The Extrusion Process:
The practice of extruding aluminum is a truly fascinating process. When a company can start with a near "net shape" the benefits to the end user are endless. These benefits can include reduced machine time, a reduction in scrap rates, and a more efficient supply chain.
Many people have asked Schupan Aluminum over the years "How does the extrusion process work?" The extrusion process involves pushing a heated billet through a die with a tremendous amount of force and precision to produce a desired shape.
Initially, these aluminum billets are heated between 800 and 1000 degrees farenheight prior to being extruded or "pushed." Steel dies are machined to the desired profile and placed in the extrusion container. These steel dies are also heated due to the fact that both the die and the aluminum must be of a comparable temperature to extrude. The heated billets are then pushed through the steel dies at a force which can exceed 6,000 tons. This tremendous force creates the desired shape and an extrusion is formed.
The process is very similar to the manner in which toothpaste is forced out through an opening when you squeeze the tube! In addition, die inserts can be added to form a wide variety of voids, hollows, ribs, channels, grooves, and many other oddly shaped openings. The result is a part that has all the characteristics of wrought metal in the desired shape.
Extrusions are classified according to their general cross-sectional configuration as rod, bar, solid shapes, hollow shapes, semi-hollow, hollow, structural and tube. In general, the more intricate the shape the slower the metal has to be pushed and the more time it takes to construct a die. Although not all shapes are possible, aluminum extrusions provide a fantastic opportunity to streamline the manufacturing process in an efficient, economic manner.
