Aluminum extrusions are used to create a wide variety of aluminum profile shapes and components. Selecting the optimal aluminium extrusion is key to achieving the required strength, functionality, and performance in the application. Here are some important factors to consider when choosing an aluminum extrusion for manufacturing aluminum profiles.
- Alloy Selection
Aluminum alloys used for extrusion have different properties suited for different applications. 6xxx series alloys like 6061 and 6063 offer good corrosion resistance and are commonly used for architectural profiles. 2xxx and 7xxx alloys provide high strength but lower corrosion resistance. Specialty alloys can provide properties like high electrical conductivity or machinability. Match the alloy to strength, corrosion, and other needs.
- Size and wall thickness
The size and wall thickness of the aluminum extrusion impact the load capacity and stability of the final profile. Larger profiles with thicker walls offer higher bending strength and load-carrying capacity. Smaller and thinner-walled extrusions optimize for light weight and material use. Consider both structural needs and weight goals.
- Complexity of Shape
More complex custom extrusion shapes with thin walls, dramatic changes in cross-section, and internal details require more experienced extruders. Simpler and more uniform shapes can be produced by more vendors. Factor in capabilities when the shape complexity increases.
- Tight Tolerances
When the aluminum profile requires very tight tolerances, specially controlled cooling and processes are necessary during extrusion. Wider tolerances are more forgiving and have greater manufacturing process flexibility. Be realistic about tolerance needs and capabilities.
- Surface finish requirements
Some applications demand very smooth surface finishes. This may require polished or brightened aluminum extrusion dies. More utilitarian finishes, like mill finish, may be acceptable for non-visible structural profiles. Consider appearance needs and finishing costs.
- Fabrication Requirements
If the aluminum profile requires extensive secondary machining, drilling, bending, or other fabrication, look for an extrusion alloy that optimizes machinability and formability. Avoid alloys prone to cracking if extensive forming is needed after extruding.
- Cost Factors
Aluminum extrusion costs are affected by alloy choice, size, shape complexity, and order quantity. Get price estimates for different extrusion options. Standard catalog profiles can offer cost savings over custom extrusions for production runs.
- Code Compliance
Building aluminum profiles must meet standards for performance and fire safety. Choose aluminum alloys and wall thicknesses that align with relevant building codes for the application and use.
- Sustainability Goals
The environmental impact of aluminum extrusions can be optimized by selecting alloys and designs that use the least material for the performance required. Post-consumer recycled aluminum content and vendor sustainability practices should also be considered for LEED and other projects.
- Supplier Capabilities
Research aluminum extrusion suppliers to find those capable of meeting the needs of the specific application. Evaluate their experience, in-house processes, production capacity, certifications, and aluminum profile shape libraries.
Aluminium extrusion
Aluminum extrusion is a process that transforms aluminum alloy materials into specifically designed profiles and sections by pushing or pulling heated cylindrical aluminum billets through a steel die opening. Here are some of the key characteristics and capabilities of aluminum extrusions:
- Flexible Shapes: The aluminum extrusion process can produce an almost infinite variety of cross-sectional profile shapes. Common shapes include rectangular bars, tubes, angles, and channels. Custom shapes are also possible.
- Complex internal details: Aluminum extrusions can include complex internal ribs, channels, and voids for functionality and structural optimization. This allows for features like improved airflow or reduced weight.
- Excellent Strength: Properly designed aluminum extrusions have very good strength for their weight. Strength can be oriented in desired directions based on extrusion shape details. Different alloys provide varied strength levels.
- Tight Tolerances: The aluminum extrusion process is capable of producing profiles with tight dimensional tolerances that rival machining processes when properly controlled. This allows for a precise fit with secondary components.
- Consistent Profiles: Continuously extruded aluminum profiles are very consistent in size, shape, and material properties along the length. This consistency facilitates assembly and installation.
- Smooth Finishes: The extrusion process results in smooth, uniform surface finishes free of porosity and imperfections. Finishes can be modified by anodizing, powder coating, and other processes after extruding for appearance needs.
- Fastener Friendly: Extruded aluminum profiles can integrate attachment channels and internal tapped holes for easy joining to other components and structures without separate fasteners.
- Creative Freedom: Aluminum extrusions place minimal restrictions on designers for creating continuous profile shapes optimized for function and aesthetics in both standard and custom options.
- Code Compliant: Major building code organizations publish standards for aluminum extrusion profiles to ensure adequate performance for structural applications and acceptable fire safety. Extrusions can be designed to meet relevant codes.
- Lower Cost: The high-volume production and process efficiencies of aluminum extrusion make it one of the lowest-cost methods for producing aluminum profiles and sections.
Aluminum profiles for windows
Aluminum profiles are commonly used for windows because they offer many benefits:
- Durability: Aluminum window profiles are highly resistant to corrosion, maintaining strength and aesthetics over long-term use. This durability exceeds most other window frame materials.
- Strength: Aluminum alloys used for window extrusions provide excellent strength-to-weight ratios. Frames can be designed with the required structural integrity.
- Thermal Breaks: Insulating thermal barrier inserts can be added to aluminum window profiles to limit heat transfer and condensation. This improves window energy efficiency.
- Design Flexibility: A wide range of frame geometries, shapes, and structural reinforcements are possible with aluminum extrusions to create high-performing and visually appealing windows.
- Light Weight: Aluminum window profiles are lighter than many alternatives like steel, vinyl, and wood. This facilitates installation and reduces the load on the window structures.
In summary, selecting the optimal aluminum extrusion requires consideration of capabilities, alloy properties, size, geometries, tolerances, finish, machinability, sustainability, codes, and cost. Matching the extrusion to the aluminium profiles for windows performance and production requirements results in the best outcome. Engage early with potential aluminum extruders and get extrusion design guidance. Overall, the material properties and extrusion flexibility make aluminum an exceptional choice over other options for window frame profiles in both performance and cost. Correct alloy and profile shape selection is critical for optimization.
