIFICATIONS	Diameter 100-500 mm, Length 1-7 m
MAXIMUM EXTRUSION CROSS-SECTION	Width 1100 mm
MINIMALE WANDDIKTE	0.8 mm
PRECISION CONTROL	±0.05 mm (for length 5 m)，Coarse grain ring depth ≤ 0.3 mm，Straightness ≤ 0.3 mm/m

Aluminum extrusion guideline:

ARTIKEL	SPECIFICATIE
HEATING TEMPERATURE	6063 Alloy: 480±20°C； 7075 Alloy: 450±10°C
EXTRUSION SPEED	20-50 m/min (simple cross-section)； 5-15 m/min (complex cross-section)
MOLD PREHEATING	450-500°C (mold steel H13)
MAATTOLERANTIE	Precision grade ±0.1 mm/m
SURFACE TREATMENT	Anodized film thickness ≥ 10μm (architectural material)； Salt spray test ≥ 1000 hours
MECHANICAL PROPERTIES	6061-T6 Yield strength ≥ 276MPa, Elongation ≥ 10%

Advantage of aluminum extrusion:

Material utilization rate: Nearly 95% (traditional machining achieves only 60%)
Design flexibility: Capable of forming complex cross-sections (e.g., multi-hole heat dissipation profiles)
Cost advantage: Unit cost during mass production is 30% lower than die-casting processes
Weight reduction: 40-60% lighter than steel structures
Sustainability: 100% recyclable; recycled aluminum requires only 5% of the energy needed for primary aluminum production

Application of aluminum extrusion:

Construction Industry:
Used in doors, windows, curtain walls, and more to enhance architectural aesthetics and durability while reducing structural load.

Transportation:
Manufacturing lightweight components for automobiles and trains to improve fuel efficiency and operational performance.

Electronics and Appliances:
Serving as heat sinks and housing materials to ensure stable device operation and extend service life.

Machinery and Equipment:
Employed in frames, guide rails, and similar applications to provide high-strength support and guarantee precise equipment movement.

Home Furnishings:
Furniture frames and decorative elements enable flexible design, enhancing both style and durability in home interiors.

Renewable Energy:
Solar panels and wind turbine supports feature corrosion resistance and lightweight construction, supporting clean energy initiatives.

FAQ of aluminum extrusion

How to Address Surface Bubbling in Aluminum Extrusions?

① Homogenize billet treatment (560°C/6 hours); ② Mold vent groove depth 0.03-0.05mm; ③ Reduce extrusion speed by 15%

How to Select Between 6061 and 6063 Alloys?

Select 6061 for structural load-bearing (high strength); choose 6063 for decorative components (superior surface finish).

What Factors Limit Maximum Extrusion Length?

① Extruder bed length (typically ≤50m); ② Profile rigidity (length-to-diameter ratio >200 prone to instability).

How to control deformation in thin-walled profiles?

Employ “progressive cooling” (rapid cooling in initial section, gradual cooling in final section), maintaining elongation within 0.8-1.2%

Cost break-even point between aluminum extrusion and 3D printing?

For batches <500 units, choose 3D printing; for >1000 units, aluminum extrusion is more economical (lower mold cost allocation).