Aluminium Extrusion Training

By: Sajid Hussein

QMEA 1st Powder coating Workshop

Date: 25.01.2011
 OBJECTIVES

1 Introduction to Gulf Extrusions

1. Introduction to Gulf Extrusions

2 Aluminium Extrusions Process

2. Aluminium Extrusions Process

3. Aluminium Alloy  & Heat Treatment
3 Al i i All & H t T t t

4. Extrusion Surface Defects

5. Extrusion Dimension Tolerances
1. Introduction to Gulf Extrusions

• Over 32 Years of excellence in in MENA region
• 480 Skilled employees
• , p p y
60,000 MT production capacity
• Extrusion, Powder coating, Anodizing & Thermal 
Crimping
• Largest Press in MENA region ‐ 4400 MT
• In‐house established R&D facilities
I h bli h d R&D f ili i
• Over 15,000 different extruded shape
2. Aluminium Extrusion Process
Why Aluminium??? 

• The most common metal in nature
• It is light with a density (1/3rd of steel)
• Can be easily recycled‐5%
Can be easily recycled 5% of the original energy consumption
of the original energy consumption
• It can be extruded
• Aluminium alloys can be produced with a range of strengths
Aluminium alloys can be produced with a range of strengths
• It is easy to machine
• It can be joined using the normal methods of welding, 
It can be joined using the normal methods of welding
adhesive bonding, riveting
• It can be given a range of decorative and protective surface 
g g p
finishes
Why Aluminium Extrusions

• Practically unlimited range of shapes
• Designer can incorporate the metal where it is needed
• Functions can be included to reduce the number of 
components
p
• Low tooling costs
Extrusion Processes ‐ classification

¾ By Direction: DIRECT            INDIRECT

¾ By Operating Temp.: HOT / COLD 

COLD 

By Equipment: 
¾ By Equipment : HORIZONTAL / VERTICAL
/ VERTICAL
Aluminium Extrusion Press
Basic Direct Extrusion Process

CONTAINER CONTAINER

BILLET
BILLET
STEM STEM

BILLET LOADING UPSETTING

CONTAINER CONTAINER

STEM

EXTRUSION SHEARING
Specification needed Prior to Extrusion

1. Application 12.Wall Thickness Variations
2. Alloy 13.Number of Cores  
3. Mechanical Properties 14 T
14.Tongue Ratios
R i
4. Weight per Metre 15.Exposed Surfaces
5 Circumscribing Circle
5. Circumscribing Circle 16 Details that will affect Surface
16.Details that will affect Surface 
6. Cut Length Finish
7. Tolerances 17.Custom Tooling
8. Surface Finish 18.Back End Defect
9. Quantity 19.Charge Weld
10.Packaging 20 Mill Fi i h A di d O C t d
20.Mill Finish, Anodised Or Coated
11.Minimum Wall Thickness 21.Fabrication
Extrudability 

Aspects that are key to the extruders are:
• Alloy Suitability based on end application
Alloy Suitability based on end application
• Design of profiles
• Extrusion to the desired tolerances
• Finish required 
required
• Can all the extrusion needs be accomplished 
at a feasible cost
Preheating

• Billet Loading
– aluminium logs bundle is loaded on to the loading tables
• Die Preheating
– Relevant dies as per the production programme are loaded into 
the die oven, heat the Dies between 430°C to 470°C
• Preheating
– The billet logs are preheated as per the following parameters:
Dies                   :        Hollow           Semi Hollow             Flat
1st billet temp  : 510 – 530°C  490 – 510°C 480 ‐ 500°C
Extrusion

– Start up of Press
• Switch on press power controls ‐ PICOS,CADEX & handling system
• Th
The press is operated on dry cycle at least twice.
i t d d l tl tt i
• Die oven temperature is set between 430°C ‐ 470°C.
• All the movements of ancillary equipments such as slat conveyor
All the movements of ancillary equipments such as slat conveyor, 
puller saw machine, belt conveyors in cooling beam and lift off 
arms is checked
– Setting the Billet Length & Number of Billets
– Lubrication of Dummy Block 
– Production
Post Extrusion

