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What You Need To Know About Aluminium Extrusion

What You Need To Know About Aluminium Extrusion


Even though most people don’t even notice them, aluminium extrusions are an important part of our homes. Most of the time, they are part of a window or door system, but they can be used for other things as well. Aluminium bars are used in many ways in the building and manufacturing industries, so each one must be of the highest quality. In the following article, you will know more about Aluminium profile production.

Impel is the biggest European supplier of extruded bars of aluminium for forging and one of the biggest European and US suppliers of drawn bars. In our manufacturing process, which is trusted by all of the biggest automakers and airlines in Europe, we use the best possible production methods, which we keep getting better at. Read on to find out why this process is important for so many industries and why Impol is the best choice for quality extrusion rods, tubes, and profiles.

Aluminium Extrusion Basics

Extrusion is a modern process in which heated aluminium blocks are pushed through a shaped hole in a die. The shape and size of the opening can be changed to meet the needs of each user.

  • We use different steel dies for different types of aluminium bars.
  • Flat dies with pre-chambers are used to make solid bars or profiles.
  • Chamber dies are used for hollow bars or shapes.

What Makes Extrusion Happen:

Even though the steps of the extrusion process listed above may seem simple and easy to do on their own, they are anything but. In reality, extrusion is a very complicated process that depends on how many different parameters work together and need to be changed during the process. These are known as TST parameters, which stand for temperature, speed, and time.

In short, the following things must be closely watched before, during, and after extrusion:

  • Billet temperature in the heating furnaces 
  • Container temperature 
  • Tool temperature 
  • The exit temperature of the aluminium bar/profile 
  • Quenching medium temperature 
  • Extrusion rate and delay 
  • Extrusion speed 
  • Final products and tool dimensions

These parameters must be controlled and watched closely. The most important of these is temperature, which must be changed based on the material being extruded and the shape of the final product. Most of the time, the billets of aluminium alloy need to be heated to between 300°C and 595°C.

Quenching is another very important step in the extrusion process. As you can see above, the profiles that come out of the die are cooled right away. At this stage, it’s important that the right amount of water covers every part of the aluminium bar for the right amount of time. That is, they go from the temperature at which they were extruded to room temperature as quickly as possible. We are among the best Aluminium profile extrusion in town. 

After the extrusion and quenching process is done successfully, the following parameters need to be closely watched:

The Pros of Extruding Aluminum

When compared to other products, aluminium extrusions are the best choice because they are both light and strong. From the point of view of the business world, aluminium extrusion has more benefits:

  • In general, they are a competitive and cost-effective way to make parts, especially when the cross-sections are very complicated.
  • They’re tougher and stronger.
  • Extruded products have a perfect finish on the outside, and in general, they are stronger than cast aluminium products.
  • Even though there are many benefits to aluminium extrusions over casting, there is also a major drawback. And that’s how big they are. The size of the billet and the size of the steel container on the extrusion press determine how big an aluminium extrusion can be.

Different kinds of Extrusion:

There are two different ways to extrude something when it is hot:


  • direct extrusion
  • Indirectly pushing out

Direct extrusion

Direct extrusion is the easiest way to make something. Most of the time, this method is used to make aluminium extrusions. In this method, the die stays still while the ram pushes the billet through the opening in the die. This method is called the forward or direct aluminium extrusion process because both the billet and the ram move forward in the same direction.

Extrusion from the side

In indirect extrusion, the billet does not move. Instead, the assembly at the end of the ram moves against the billet. This makes the pressure that the metal needs to move through the die.

The main benefit of the indirect press is that it can press harder alloys (2xxx, 7xxx) and products with smaller cross-sections because the extrusion pressures are lower. Lower pressures also let you press at lower temperatures, which means you can extrude at a faster rate. This will, of course, make people more productive.

What kinds of shapes can be extruded?

Extrusion is used in so many different industries that it would be impossible to list all of the different kinds of extrusion. There are an infinite number of possible shapes, and they come in many different sizes and configurations. These are the main groups:


Bars and rods that are solid and have different cross-sections are solid shapes (e.g. circles, rectangles, squares, etc.)


Angles, channels, and other half-open shapes are examples of semisolid shapes.

Tubes or profiles with different cross-sections are hollow shapes (e.g. circles, rectangles, squares, etc.)


As a semi-finished product, extruded billets are used.

Extruded bars sometimes can’t be used as finished products, especially in industries that are big and complicated, because their tolerances are bigger, they aren’t as straight, and the surface isn’t as smooth. For industries with such high standards, drawn products are better because the tolerances are much tighter and the surface is smoother. Customers can get more work done with less work operations and less waste by using drawn products.


Unlike extrusion, drawing is a cold process that changes the shape of aluminium bars by making their cross-section smaller. To do this, the bar or tube is pulled through a smaller die. The process is similar to extrusion, but the force is applied in a different way. In extrusion, the billet is pushed through the die opening, but in drawing, it is pulled through.


During the drawing process, many important factors like die angle, drawing speed, lubrication condition, and pass reduction ratio affect the quality and precision of the formed bars or tubes.


When the final product is very complicated or thin, rolled products, mechanical processing, or forging of simpler extruded products are used instead of extruded products (flat, square or hexagonal bar). This is how we can make sure that products have harder shapes or more exact sizes.



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