What Are Aluminum Extrusions?
Aluminum extrusion occurs when an aluminum alloy is transformed into an object with a definitive cross-sectional profile. Aluminum extrusion is compatible with a wide array of applications due to the unique physical characteristics aluminum possesses.
The unique flexible properties of aluminum allow the raw material to be easily machined and cast. With one-third the density and stiffness of steel, aluminum can form strong and stable products, particularly when alloyed with other complementing metals.
The following steps are involved in the aluminum extrusion process:
- After establishing the shape of the die, a cylindrical aluminum alloy billet gets heated to extreme temperatures ranging between 800ºF and 925ºF.
- The aluminum billet gets transferred to a loader and a lubricant is applied to prevent the material from sticking to the extrusion machine, ram, or handle.
- Significant pressure is applied to a dummy block, pushing the billet into a container, thus forcing it through the die.
- Nitrogen (in liquid or gaseous form) is introduced to the aluminum alloy to prevent the formation of oxides in the die sections. This step increases the life of the die by creating an inert atmosphere.
- The extruded part is pushed onto a run-out table, taking on the shape of the die opening. The elongated piece is pulled onto the cooling table, allowing fans to cool the newly formed aluminum extrusion.
- Once the cooling process is complete, the extruded aluminum is moved to a stretcher to be straightened and work hardened.
- The cured aluminum extrusions are then brought to the saw table and precisely cut according to the specified lengths required by the application.
- The final step in the extrusion process is to place the piece in an age oven to harden the aluminum and speed up the aging process of the end product.
Aluminum Extrusion Industrial Applications
The primary industries served by New Source Corporation include the aerospace and military/defense sectors.
Aerospace
Aluminum extrusions are beneficial in a wide range of applications, including components used on the International Space Station and a diverse variety of other aerospace needs.
The beneficial attributes of aluminum used in aerospace components include:
- Strength-to-weight ratio
- Ductility
- Conductivity
- Non-magnetic properties
- Repeated recyclability without a loss of integrity
These combined capabilities make aluminum extrusions an adaptable and viable solution for the unique needs of the aerospace industry.
Military/Defense
Aluminum is not only stronger than other commonly used metals, but it is also lightweight, which provides a variety of benefits for military applications. Some of the other advantages of using aluminum include:
- Minimal maintenance
- Absence of brittleness, especially at low temperatures
- Ability to engineer functionality into a variety of components
- Greater corrosion resistance compared to steel
- Abrasion-resistant
Steel parts require an additional coating to limit corrosion over time. Since aluminum does not rust, no further treatments are needed, making it the perfect material for harsh environments.
Aluminum extrusions are an essential component of military solutions, commonly used in:
- Aircraft and Helicopters
- Military vehicles
- Landing mats used during rapid deployment
- Tents used for hospitals and command operations
- Vessels used in combat
- The International Space Station
Benefits of Aluminum Extrusions
Some of the many benefits of aluminum extrusions include:
Corrosion Resistant
An aluminum extrusion offers excellent abrasion and corrosion resistance. Aluminum does not rust and is further protected by the naturally occurring oxide coating found on the material. Finishing processes, such as anodizing, further enhance aluminum’s natural corrosion resistance.
Easily Tailored
Compared to steel, aluminum is extremely malleable and elastic, making it easily machinable. The unique trait allows the aluminum to mold into complex-shaped extrusions ideal for military applications.
Hard alloy aluminum extrusions can also withstand harsh weather conditions and are the best solution for parts used in military-grade equipment and vehicles that commonly operate in intense environments.
High in Strength-to-Weight Material
The unique combination of low weight and high strength makes aluminum extrusion profiles beneficial in the following applications, where load carrying is a primary concern for key performance:
- Aerospace
- Truck Trailer
- Bridges
Using aluminum in military vehicles lightens the load, allowing for cost-effective and efficient movement of troops.
Lightweight
Weight reduction is a growing concern in areas such as transportation, and using lighter parts makes shipping less costly. Aluminum is an attractive material for applications involving moving parts since it is easier to handle and weighs considerably less than other commonly used materials.
Aluminum is approximately 1/3 the weight of brass, copper, steel, and iron and is 2 ½ times less dense than steel. Despite aluminum’s strength, it is incredibly lightweight, making aluminum extrusions the perfect solution for various industries and applications.
Strength
The extrusion process allows manufacturers to control and concentrate the strength of aluminum to where it is needed most. Internal reinforcement and varying wall thicknesses can be modified to meet the specified needs of the aluminum extrusion profile design.
Aluminum becomes further strengthened in low temperatures, making it the perfect solution for cold-weather applications.
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