• Stretching
– After cooling profiles are stretched to eliminate bowing effects 
and waviness
and waviness.
– This is done by holding two ends in the stretcher and stretching 
to obtain optimum straightness by stretching operator and tail 
p g y g p
end operator.
– Profiles from multi cavity dies may be stretched together.
– After stretching, the profiles are arranged in batches. The width 
of the batch should not exceed the width of the cold saw 
conveyor.
conveyor
Post Extrusion Contd…

• Cutting
– The profiles are cut to the specified lengths by the operator
– Stacked in stillages as per the requirement –
St k d i till th i t finish/ soft/ hard.  
fi i h/ ft/ h d
Hard materials are sent for aging.
– The cutting operator fills the necessary information in 
The cutting operator fills the necessary information in
Production Card such as number of lengths and stillage number.
– The scrap generated during the process is sent to re‐melting 
department.
– Lubricated saws are equipped with delivery systems for optimal 
efficiency and cut surface
efficiency and cut surface.
– Automatic devices clamp profiles in place for sawing. Saw chips 
are collected for later recycling.
y g
Aging
• Extrusion alloys reach their optimal strength through the process of 
aging, sometimes known as age‐hardening
i ti k h d i
• Natural aging occurs at room temperature
• Artificial aging takes place through controlled heating often 
Artificial aging takes place through controlled heating often
referred to as precipitation heat‐treating
• When the profile emerges from the press it is in a semi‐solid state, 
p g p ,
but rapidly solidifies as it cools or is quenched (whether by air or 
water). 
• Non‐heat‐treatable alloys ‐ natural aging and cold working. 
• Heat‐treatable alloys ‐ controlled thermal treatments
• Either way, the aging process ensures the uniform precipitation of 
Eith th i th if i it ti f
fine particles through the metal, yielding maximum strength, 
hardness, and elasticity for the specific extrusion alloy
y p y
Extrusion Tooling
Dies

• Dies are divided into two groups:
– Dies for Solid Extrusion
– Dies for Hollow Extrusion
Dies – Solid Extrusion
Dies – Hollow Extrusion
Dies for hollow extrusion consist of two parts 
• A port through which aluminium flows
A port through which aluminium flows
• A mandrel over which the aluminium rewelds to form the extrusion’s outside 
surface
Three Piece Tool Stack
Die Ring Die and Bolster
Backer
DIE RING BOLSTER SUB BOLSTER

Sub bolster

DIE BACKER
Tool Stack With Insert Bolster

Die Ringg Die and Insert

Insert
backer bolster
bolster
DIE RING INSERT BOLSTER HOLDER
holder

DIE BACKER INSERT BOLSTER

Sub
bolster
Two Cavity Flat Die with Backer

Die-plate forms the Backer‐ provides 

additional support to the 
extruded profile
die to reduce deflection
Die Number

NO LOAD UNDER LOAD

TONGUE DEFLECTION

Dies deflect under the high 
Dies deflect under the high
stresses. The die backer 
Tongue support
and the bolster should be 
in backer
designed to give maximum
designed to give maximum 
support through the tool 
Tongue with support to 
reduce deflection
stack
Die aperture Cavity identification
Material flow is fastest in the center of the container

CONTAINER

BILLET

STEM

DIRECT EXTRUSION
3 Aluminium Alloys & Heat Treatment
3. Aluminium Alloys & Heat Treatment
Classification of Aluminium Alloys

Most Aluminium Extrusions are made from the alloy 
series listed below:

