Lecture Notes: Aluminum Extrusion Process

Introduction to Aluminum

• Aluminum is recyclable, environmentally friendly, strong, and lightweight.
• It's the metal of choice for various product applications.

Aluminum Extrusion Process

• Definition: A forming process used to create profiles for specific needs.
• Tooling: Can be procured in a short time (weeks).
• Service Expectation: Clients expect high-quality service due to quick turnaround times.

Basic Principles of Extrusion

• Comparison: The process is similar to forcing modeling clay through a toy press.
• Mechanics: A hydraulic press pushes heated aluminum through a steel die to create desired shapes.

Process Overview

1. Billet Preparation:

   • Aluminum alloy is cast in log form and pre-cut to uniform length (Billet).
   • Billets are heated to almost 900°F in a furnace.

2. Extrusion Press:

   • The heated Billet is pushed through the Extrusion press using hydraulic force.
   • Excess material is sheared off.
   • The formed profile exits the press and goes through a water bath (quenching) to cool uniformly.

Importance of Temperature Control

• Temperature Monitoring:
  • Critical to maintaining the desired mechanical properties of extrusions.
  • Infrared laser temperature monitoring cameras are used at several stages:
    • Before entry into the container
    • At the exit of the press during the push
    • After the quench process
• Process Components: Container die and tooling are preheated to ensure temperature control.

Finalizing the Extrusion

• Cutting and Straightening:

  • Extrusions are cut at the Billet seam and straightened to relieve stress.
  • Process includes passing through a cooling table and sawing station to specified lengths.

• Artificial Aging:

  • Extrusions are placed in aging ovens to develop final mechanical properties.

Additional Services Offered by Ilco Extrusions

• Cut to Length Parts: Specialized work centers for quality assurance.

• Deburring and Finishing:

  • Parts can be finished in a vibratory Roto finish machine for sharp edge removal.
  • Prepares surfaces for paint, e-coating, or powder coating.

• Shipping: Finished parts are stored and delivered via trucks or contract carriers.

Conclusion

• Ilco Extrusions incorporates quality service and precision in aluminum extrusion to meet custom needs, ensuring that clients can focus on their business growth.