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Manufacturing Process

Aluminium Extrusions

An amazing metal, aluminum is one-third the weight of steel, resistant to corrosion, non-combustible, and non-toxic also, a superb conductor and 100% recyclable. Aluminum is the most abundant metal in the Earth’s crust. It ranks second, next only to steel, in terms of volume and is widely used in the food and packaging industries. Of the common metals, on a weight basis, aluminum is the most efficient thermal conductor. High purity aluminum is soft and ductile.  This metal is malleable and easily worked by the common manufacturing and shaping processes of Aluminum sections. Its strength and hardness are acquired by the addition of alloying elements like silicon, magnesium, manganese and copper. The product of future increasing demand for its great futures for light weight  and strong and fully recyclable

Metallic aluminium has many properties that make it useful in a wide range of applications. It is lightweight, strong, nonmagnetic, and nontoxic.

It conducts heat and electricity and reflects heat and light. It is strong but easily workable, and it retains its strength under extreme cold without becoming brittle. The surface of aluminium quickly oxidises to form an invisible barrier to corrosion. Furthermore, aluminium can easily and economically be recycled into new products.

The principle of extrusion is simple :

A heated billet is pressed through a die with great force and the finished profile emerges from the die. Cooling takes place immediately, by air or water. To ensure that the profiles are straight, the profiles are stretched after cooling. At the same time, they are checked to ensure that all key functional dimensions are correct and that the surface quality is as desired. The profiles are then cut to the appropriate length. The material is then subjected to an appropriate heat treatment to bring it to its required permanent level of strength.

The common issues of aluminium extrusion

  • Material & die design issue
  • Extrusion issue
  • Labour handling issue
  • Bubble Holes: Oil and air formed on aluminium billets during the extrusion processing.
  • Cracks on Aluminium Surface: Die flow issue during the extrusion process.
  • Deformation: Inconsistency on the speed of extrusion.
  • Temperature control issue.
  • Dents on Aluminium Surface: Labour handling issue.

Technology

The company had imported the `State of Art’ technology from Mingsheng Mechanical & Electricals.  They export such lines to major countries with professional strength and rich experience

The modern plant is equipped with an automatic PLC controlled 638 MT Oil Hydraulic Extrusion Mingsheng press with the flexibility to extrude 4” diameter billets. All presses have close controls on the speed and a high degree of stability.

In-house foundry for melting aluminum and hot top casting technology for production of quality logs  with closed grained oxide free logs to achieve fine finish extruded profiles and complete range of fully automated PLC controlled  puller and handling systems, producing extrusions which are bent and twist-free and best option for multi-cavity extrusions of aluminum profiles synchronizing with extrusion speed to meet the precise quality standards.

A “stretcher” is engaged after the profile has been cooled to straighten the extrusion and correct any twist that may have occurred subsequent to extrusion.  Conveyors then feed the work to the saw.

Ageing

Aluminium  extruded profiles reach their optimal strength through the process of ageing, or age-hardening. Natural aging occurs at room temperature. Artificial aging takes place through controlled heating in an aging oven and is sometimes referred to as precipitation heat-treating.

Either way, the aging process ensures the uniform precipitation of fine particles through the metal, yielding maximum strength, hardness, and elasticity for the specific extrusion alloy.

Packing

our extrusion plants are equipped to accommodate any likely packaging requirement. Profiles are packed in such a way as to be protected from surface damage, twisting, or other hazards. Customers may specify their own packaging requirements, or the type of extruded product may suggest a particular method of packaging for ease of storage or delivery.

The selection of raw materials is carefully controlled through inspection as well as our supplier management system to ensure the quality standards of our finished products. All finished profiles are inspected for defects before they leave our facilities.

Aluminum is used in varied applications from Aerospace, Automobiles and marine to industrial and domestic applications.

Aluminum is an integral part of our daily life that can be manufactured as costumers requirements.

6063 is the most popular of the aluminum extrusion alloys. This alloy makes a good surface finish, is corrosion resistant, and can be heat-treated for strength. This alloy is used in fabricated parts such as windows, doors, storefronts, and commercial buildings. In other words, it is primarily used in nonstructural applications, but occasionally it is used in structural applications.