• 1xxx series –
1xxx series – Aluminium of 99% minimum purity
Aluminium of 99% minimum purity
• 3xxx series – Aluminium + Manganese
• 5xxx series – Aluminium + Magnesium
• 6xxx series – Aluminium + Magnesium + Silicon
• 7xxx series ‐ – Aluminium + Zinc + Magnesium 
Properties – Achieved when alloyed with metals
Chemical Composition 0f 6xxx Series
Various Tempers
The 6xxx series has good extrudability and can be  solution heat
treated during hot working at extrusion temperature
F  – Extruded profile is not subjected to heat treatment, just air 
cooled
l d
O  – Extruded profile is softened, annealed at 350 – 500 °C for 1–5hrs
T1 Extruded profile is cooled from an elevated temperature and 
T1 – Extruded profile is cooled from an elevated temperature and
naturally aged
T3 –
3 SoSolution heat treated, Cold worked and naturally aged to stable 
ut o eat t eated, Co d o ed a d atu a y aged to stab e
condition
T4 – Extruded profile is naturally aged at 20°C to a stable condition
T5 – Extruded profile is cooled from extrusion temperature and 
artificially aged, typically 160 ‐190°C, for 4 – 10 hrs
T6 – Extruded profile is solution heat ‐
E t d d fil i l ti h t treated and artificially aged
t t d d tifi i ll d
Alloy Specification – AA 6060
Alloy Specification – AA 6061
Alloy Specification – AA 6063
Alloy Specification – AA 6005 A
Alloy Specification – AA 6082
Important Parameters ‐ Extrusion

• The most important parameters in Extrusion 
are:
– Temperature
– Temperature
T
– Temperature
p
Exit Temperature Profile in Extrusion
570

560
g
•Although heat is lost to the die 
550
and container during extrusion 
RE C

the heat generated during the 
O

540
EMPERATUR

530
deformation process raises the 
520
exit temperature well above the 
billet temperature
billet temperature.
EXIT TE

510

500
•During extrusion the exit 
490
t
temperature must be high 
t t b hi h
480
enough to dissolve the 
470

EXTRUDED LENGTH
G magnesium silicide particles
magnesium silicide particles

ISOTHERMAL EXTRUSION IS KEY TO UNIFORM PROPERTIES

Contd..
• During Extrusion the exit temperature must be high enough to 
dissolve
dissolve  
the magnesium silicide particles
600 SOLIDUS
Mg2Si
DISSOLVES
IN ALUMINIUM

SOLVUS
TEMPERATURE C
o

400

ALUMINIUM
PLUS Mg2Si

200

0.5 1.0 1.5 2.0

SOLUBILITY OF Mg2 Si IN ALUMINIUM
Quenching after Extrusion
• After extrusion the section must be cooled quickly enough to 
keep the magnesium and silicon dissolved in the aluminium
6061
Solvus tempp ((545 C))

• Low Quench Sensitivity 550

Alloy  ‐ 6060/6063 

ure C
450
Cooling Rate ‐ 50oc/minute
Cooling Rate  Precipitation
ec p tat o occurs
occu s

Temperatu
Comples Extrusion  350

• High Quench Sensitivity Quench rate

too slow
250
Alloy  ‐ 6082/6061/6005A
Cooling Rate  ‐ 250oc/minute Recommended
150 quench rate Critical Quench Rate
650 C/minute for 6061 300 C/minute

0.1 1.0 10 100 1000

Time (Minutes)

Typical C Cooling Curve for 6061 alloy
Quenching after Extrusion
Age Hardening 

•When aluminium  magnesium silicon alloys are age‐hardened the following precipitation 
sequence occurs:
Clusters  Needles  Rods
•The clusters and needles strengthen the  alloy, whereas rods reduce the strength
•The cooling rate after extrusion, the age‐hardening temperature and the time, control    
the size and distribution of the precipitates
p p
High Mechanical Properties

