What is Aluminum Extrusion?
Aluminum extrusion is used to make prototypes and end-parts from aluminum materials by forcing an aluminum billet through a steel die. The die is shaped to match the part design profile, and the emerging aluminum material will have a cross-section area that fits the desired shape.
Aluminum dies are made from steel tools, with geometries and shapes ranging in complexity. The 6061 and 6063 aluminum are our most widely-used aluminum profiles. At Premium Parts, we leverage our in-house experience and capacity to make small volume parts from 1 to 1000 units, and mass production units of up to 10,000 pieces or more. Parts are also finished through anodizing or painting to complement the appearance of the piece.
Aluminum Extrusion Process
The aluminum extrusion process at Premium Parts begins with some preparation of the billet and ends with ejection. A step by step analysis of our high-quality extrusion operation is detailed below:
• The process starts with the designing of the die shape and its tooling. We perform a free design-for-manufacturability analysis and discuss design optimization with your team.
• After the die tooling is complete, the next process is heating the billet (aluminum alloy) to around 750F or 925F depending on the type of alloy. This is done to soften the aluminum.
• The heated billet is transferred to the loader, where a lubricant is added to prevent the aluminum from smearing the extrusion machine.
• Pressure is then applied to the billet to push it into a container and force it through the die opening.
• Next, nitrogen gas is applied to create an inert atmosphere and prevent oxide formation.
• The extruded part, now formed to the same profile and cross-section of the die, is then cooled.
• The aluminum extruded is cut to the desired length and left to harden. Any subsequent adjustments, quality control, and treatments are done here.
• Post-extrusion, we carry out other finishing operations relating to texture, color, protection, and more.
Why Should You Choose Aluminum Extrusions?
• Ease of machining
Aluminum alloys and profiles have a high level of machinability and malleability. This makes forming complex geometries easier than other metals, which translates into a lower cost of production.
• Strength/Weight Ratio
Aluminum extrusion processes help to improve the strength and performance of different aluminum profiles. Aluminum itself also has a high strength-to-weight ratio. This makes it suitable for automotive and aerospace applications where excellent strength but lower density is imperative.
• Finishing Options
Extrusions can be finished in an array of methods to augment functionality and complement beauty. Aluminum parts may be anodized, coated, painted, and more.
• Corrosion Resistance
Unlike iron and other metal alloys, aluminum parts have a natural corrosion resistance arising from the presence of a natural oxide layer. Aluminum extrusions are therefore suitable for harsh conditions where other metal parts would rust and fail.
Aluminum is one of the most abundant metals on the planet. This makes the material and its alloy profiles readily available for processing into varied end-parts.
Aluminum extrusions are relatively easier to clean. This makes them suitable for medical uses where they can be sterilized and prevent bacterial growth.
Aluminum parts are non-degradable and can be recycled for re-processing into entirely new parts where possible.
• Complex Geometries
Aluminum profiles can be made into complex geometries without any secondary assembly operations like welding, riveting, and more. This is an advantage of the high malleability and ease of machining of aluminum alloys.
Aluminum Extrusion Applications
• Construction, Automotive and Aerospace
Aluminum extrusions have high strength and low density. This gives them an excellent strength-to-weight ratio that is leveraged across projects in the construction, automotive, and aircraft industries. In construction, aluminum parts are used in making window and door frame components. Aluminum is used in making plane wings and components to manage weight during flight. In vehicles, aluminum and engineering-grade thermoplastics are substituting heavier metals to drive down fuel costs and boost engine efficiency.
• Reflective and Lighting
Aluminum extrusions can be used in making parts for lighting applications. At Premium Parts, we can complete your extrusions to certain finish that facilitate their use in high-reflection applications.
• Medical and Diagnostics
Aluminum extrusions are easy to integrate and have some extent of bio-compatibility as they won’t corrode or react easily. Its high-temperature resistance also means that it can be sterilized. Aluminum extrusions can be used for making snap-to-fit hinge components, walking frames, wheelchairs, mobile hoists, and features of diagnostic and surgical devices.
• Heat and Thermal conduction applications
Aluminum has excellent thermal and electrical conductivity. It is used industrially as components in electronics, heat exchangers, and applications that required hot and cold temperature extremes.
• Enclosures for Electronics and Consumer Products
Aluminum can easily be machined in varying lengths to make component enclosures, brackets, chassis, and housing for electronic and consumer components.
The key properties of aluminum such as lightweight, strength, corrosion-resistance, bio-compatibility, and high conductivity make it ideal for extrusions in the following industries:
• Automobile and vehicles
• Aerospace and Aircrafts
• Consumer Electronics
• Consumer products
• Energy and Power
• General Transportation and logistics
At Premium Parts, we offer aluminum 6061 and aluminum 6063 for options. They are the most widely used aluminum grade that is used for extrusion.
Improve the appearance of your aluminum extrusions, increase corrosion resistance, and beautify your finished parts with our premium finishing services. Below is a list of finishing services available for your extrusions:
• Powder coating
• Bead blasting
Why Choose Us
• Quick Turnaround Service
Premium Parts offers a competitive lead time for our customers. We always optimize our processes to deliver the extrusions with a fast turnaround and high quality.
• High Quality
Premium Parts is committed to delivering parts of the highest quality for functional applications. From raw material sourcing to extrusion and quality inspection, our processes are designed to ensure that only the best parts are manufactured under our operations.
• Consistency and Repeatability
Whether ten or a thousand, our services and products are consistent, helping you scale up or down as required without compromising on quality.
We don’t have MOQ required for our part production. That means you can just order 1 unit for a prototype test or thousands for end-use production need.
Request A Quote
Contact us with details of your project to take advantage of our instant quoting services to start your product development discussions. Premium Part is your one-stop service provider for all aluminum extrusion needs. From basic manufacturing to post-extrusion finishing, we have got you covered.
Aluminum Extrusions RFQ:
1. Can you heat treat the material to T6 temper after aluminum extruded?
Yes, we can heat treat the aluminum 6061 and 6063 to T6 temper after parts extruded.
2. Can you extrude any other grade of aluminum except 6061 and 6063?
For now, we can only extrude 6061 and 6063 aluminum.
3. What’s the longest length of part can you extrude one time?
Technically, we can extrude parts up to 10 meters. But in most of the cases, there would be some limitation to ship parts with a long length due to the shipping policy from carriers.
4. Do you offer the plastics extruded service?
No, we don’t extrude plastics.
5. What’s the typical life of the die?
Generally, the tool can make hundreds to thousands of tons of parts totally.
6. Any additional cost after the initial order?
There would be a tooling setup cost after every initial order if the quantity ordered is smaller than our MOQ.
7. What’s the minimum thickness wall you can extrude?
Theoretically, the minimum thickness wall we can extrude is 1mm.