Aluminum extruders use powerful hydraulic pressures which vary from 100 to 15,000 tons. Center burst defect is an internal crack that develops as a result of tensile stresses along the center line of the workpart during the extrusion process. Recovery is only possible with stripping off the anodic film and remove the pits mechanically. Capalex aluminium extrusion process how we make your. Keywords hot metal forming, aluminum extrusion, anodizing, painting, product defects, origin of defects, defect classification, metal flow patterns, operational. Aluminum extrusions are popular in the automobile, aircraft, and construction industries. Alloys, shapes and properties 16 pages, 23 figures basic level prepared by roy woodward, aluminium federation, birmingham objectives. It is used to produce cylindrical bars, tubes and sections of any regular or irregular types.
Extrusion, aluminum extrusion process explained in 10 illustrated steps. Jul 06, 2009 up close, indepth look at the aluminum extrusion machining process and how pbc linear is able to maintain the highest precision for their products request a free sample here. Pdf product defects in aluminum extrusion and their impact on. The text was written for research students in manufacturing who are work. As shown previously, grainy defects could not be related to extrusion defect observed at high shear rates. Seamless tubes and seamless hollows sections must be produced using either hollow billets or solid billets using a piercing press and mandrel system. The identification and prevention of defects on finished. If you have any questions or good suggestions on our products and site, or if you want to know more information about our products, please write them and send to us, we will contact you within one business day. Product defects in aluminum extrusion and their impact on.
Experience our interactive, profoundly engaging digital publication. Streaking is a common problem on anodised extrusions of 6xxx series soft alloys. The proposed inspection system can be applied in industry for online monitoring of aluminium extrusion processes and the inspection of defects arising in extruded products. Product defects in aluminum extrusion and their impact on operational cost vol. Keywords extrusion press, guideways, linear motion guideways. Important extrusion parameters and conditions are exit temperature, extrusion. Because of its versatility and netshape ability, extrusion is a very common manufacturing process, especially for aluminum alloys. For a soft alloy, aluminum extruders can produce extrusions at the rate of 180 feet per minute if the cross section is a simple shape. Place your order easily and securely via spec2000, by fax at 6268552872 or via email protected. As new purposes are discovered in space exploration and here at home, aluminum extrusion will continue to be an important part of the future. The extrusion process makes the most of aluminums unique combination of physical characteristics. The best way to avoid this type of defect is to etch and anodise as soon as possible after extrusion. Classification of main faults in the production process of. Effect of process variables on the formation of streak.
During the aluminium extrusion, defects are largely responsible for decreasing the quality of the finished product profiles which requires the duplication of work. They are highly versatile, have relatively modest prototyping costs. Pdf commercial hot extrusion of aluminum involves different operations, such as billet preheating, and shearing, loading and deformation. Extrusion defect article about extrusion defect by the free. When pressure is applied at the closed end, complex shapes can be produced by complex openings fig. Aluminum extrusion manual table of contents for the digital edition of aec aluminum extrusion manual. The process begins with the billet which is the aluminum alloy that is heated to 700 degrees fahrenheit for soft. The aluminium extrusion process begins with heating. Pdf commercial hot extrusion of aluminum involves different operations, such as billet preheating and shearing, loading and deformation. Aluminum fabrication refers to building aluminum components by cutting, mitering, notching, piercing, forming, bending, cnc machining. This paper presents various types of streaking defects on the basis of industry practice and experimental results. We can satisfy your requests for any number of standard or unusual metal shapes, styles and products, offering you the advantage of singlesource responsibility. Defects in extrusion process and their impact on product quality j g khan1, r s dalu2 and s s gadekar1 corresponding author.
Aluminum extrusion raw materials aluminum extrusion and. Saha asm international materials park, ohio 440730002 xxx jsbo nbwbe dpn yao a. The evaluation of defects in the aluminium extrusion. Some defects may originate in the substrate metal as a result of the thermomechanical fabrication process used to produce the sheet or extrusion or during handling and storage of the material before finishing. A large number of products for the automotive, aerospace, and construction sectors are produced through aluminum extrusion. Pdf product defects in aluminum extrusion and their impact. Effect of process variables on the formation of streak defects 107 hibits relatively uniform colour figure 1b.