• High Mechanical Properties require High Alloy Content ‐ AA 
6082, AA 6061, AA 6005A
• High Strength Alloys are:
Hi h St th All
¾ High Quench Sensitive
¾ Slow Extrusion Speeds
Sl E i S d
¾ High Extrusion Pressures
¾ Poor Surface Finish
f h
¾ Challenge to extrude Complex sections
• For the same Temper, the UTS values are in this order
AA 6068 >  AA 6005 > AA 6063 . AA 6060
Mechanical Properties Comparison
Alloy 6060 6063 6005 A 6082
T6 T6
Temper T4 T6 T4 T6 T66 T4 T6
Solid Hollow
Proof Stress Rp 
Stress Rp
0.2
60 150 65 170 200 225 215 110 215

Tensile Strength 
R
Rm
120 190 130 215 245 270 255 205 290

Elongation A5% 16 8 14 8 8 8 8 14 8
Webster B 
Webster B
Hardness
5 10 5 12 13 14 14 11 15

• Proof Stress and Tensile strength in Mpa (min)
g p ( )
• Note Values depend on wall thickness ‐ see standard
• Young's Modulus  for all alloys approximately 70,000 Mpa
4 Extrusion Surface Defects
4.  Extrusion Surface Defects  
Extrusion Surface Defects

Extrusion surface defects that effect the quality of powder
q y p
coated aluminium:
– Blisters
– Pickups
– Tearing
– Graphite Pickups 
– Stains
– Die lines
– Twists / Bends
– Orange Peel
Surface Defects – Blisters 
Entrapment of air/gases/moisture in the extrusion chamber results in the 
f
formation of blisters/bubbles on the surface of aluminium.
i f bli /b bbl h f f l i i

This is best avoided by a burp cycle
Surface Defects – Pickups
Inclusions in the billet, inadequate homogenization treatment, die deflection 
and billet temperature results in spots on the surface of aluminium 
d bill l i h f f l i i

This is best avoided by good nitriding practices, die steel and inert atmosphere 
Surface Defects ‐ Tearing

Melting of Magnesium Silicides (MgSi2) results in tearing on the surface of 
Aluminium

This is best avoided by reducing the extrusion speed and reducing the billet
temperature
Surface Defects – Graphite Pickups 
Friction between the profile and graphite on the run out table results in 
adhering of graphite particles on to the aluminium surface
dh i f hi i l h l i i f

This is best avoided by reducing the extrusion speed and reducing the
billet temperature
Surface Defects – Stains
Oil stains left over after extrusion result in appearance of a distinct patch on 
the surface of aluminium
h f f l i i

This is best avoided by complete pretreatment of extruded aluminium prior 
to powder coating / surface treatment 
d i / f
Surface Defects – Die Lines
Prominent lines / streaks /longitudinal depressions / protrusions on the 
surface of aluminium due to imperfections on die surface, also caused by the
f f l i i d i f i di f l db h
interaction of the die land area

This is best avoided by mechanical treatment of this section, die correction 
and polishing
Surface Defects – Twists / Bends
Improper centering of die cavities, non uniform billet heating resulting in non 
uniform temperature distribution, and improper support during stacking 
if di ib i di d i ki
results in twists / bends on surface of aluminium

This is best avoided by proper centering of the die cavities to maintain equal 
metal flow for all sections
Surface Defects – Orange Peel
Porous appearance on the surface of aluminium very much like the skin of an 
orange having minute projections & depression due to improper pressure 
h i i j i &d i d i
and  
current settings
g

This is best avoided by maintaining proper pressure and current settings in 
the powder coating process
5 Extrusion Dimensional Tolerances
5.  Extrusion Dimensional Tolerances  
Basics to Dimensions & Tolerances

• A complex section need not be a difficult  extrusion, but a 
simple section can be a difficult extrusion
• EN755‐9 : 2008–
EN755 9 2008 general tolerances 
lt l
• EN 12020‐2: 2008 tighter tolerances for specific applications
• Why do we need tolerances?
– Extrusion is a hot working process
Extrusion is a hot working process
– Extrusion is a hot working process
– Residual Stresses during cooling distort the sections
– Dies wear
Dies wear
Factors – Section Size

