All aluminum alloys can be extruded, but there are some factors to consider when determining whether a particular part can be successfully extruded. Factors such as size, shape, alloy, tolerance, scrap rate, extrusion ratio and tongue-and-groove ratio. And whether you should use forward or reverse extrusion for production. The forward extrusion process is the most commonly used process in the extrusion industry. It is simpler in design and more flexible in profile manufacturing. The benefits of the reverse process (often called reverse extrusion) include reduced friction and improved consistency. The enhanced consistency is manifested in the dimensional and metallurgical structure along the length of the extruded profile. The reverse process is used to achieve more consistent workability, for example, in rod and bar products through more consistent metallurgical structure. Enhanced dimensional tolerances help rods used as screw machine billets. Forward Extrusion In the forward extrusion process, a heated aluminum billet is pushed through a fixed die by a cylinder head to form a specified shape. The aluminum flows in the direction of the plunger's travel, creating friction between the billet and the container. This increases the workload during the extruder cycle, resulting in higher temperatures before and after the extruder. This variation in work and temperature along the length of the extrusion results in a change in the metallurgical structure along the length of the extrusion. The temperature variation and increased work along the length affect the grain structure and microstructure, which are important for machinability. Dimensions are affected by the pressure on the die of the extruded profile, which decreases during the extrusion cycle. Pressures in the indirect process are highest at the front of the extrusion due to the additional force required to overcome the pressure. Reverse Extrusion In the direct extrusion process, as described above, the die is stationary and the ram applies pressure to the aluminum bar. In the reverse extrusion method, the extrusion head carries the die and applies pressure to the stationary aluminum bar in the opposite direction of the extrusion. There can be variations on this concept, but in all cases the aluminum bar is stationary relative to the container. Therefore, there is no billet-to-container friction effect and the forces in the extrusion process remain relatively constant from the front to the back of the extrusion. As an added benefit, the work also remains relatively constant, eliminating friction in the direct process. Advantages and Disadvantages of Reverse Extrusion The result of reverse extrusion is a more consistent work and less temperature variation throughout the length of the extrusion. This provides more consistent dimensions, grain structure, and mechanical properties. The reverse process does have its pros and cons. For example, since there is no friction, anything on the surface of th...

1) Correct die numbering. Die, suffix, backing, pad and feeder plate numbers are important. If the number on the die is wrong, it can be a loading and running error, leading to major problems. Also, the date and vendor ID are needed. Advanced factories now use lasers to put computer identification codes. 2) Check for metal chips or shavings from the manufacturing process. These tiny metal chips can hide in the weld chamber area or work belt area of the die and form die lines in the extruded product or may form. 3) Check that the die and related tooling meet Rockwell hardness standards. Although most die manufacturers check this thoroughly, it is not impossible to be off by a few Rockwell C points. 4) Tool diameter, thickness and step size. It is better to be safe than sorry. Checking the tool size will prevent the tool from getting stuck in the die ring or coming loose, causing misalignment and/or aluminum seeping into unwanted spaces, butt shear forces hitting the tool surface, etc. 5) Pinout of the die opening. This will tell you what the tool deflection on the die is, which is very useful for future dies. It will provide accurate information to zero in the minimum weight per foot, thus allowing for the maximum weight per die. 6) Support tool clearance. Check backing, shim, subshim and platen openings for interference. It is best to grind in some clearance, which will reduce the possibility of clogging and/or possible damage to the components. 7) Proper support for overhangs, etc. Make sure the backing and supports have proper support to eliminate as much tool deflection as possible and minimize the chance of tool breakage. 8) Proper exit size, check that the step behind the work band has proper clearance. Key tongues, screw bosses, etc. should have a minimum clearance. Too much clearance will cause the die to collapse and squeeze out the scrap. A blanking of approximately 0.040 inches (0.10 mm) is considered normal.  9) Proper die support. On the tongue, you want maximum support for best results. In areas with small or long tongues and screw bosses, a zero degree back taper is usually required.  10) Work band finish. Check the die work belt for: Wire cut lines, scratches from files, gauge pins or emery paper. Scratches from shipping Rail EDM or milling relief Burrs on the exit side of the work belt; it is best to catch one of these points and check before sampling or attempting a batch extrusion order.  11) Work belt flatness, verticality. The importance of these cannot be overstated.

1. Aluminum Quick-Connect Topclamp Connector.  The patented design developed for production by Adriaan Maris and Ronald Boertje is an extruded aluminum part that connects square aluminum tubes flush or to each other with the Topclamp connector. According to the company, the flexible and modular nature of the system makes it suitable for high-end interior and exterior design structures, including Expo stands/booths, pop-up stores, museum exhibitions, etc.  2. New Energy Charging Stations  With the Canadian government’s recent announcement of an impending ban on non-electric vehicles by 2035, it is expected that 4 million electric vehicles will be on the road in Quebec by then (and more in the United States), and 135,000 Type 2 public charging stations are expected to be installed in Quebec alone. Faced with the government’s goal of achieving 35% electrified parking spaces by 2035, all existing electric vehicle charging station solutions are unsuitable or restrictive. The system provides a large number of shared charging terminals, thereby simplifying the installation and configuration of electric vehicle charging stations to better adapt to changes and provide modular and upgradeable solutions.  Plus+ leverages the advantages of aluminum profiles to meet the rapid electrification needs of future parking lots. The concept is a series of easily assembled and disassembled building blocks to configure an ideal urban installation: The positive (+) shaped assembly modules allow for extrusion connections within four axes. Extruded rails, assembly modules and accessories can be flexibly laid out to accommodate different parking spaces - from linear front-to-front, to narrow interior parking with walls, to exterior parking where light or shade is required. Power first comes from a panel mounted on the main base, then passes through the aluminum profiles to power up to six chargers or electrical accessories. Groups can be multiplied to accommodate any parking layout and configuration - reducing the need for demolition and construction to increase power supply when demand for EV charging bays multiplies in the future. The extrusions are composed of alloy 6063, used for its heat treatment characteristics and good strength, corrosion resistance, formability, machinability and weldability. Three Class III hollow profiles are designed to standard tolerances with a Class I architectural anodized coating best suited for outdoor applications. The designers note that the shape has a medium-sized circumscribed circle, a uniform thickness of 3.5 mm all around, rounded transitions and corners, and follows perfect 2-axis symmetry, making it economical to manufacture and suitable for most standard extruders. 3. Energy-saving and thermostatic aluminum profile sun room  The designer explained: "Function defines aesthetics, using new technologies to reinterpret timeless themes in an attempt to synthesize spatial quality through a specific architectu...