The grain boundary grooves in the lowiron extrusion are deeper and wider in the normal region figure 1d than in the web intersection region figure 1c. Relatively simple shapes or more complex shapes the bulk of aluminum profiles in the construction industry is produced through hot extrusion. Inspection method of aluminium extrusion process sciencedirect. Possible thermal track visible surface the visibility of the extruded profile shapes on the opposite side of the wall can be smoothed out by breaking up the surface shape with grooves, for example. Aluminum can be extruded into standard shapes or specific designs depending on a customers preference. Tight tolerances are required to ensure an accurate interface with other parts. The short history of aluminum extrusion, in comparison to other metals, has seen extensive development and growth, revolutionizing the way we live. Aluminum extrusion our extrusion process dajcor aluminum. This presents particular durability problems for heavy duty extrusions and, as a rule, 15 metres are cut away at each ingot seam if the extrusion is to be processed, if it is to be.
Some defects may originate in the substrate metal as a result of the thermomechanical fabrication process used to produce the sheet or extrusion or during handling and storage of. Tslots fractional extrusion includes our 10 series and 15 series extrusion profiles. Aluminium extruded profiles, defects, scratches, faults. Proceedings of the third international aluminum extrusion technology. The most common defects may be described as pitting, streaking or general nonuniform appearance. Types of aluminum extrusion shapes international extrusion is your fullservice shop, with solutions for all of your aluminum extrusion needs. Aluminum extrusion design 6 mistakes designers make and how. The aluminum is used as a raw material for extrusion. Defects classification in 6xxx aluminum extrusions. Visual quality characteristics of aluminum sheet and plate has been compiled by the technology committee of the sheet and plate division as a reference for those who have an interest in these rolled products and who may have a need to know the terminology commonly used in this largest segment of the aluminum industry. Analysis of product defects in a typical aluminum extrusion facility. The extrusion process can produce aluminum extrusions that have a very complex cross section.
It is a cast or forged steel that supports for extrusion tooling and so it is designed for minimum deflection under load. Thermograms present the temperature distribution on the surface of the extruded profile and contain information about the extrusion process. The ranges ability to cover substrate imperfections, such as welds and extrusion defects, and the consistent appearance at different film thicknesses, reduces nonconformity and can lead to fewer rejected parts. Extrusion defect article about extrusion defect by the. The shape is engineered to distribute material at optimal locations to strengthen final parts.
This provides a basis for developing effective methods for preventing the formation of these defects for the extrusion. The proposed inspection system can be applied in industry for online monitoring of aluminium extrusion processes and the. Zasmhba0004006 a potential downside to this approach is that the sheared ends tend to be distorted, and this distortion can result in entrapped air that causes surface defects in some aluminum extrusion applications. Classification of main faults in the production process of extruded. To provide optimum lubrication on the outside of billet and to use optimal ram speed. The darker patches carry oxides and other inclusions into the extruded section, leading to extrusion defects.
Hot metal forming, extrusion, anodizing, painting, defects, origin, classification, flow. Thus, defects lead to increased production costs, delays in delivery and increase of the scrap percentage. The streaking defects are classified according to their root causes. Extrusion defects at high shear rates were observed, as shown in fig. Classification of streaking defects on anodized aluminium. Real world data from local industry is used for partial cost analysis. Some cross sections, when extruded, will produce undesirable force distributions and metal flow. Pdf product defects in aluminum extrusion and their. Visual quality characteristics of aluminum sheet and plate. To ensure quality extrusion pipe manufacturing, it is. Nov 22, 2014 casting defects surface defects internal defects incorrect chemical compo. As suggested by these toothpaste tubes, the shape of the extrusion profile is determined by the. Zone 1 shows the flowing metal through the rigid conical zone 2, which is defined to be a deadmetal zone. Aluminum extrusion design 6 mistakes designers make and.
Its malleability allows it to be easily machined and cast, and yet aluminum is one third the density and stiffness of steel so the resulting products offer strength. These can arise during the end of the pressing cycle if the inlet opening in the tool is too large or if not enough of the butt end of the. Extrusion is a continuous solid state deformation process which is widely used in the aluminium industry. One of the defects that can occur in extrusion is known as a back end defect. Register to use our catalog system and browse our vast inventory of shapes and seat tracks. Irregularities during the process of extrusion these are mainly due to non uniform flow and stress distribution number of defects depends upon. Aluminum extrusion manual table of contents for the digital edition of aec aluminum extrusion manual 4th edition. You get it all from international extrusion, including turnkey. Various profiles of extruded sections can exhibit streaking on the surface finish. First, aluminum offers many unique properties, such as its high strengthtoweight ratio, corrosion resistance, and electric conductivity, to. Types of aluminum extrusion shapes international extrusion. Front end defects, also known as charge weld faults, occur when residual material in the tool mixes with the new ingot at the start of each new press cycle. However, no exhaustive and systematic study has yet been reported in this area.