• Factors that limit section size are:

– Container draw: maximum diameter that can be taken from billet
– Extrusion ratio: area of container / area of section
/
– Extrusion factor: circumscribing circle / section thickness
– Shape factor: periphery  / cross sectional area
Sh f t i h / ti l
Basic Rules

1. Avoid sudden changes in metal thickness
2 Keep sections symmetrical
2. Keep sections symmetrical
3. Avoid sharp corners
4. Avoid narrow slots or grooves
5. It is easier to control metal dimensions than space 
dimensions
What is to be achieved

• Correct shape within the dimensional tolerances
• Acceptable surface finish
Acceptable surface finish
• Specified mechanical properties
• Maximum productivity
• Maximum recovery
EN‐755‐9 Linear Dimensions ‐ Alloy Group 1
E H E

H H H
H

H
CD

Dimension
Di i H Tolerances on H for circumscribing circle CD
Up to and
Over including ?100
CD 2
?
100<CD
00 3
?
200<CD
00 5
?
300<CD
00 8
?
500<CD
00
10 ±0.25 ±0.30 ±0.35 ±0.40 ±0.50
10 25 ±0.30 ±0.40 ±0.50 ±0.60 ±0.70
25 50 ±0.50 ±0.60 ±0.80 ±0.90 ±1.0
50 100 ±0.70 ±0.90 ±1.1 ±1.3 ±1.5
100 150 ±1.1 ±1.3 ±1.5 ±1.7
150 200 ±1.3 ±1.5 ±1.8 ±2.0
200 300 ±1.7 ±2.1 ±2.4
300 450 ±2.8 ±3.0
450 600 ±3.8 ±4.2
600 800 ±5 0
±5.0
EN‐755‐9 Linear Dimensions ‐ Alloy Group 2
E H E

H H H
H

H
C
CD

Dimension H Tolerances on H for circumscribing circle CD

Up to and
Over including ?
CD
100 ?
2100<CD
00 ?
300
200<CD ?
500
300<CD ?
8500<CD
00

10 ±0.40 ±0.50 ±0.55 ±0.60 ±0.70

10 25 ±0.50 ±0.70 ±0.80 ±0.90 ±1.1
25 50 ±0.80 ±0.90 ±1.0 ±1.2 1.3
50 100 ±1.0 ±1.2 ±1.3 ±1.6 ±1.8
100 150 ±1.5 ±1.7 ±1.8 ±2.0
150 200 ±1.9 ±2.2 ±2.4 ±2.7
200 300 ±2.5 ±2.8 ±3.1
300 450 ±3.5 ±3.8
450 600 ±4.5 ±5.0
600 800 ±6.0
EN‐755‐9 Wall Thicknesses ‐ Alloy Group 1
B

A B

B
A

CD
Tolerances on wall thicknesses
Nominal wall
thickness A,B,C Wall thickness A Wall thickness B Wall thickness C
Circumscribing circle Circumscribing circle Circumscribing circle
Up to and
Over including
g ?100
CD 100<CD
300
? CD
?100 100<CD
300
? CD
?100 100<CD
300
?

1.5 ±0.15 ±0.20 ±0.20 ±0.30 ±0.25 ±0.35

1.5 3 ±0.15 ±0.25 ±0.25 ±0.40 ±0.30 ±0.50
3 6 ±0.20 ±0.30 ±0.40 ±0.6 ±0.50 ±0.75
6 10 ±0.25 ±0.35 ±0.60 ±0.8 ±0.75 ±1.0
10 1 ±0.30 ±0.40 ±0.8 ±1.0 ±1.0 ±1.2
15 20 ±0.35 ±0.45 ±1.2 ±1.5 ±1.5 ±1.9
20 30 ±0.40 ±0.50 ±1.5 ±1.8 ±1.9 ±2.2
30 40 ±0.45 ±0.60 ±2.0 ±2.5
40 50 ±0 70
±0.70
EN‐755‐9 ‐ Flatness
W1

