Perks of Leveraging Aluminum Extrusion

Metals and Mining Review | Tuesday, October 17, 2023

Aluminum extrusion tooling is relatively affordable and has a short lead time. 

FREMONT, CA: Aluminum is one of the most abundant minerals in the Earth's crust but is not usually found in its pure form in nature. Instead, it is derived from bauxite, a mineral mined globally. The bauxite extracted from mines is initially crushed and then mixed with water. By-products like clay and silica are removed, leaving behind the bauxite. Small amounts of elements like copper, magnesium, silicon, and manganese are added during the alloying process to create specific material properties. Compared to other materials and methods, aluminum extrusions have numerous advantages.

The high-strength and low-weight aluminum extrusions make them ideal for load-carrying applications such as aerospace, truck trailers, and bridges. Aluminum offers a balance of strength and flexibility, allowing it to flex under loads or spring back after impact. The characteristic is utilized in automotive crash management systems. Aluminum extrusions exhibit exceptional corrosion resistance. They do not rust, and aluminum surfaces' naturally occurring oxide layer provides protection. The protection can be further enhanced through processes like anodizing.

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The conductivity of aluminum is higher than that of other common metals. It makes extrusions suitable for applications requiring heat exchangers or heat dissipation, with design flexibility for optimizing heat management. Aluminum's non-sparking property makes extrusions safe for explosives or high-flammability environments. Aluminum is twice as conductive as copper. It makes aluminum extrusions cost-effective for electrical connectors and busbar distribution components. Aluminum remains non-combustible and does not produce toxic fumes even at extreme temperatures. Aluminum does not acquire a magnetic charge, rendering extrusions suitable for high-voltage applications and electronics.

Aluminum is much lighter than iron, steel, copper, or brass – approximately one-third of their weight. This quality makes aluminum extrusions easier to handle, more cost-effective to ship, and a favorable choice for applications prioritizing weight reduction, such as transportation. Aluminum extrusions can be tailored as strongly as required for various applications. The extrusion process allows the strength to be concentrated where necessary by adjusting wall thicknesses and incorporating internal reinforcement in the design. It makes them suitable for cold-weather conditions where aluminum becomes firmer in lower temperatures.

Aluminum's surface can be treated for high reflectance, making it valuable for lighting applications and shielding against various types of radiation. Complex shapes can be achieved using one-piece extruded aluminum sections, eliminating the need for mechanical joining. The resulting profile is often more robust and less prone to loosening or leakage. While standard extrusion profiles exist, the ability to design customized profiles to meet specific functional, aesthetic, and manufacturability goals makes aluminum extrusions highly versatile. Effective design of aluminum extrusions simplifies subsequent fabrication and assembly processes. A range of fabrication techniques is used in producing extrusion-based components and assemblies.

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