Aluminum Extrusion Process Lecture Notes

Introduction to Aluminum

• Aluminum Characteristics:
  • Recyclable
  • Environmentally friendly
  • Strong and lightweight
• Widely used in thousands of product applications.

What is Aluminum Extrusion?

• Definition: A forming process to create various profiles from aluminum.
• Advantages:
  • Quick turnaround time compared to other forming methods.
  • Tooling can be procured in as little as a few weeks.
  • Consistent lead times and great service at Ilco Extrusions Incorporated.

The Extrusion Process Explained

1. Initial Setup:

   • Starts with an aluminum alloy cast into log form, referred to as a Billet.
   • The Billet is heated to nearly 900°F in a Billet furnace.

2. Extrusion Press:

   • The heated Billet is placed into an extrusion press.
   • Excess material is sheared, and the ram pushes the new Billet through the die under thousands of tons of hydraulic pressure.

3. Cooling:

   • The formed profile exits the press and is cooled in a water bath (quenching) to establish desired mechanical properties.
   • A puller device guides the hot extrusions down a runout table.

Importance of Temperature Control

• Critical Success Factor: Maintaining temperature is essential throughout the extrusion process.
• Multiple components (Billet, die, and tooling) must be preheated to ensure optimal operating temperatures.
• Infrared Laser Temperature Monitoring:
  • Monitors:
    • Billet temperature before entering the container.
    • Profile temperature during extrusion.
    • Quench exit temperature to ensure mechanical properties.

Final Steps in Extrusion

• Cutting: Extrusions are cut at the Billet seam.
• Cooling Table: Ensures straightened and true extrusions.
• Stretching Process: Relieves stress on the aluminum.
• Length Specification: Cut to customer order length at sawing station.
• Artificial Aging: The cut extrusions are placed in ovens to harden and develop final mechanical properties.

Additional Services Offered by Ilco Extrusions Incorporated

• Cut-to-Length Parts: Dedicated work centers for specific lengths and types.
• Quality Control: Continuous review of parts to meet specifications.
• Secondary Services:
  • Final part deburring and finishing.
  • Use of vibratory Roto finish machines for edge removal and surface finishing.
• Shipping: Finished parts are shipped to clients using trucks or contract carriers.

Conclusion

• Ilco Extrusions Incorporated emphasizes quality in the aluminum extrusion process to support client needs and business growth.