F1
F

Deviation F
Width W
Hollow Profiles
Up to and Solid Profiles
Over including ?
Wall
5 thickness t Wall thickness t> 5

30 0.30 0.20 0.20

30 60 0.40 0.30 0.30
60 100 0.60 0.40 0.40
100 150 0.90 0.60 0.60
150 200 1.20 0.80 0.80
200 300 1.80 1.20 1.20
300 400 2 40
2.40 1 60
1.60 1 60
1.60
400 500 3.00 2.00 2.00
500 600 3.60 2.40 2.40
600 800 4.00 3.00 3.00
EN‐755‐9 ‐ Angular Deviation

Width W
Maximum allowable deviation Z from a right angle

Over Up to and including

30 0.4 0.4
30 50 0.7 0.7
50 80 1 1
80 120 1.4 1.4
120 180 2 2
180 240 26
2.6 26
2.6
240 300 3.1 3.1
300 400 3.5 3.5
EN‐755‐9 ‐ Straightness
Ruler
300

Hs

Ht

Straight Edge
L
EN ‐ 12020‐2 ‐ Linear Dimensions
H E

H H H
H

H
CD

Dimension H Tolerances on H Tolerances on H (open ends)

over upto/inc Except open ends E≤60 E60<E≤60
- 10 ±0.15 ± 0.15 a
10 15 ±0.20 ±0.20 a
15 30 ±0.25
0.25 ±0.25
0.25 a
30 45 ±0.30 ±0.30 ±0.45
45 60 ±0.40 ±0.40 ±0.55
60 90 ±0.45 ±0.45 ±0.65
90 120 ±0.60 ±0.60 ±0.80
120 150 ±0.80 ±0.80 ±1.00
150 180 ±1.00 ±1.00 ±1.30
180 240 ±1.20 ±1.20 ±1.50
240 300 ±1.50 ±1.50 ±1.80
EN ‐ 12020‐2 – Wall Thickness
B

A B

B
A

CD
Tolerance on wall thickness
Nominal wall Wall thickne ss A for Wall thickne ss B or C for
thickness circumscribing circle CD circumscribing circle CD
over upto/inc 0 to 100 100 to 300 0 to 100 100 to 300
- 1.5 ±0.15 ± 0.20 ± 0.20 ± 0.30
1.5 3 ±0.15 ±0.25 ±0.25 ±0.40
3 6 ±0.20 ±0.30 ±0.40 ±0.60
6 10 ±0.25 ±0.35 ±0.60 ±0.80
10 15 ±0.30 ±0.40 ±0.80 ±1.00
15 20 ±0.35 ±0.45 ±1.20 ±1.50
20 30 ±0.40 ±0.50
30 40 ±0 45
±0.45 ±0 60
±0.60
EN ‐ 12020‐2 – Convexity / Concavity
W1

F1
F

Width W
Maximum allowable deviation F
Over Up to/inc
30 0.20
30 60 0.30
60 100 0.40
100 150 0.50
150 200 0.70
200 250 0.85
250 300 1 00
1.00
EN ‐ 12020‐2 – Twist

Width W Twist tolerance T for specified length L

1000 to 2000 to 3000 to 4000 to 5000 to
Over Up to/inc to 1000 2000 3000 4000 5000 6000 over 6000
25 1.00 1.50 1.50 2.00 2.00 2.00
25 50 1.00 1.20 1.50 1.80 2.00 2.00
50 75 1.00 1.20 1.20 1.50 2.00 2.00 subject
75 100 1.00 1.20 1.50 2.00 2.20 2.50 to
100 125 1.00 1.50 1.80 2.20 2.50 3.00 agreement
125 150 1.20 1.50 1.80 2.20 2.50 3.00
150 200 1.50 1.80 2.20 2.60 3.00 3.50
200 300 1.80 2.50 3.00 3.50 4.00 4.50
 Thank You
Thank You

Time for Test?