Perhaps one of the most underrated innovations of modern manufacturing is an aluminum extrusion. This process allows aluminum and specially-created aluminum alloys to be precisely formed into an almost limitless variety of shapes. These shapes can then be put to use in a number of different mechanical and decorative ways, furthering the many beneficial qualities of aluminum extrusion.
How Aluminum Extrusion Works
Any child who has ever put Play-Doh through the “Play-Doh Factory” has basically seen how an extrusion process works. You put a formable material in one end and pull or push it through a shaped die until it comes out the other end. An almost unlimited number of possible aluminum extrusion shapes can be created. The piece can then be precision cut to the length you want, giving you exactly the size you need. No matter where along the piece a cut is made, the cross section will be exactly the same. So a long run of extruded material could be used as one long piece, or numerous smaller pieces with identical cross sections.
Extrusion Alloys
Most often pure aluminum is not what you need for custom aluminum extrusions. Creating an alloy by combining aluminum and another element can increase the strength, formability, weldability or corrosion resistance of the finished product. Some of the other materials that aluminum is frequently combined with can include copper, zinc, manganese, magnesium, silicon, nickel, iron and chromium. For extrusion purposes, the alloy usually has an aluminum content of at least 93 percent.
Uses for Extruded Aluminum Pieces
The aluminum extrusion process can create virtually any shape you need in an aluminum form, which means its uses are widely varied. Perhaps the most common application we see an extrusion in are window and door frames or trailer and piers. Their combination of length and precise shape is difficult to create through other methods without creating seams that could leak or rupture along the length. For similar reasons, pipes and ductwork are often made through the extrusion process. Simpler heavier extruded shapes are often used to minimize machining operations that require tighter tolerances than an extrusion can offer. Using an extrusion in this application reduces both material and machining time.
Product designers, architects, and contractors can derive many benefits from working with extruded aluminum. Extruded aluminum products are a popular choice for businesses in many industries for a variety of reasons, including its versatility and ease-of-use. Some of the benefits afforded with aluminum extrusion include:
Reduce or Eliminate Machining
The fewer parts involved, the simpler the design, and the fewer steps involve result in products that are less expensive to manufacture. As an example, a part may be manufactured without the traditional use of machining through the use of a punch die instead, resulting in faster and lower cost production.
Reduce the Number of Required Parts
The design of complex shapes to reduce the number of parts required is possible through the use of extruded aluminum. A single aluminum shape produced through extrusion can substitute for multiple rolled shapes connected together through welding or another attachment method. This results in savings on connection costs and a potentially higher strength shape.
Adding Design Features
Extruded aluminum makes it possible to add design elements in construction applications. Examples include complex shapes such as grooves for windows. With the great flexibility afforded by aluminum extrusion, the design possibilities are almost endless.
Energy Efficiency
In the construction industry, aluminum, which includes aluminum products formed through the extrusion process, is one of the most energy efficient materials.
Surface Finish Options
There are various options available to enhance the surface of aluminum formed through extrusion. The material’s corrosion resistance can be enhanced through an applied pretreatment which helps ensure the material’s bond with the finish. The options for finishing include grinding, anodizing, blasting, painting, plating, buffing, polishing, and more. Two of the most frequently applied finishes to aluminum surfaces are painting and anodizing.
Recyclability and Reusability
For construction applications, particularly as property owners are opting for deconstruction and disassembly as opposed to building demolition, recyclability and reusability are becoming increasingly essential. Through disassembly or deconstruction, it is possible to capture the recyclable materials and preserve their scrap value. This lowers the cost of material landfill dumping and any associated negative environmental impact.
Conductive for Electricity and Heat
Applications involving heating/cooling and electronics can benefit from the heat and electricity conductive properties of aluminum.
Lightweight and Strong
Aluminum extrusions help users take advantage of the material’s strength and lightweight properties. With a strength-to-weight ratio of about one-third of the weight of steel and with a strength similar or greater than steel, aluminum is ideal for applications in which high load bearing is required but the support member(s) must not be too heavy.
Easy Workability
Many designs are possible with the use of dies. As a metal that is easy to work with, it is not too difficult to manipulate the material with tools. However, its strength is not affected by the fact that it is softer than steel, workable, and malleable.
If you need aluminum for any of your project applications, consider the versatility and usefulness of this material.
