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The Aluminium Extrusion Process

How Does Aluminium Extrusion Work?

Many of you will know this already, but because we are complete geeks when it comes to aluminium extrusion, we love to talk about the aluminium extrusion process anyway.

Just for the people that are new to how extrusion works and the aluminium extrusion process of bringing those ideas we all have, to fruition. 

When complex aluminium profiles are the desire of the day, did you know that aluminium extrusion is one of the most cost-effective ways to achieve the shapes and sizes you crave? No matter how intricate or detailed, a team of highly skilled extruders can bring your designs to life using this method.

But enough with the waffle. How does the aluminium extrusion process actually work?

The Aluminium Extrusion Process

Step One – Design

You can come to us with a simple sketch of an aluminium profile design (many do) and we can bring it to life using specialist Computer Aided Design (CAD) software. We draw the line at crayon though. That’s not going to work for anyone. 

Our highly skilled CAD team will work with you to create an aluminium design that meets your requirements, whilst remaining an extrudable concept.

Step Two – It’s Getting Hot

Once everyone is happy with the final design, we proceed to manufacture the extrusion tool (die) needed to produce your extrusion.

Once that arrives it’s heated up on the extrusion press along with the aluminium billet.

Once heated the aluminium becomes more pliable for extrusion. At this stage, everything starts to warm up as the billet is heated to between 400℃ and 500℃, softening it for the aluminium extrusion process and allowing detailed and intricate shapes to be formed.

Step Three – Extrusion

The aluminium extrusion process is where your desired concepts really start to take shape as the heated billet is placed inside a container together with the die. This ‘die’ has a cross-sectional profile that matches your original shape for the final product. 

A high-pressure ram or hydraulic press is then used to force the billet through the die, forming the unique shape originally designed and created. To keep it very simple, because who doesn’t like simple? It’s like squeezing Playdough, just on a slightly larger scale.

Step Four – Cooling & Cutting

The aluminium billet is pushed through the die, where it takes the expertly crafted shape of the cross-section. As it exits the die, the newly formed extrusion profile is rapidly cooled, solidifying its shape and bringing your original vision into view. 

Your extruded aluminium is then cut to the desired length based on the original requirements using a saw.

Step Five – Stretching and Straightening

An important part of the aluminium extrusion process is when an extruded profile has been formed into an intricate shape it then needs an additional stretching and straightening process to be carried out.

This ensures that the precision of the extruded profile perfectly matches the original design. 

Step Six – Artificially ageing

Following extrusion, unless the profile is to be formed into curves it is usually artificially aged to bring the extrusion to the desired temper.

This part of the aluminium extrusion process is carried out in large ‘ovens’.

Step Seven – Finishing

This is where you have the opportunity to apply one of a range of different treatments to your final extruded aluminium profiles. Finishes such as anodising and powder coating are the most common options. Further options such as brightening, brushing and polishing are also available to enhance the appearance and protection of your finished aluminium.

If you would like to discuss your requirements with the team at Love Aluminium, contact us on the button below and we’ll be very happy to help.

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See the aluminium extrusion process in more detail