Aluminum Profile Extrusion Process 10 Steps from Shenghai

Aluminum Profile Extrusion process has around 10 steps

Aluminum extrusion is one of the core forming processes used to manufacture modern industrial structural components. With its high material utilization, flexible cross-sectional design, and stable mechanical properties, aluminum extrusion is widely used in construction, new energy, rail transportation, 3C electronics, and automobile manufacturing.

Aluminum profiles are mainly made of aluminum with small amounts of other metal elements added to form an alloy. They offer many advantages, including light weight, excellent formability, high strength, and good corrosion resistance. In addition, aluminum profiles can undergo various surface treatments, such as anodizing, electrophoretic coating, powder coating, and PVDF coating. These treatments not only improve corrosion resistance but also enhance the appearance and application value of the products.

During the extrusion process, the die is the key factor that determines the cross-sectional shape and dimensional accuracy of the profile. Heated aluminum billets are placed into customized dies and extruded under high pressure, allowing the aluminum to take the same shape as the die design. Common extrusion shapes include slots, round tubes, C-channels, and angle profiles.

Furthermore, the extrusion pressure required for aluminum profiles mainly depends on the amount of solid solution elements in the alloy at the deformation temperature, especially the magnesium content. In general, a higher solute content leads to greater flow stress, which requires higher extrusion pressure and results in a lower extrusion speed.

With its low production cost, high efficiency, flexible processing capability, and relatively simple operation, aluminum extrusion has become one of the most economical and mature methods for manufacturing complex aluminum profile sections. To help you better understand the manufacturing process, the following section introduces the 10 key steps in Shenghai Aluminum profile extrusion process.

1. Lay down Aluminum Round Rod

Spread those prepared aluminum rods flat on the shelf. Leave a certain gap between the solid aluminum rods. Be careful not to pile the solid aluminum rods, otherwise will increase the difficulty of the Extrusion machine.

2. Heating Aluminum Round Rod

Heating Aluminium round bar must control the temperature. Heating process should be carried out at room temperature. After 3.5h heating, the temperature will reach around 400-500℃.No matter the temperature is too high or too low, it will directly affect the hardness of the profiles. Therefore, the temperature must be strictly controlled during the heating and cooling process.

3. Heating Mold

The temperature of heating mold should be same as heating Aluminum Rod, both to keep warm after heating to 400-500°C

4. Prepare Mold

After the mold and Aluminum Rod are heated and insulated. Put the mold into the extrusion machine  and prepare for extrusion

5. Transfer the Aluminum Round Rod to the extrusion machine

Put the ready Aluminum Rod into the raw material entrance of the extrusion machine, before extrusion, You can smear some release agent thing on the extrusion machine to prevent the billet and ram from sticking together

6. Billet Material (Aluminum Rod) Extrusion

Waiting for the extruded aluminum profile come out from the discharge port

7. Cutting Extruded Aluminium Profile

Use tractor to drag the extruded aluminum profile into the precise saw and then cut into the required length

8. Straighten Extruded Aluminium Profile

After cutting, Put the aluminum profile to leveling table for stretching and straightening. And then go to finished product area for final Fixed length cutting

9. Heating Treatment

Load the ready aluminum profiles into the frame, and then transfer to the heating machine for heating treatment. Keep warm 2 hours after the temperature reaches 200°C, andthen wait to release. Heat treatment can increase the stretch and plasticity of aluminum profiles

10. Cooling

After heating then cooling, It has two ways, natural cooling or Air cooling. Finally perfectly meet customer needs.

Aluminium Profile Extrusion is a process that extrude heated aluminum rod based on every molds to become specific kinds of shapes for customers. The shapes might be solid, hollow or semi-hollow. They might be very simple or complex. Generally, the aluminum profile extrusion will be slotted extrusion, aluminium profile tube and aluminium channel profiles etc.

Aluminum Alloy Extrusion Parameter

Alloy	Billet Temperature (°C)	Extrusion Speed (m/min)	Relative Extrudability	Key Notes
3003	450	30–70	100	Soft alloy, maximum extrusion speed, best extrudability
6063	460–500	35–80	100	Mainstream soft alloy for construction, highest processing speed
6061	430–500	5–25	60	Medium-strength alloy, significantly reduced extrusion speed
2014/2024	420–450	1.5–3.5	15–20	Hard alloy, drastically lowered extrusion speed
7075	300–460	0.8–2.0	10	Aerospace hard alloy, slowest extrusion speed, poor extrudability
5154	460	6–15	50	Medium-strength alloy, performance between soft and hard alloys