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The Ultimate Guide to Aluminum Profiles and Extrusion

Bulk plastic deformation is a production process for aluminum extrusion, also referred to as “aluminum frames.” In order to encourage the plastic flow of the material, an aluminum billet is first preheated to a particular temperature that is comfortably below the melting point of the metal. You press the heated billet through the tooling die, mold it and then shape it into the required profile cross-section. The method used in industrial extrusion is comparable to the several types of pasta you may make at home and the way Play-Doh toys are made.

The Advantages of Aluminium Extrusion

Because it offers mechanical properties that are perfect for shaping and forming metal from billet sections, aluminum is a material that is frequently specified for use in extrusions and shape profiles. Because of aluminum’s high malleability, it can be easily molded into a variety of shapes without requiring a lot of energy during the tooling or forming process. Additionally, aluminum’s melting point is around half that of regular steel. The highly low energy footprint of the aluminum extrusion process, which translates into inexpensive tooling and production costs, is a result of both of these features. Aluminum is a fantastic material for industrial applications because of its excellent strength-to-weight ratio.

Different Profile Types

You may produce a wide range of complicated aluminum extrusion profile kinds by varying the thickness. Depending on the end-use application, you need these profiles to have a wide variety of complicated void areas. to satisfy any performance weight restrictions and to accommodate a wide range of automation applications. Several interior voids are available for utilization. The hollow beam profile, which only comes in square profile form, is the most typical type of aluminum profile. The other profile varieties are L-shaped, triangular, and single-radius profiles, to name a few. Finding an aluminum profile supplier who can aluminium profile extrusion of high quality is simple.

Surface Design

On the surfaces of the profiles, the extrusion process occasionally leaves behind tiny, hardly detectable lines. The extrusion tooling makes it possible to specify additional surface treatments in order to get rid of these lines. After the primary extrusion forming process, you can apply a few secondary surface processing techniques, such as face milling. Hence, to enhance the surface finish of the profile portion. By lowering the total surface roughness of the extruded profile, you can arrange these processing stages to enhance the geometry of the surface and the component profile. Applications where the parts must be precisely positioned or where mating surfaces must be controlled call for these treatments.

The section on Profiles’ Uses

Aluminum profiles are used most frequently in the manufacturing and industrial automation industries for automated motion applications on production lines. The automation framework allows you to construct them in as many different configurations as you require. They are robust yet light enough for people to readily handle them. You ask for structural-grade aluminum extrusions to reduce weight even outside of normal automation applications. You use them as frames in an increasing variety of end-use consumer goods, like cars and LEED construction projects. Uses are extending into these new fields as a result of the advancement of aluminum alloys and surface coating processes.

The Process of Extruding Aluminium

Extrusion is the technique of forcing aluminum alloy material into a die with a predefined cross-sectional shape. Using a strong ram, you force the metal through the die and out the die hole. As soon as this happens, the runout table retains the precise shape of the die.

Fundamentally, the procedure is quite straightforward. The same amount of force is applied when you squeeze a tube of toothpaste in your hands. The toothpaste tube pops out in the shape of an aperture when you squeeze it. An extrusion die’s aperture serves a similar purpose to that of a toothpaste tube.

Process of Direct and Indirect Aluminum Extrusion

Direct and indirect procedures are the two main categories used for aluminum extrusions. In the direct method, a moving ram is used to push metal through a stationary die head. The billet does not move, however, during the indirect extrusion procedure. To apply pressure and force the metal through the die, you place the die assembly against the billet. Here is a closer look at each procedure.

Process of Direct Aluminum Extrusion

Direct extrusion is the method that you employ the most commonly to extrude aluminum. By using an aluminum extruder, you put a heated aluminum billet into a heated walled container. Consequently, the metal is what you observe being forced into the die by a moving ram. There is a significant increase in pressure throughout this procedure.

Additionally, machine operators frequently place material barriers between the billet and the ram. Using this strategy, you keep the ram and hot billet apart. This process, also called the forward extrusion method, involves both the ram and the aluminum billet moving forward.

Process of Indirect Aluminum Extrusion

The backward extrusion method often referred to as the indirect method, is distinct from the direct method. The billet and container are moving while the die is still in this instance. Manufacturers carry out this process using a “stem.” The stem that holds the ram in place needs to be longer than the length of the container. The outcome is what you see pushing through the fixed die: an aluminum billet.

Compared to the direct approach, this method produces less friction, which enhances heat regulation. In general, indirect extrusions produce things that are more dependable and of greater quality. This might be a result of the applied force being nearly constant. Furthermore, temperature stability ensures improved mechanical characteristics and grain structure.


In conclusion, extruded aluminum sections are flexible and ideal for use in building automation applications. Aluminum is a superb structural material that works well for use in profile extrusions. There is no doubt that the aluminum profile is ideal for the particular automation application. Here are also descriptions of the many categories and varieties of aluminum.



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