How Is Extruded Aluminum Made, From Raw Material to Finished Product

What is extruded aluminum?

Aluminum extrusion is a sophisticated manufacturing process that transforms aluminum alloy into shapes with precise dimensions and mechanical properties. Widely used in industries ranging from construction to automotive, this process enables the creation of complex profiles that maintain strength and durability.

Aluminum’s unique properties – its lightweight nature, corrosion resistance, and recyclability – make it ideal for extrusion and essential for modern applications.

Step-by-step: how is extruded aluminum made?

1. Material preparation

The extrusion process begins with raw aluminum alloy, typically in the form of billets. These billets are made from various aluminum grades, chosen based on the mechanical properties required for the final profile.

Profall uses high-quality alloys, each chosen for unique mechanical and physical properties suited to various applications:

Alloy 1050 - Known for its excellent corrosion resistance and high ductility, Alloy 1050 is ideal for applications where chemical stability and formability are essential, such as in decorative profiles and electrical applications.
Alloy 1070 - With high conductivity and resistance to corrosion, Alloy 1070 is well-suited for electrical and electronic uses. Its malleability and resistance make it a prime choice for profiles in humid or chemically exposed environments.
Alloy 3103 - This alloy offers good strength and corrosion resistance, making it a popular option for structural profiles in construction, automotive, and mechanical industries. It combines durability with the ability to be shaped into complex designs.
Alloy 6060 - Known for its strength, formability, and excellent anodizing capabilities, Alloy 6060 is widely used in architectural and structural applications. Its properties allow for a smooth surface finish, ideal for applications requiring both aesthetics and durability, like window frames and furniture.

Learn more here: Aluminum Alloy Extrusion: How to Choose the Right Alloy for Your Product

2. Heating the aluminum

Next, the aluminum billets are heated to approximately 500°C (932°F) in specialized furnaces. This temperature softens the metal, making it malleable enough for the extrusion process.

3. Extrusion through the die

In the core extrusion phase, the heated aluminum billet is pushed through a die – a steel tool shaped to match the final profile’s cross-section. Using intense pressure, the aluminum takes on the shape of the die, resulting in a continuous profile that can be customized to exact dimensions and intricate designs.

4. Cooling the extruded profile

Immediately after extrusion, the profile is cooled rapidly using air or water. This controlled cooling stabilizes the aluminum and helps achieve the desired hardness and durability. Cooling speed varies depending on the alloy and specifications of the final product.

5. Cutting and finishing

Once cooled, the extruded aluminum profile is cut to the desired length. Depending on the application, additional finishing processes may be applied to enhance the profile’s appearance and resistance to corrosion. These finishes add durability and aesthetic appeal, making aluminum profiles suitable for environments with high wear and tear, like construction and automotive.

6. Quality control and inspection

Each profile undergoes rigorous quality checks to ensure dimensional accuracy, tensile strength, and surface finish. This step is essential to meet industry standards and client specifications. Quality assurance at Profall includes tests like dimensional analysis, hardness tests, and visual inspections to eliminate any defects.

Essential post-extrusion treatments for enhanced extruded aluminum profiles

After the extrusion process, extruded aluminum profiles can be treated with various finishing techniques to enhance durability, functionality, and visual appeal, ensuring they meet precise application needs.

These treatments not only improve the resistance of aluminum to environmental factors but also add value in terms of aesthetic quality. Here are some of the key post-extrusion treatments:

Anodizing: increases surface hardness, improves corrosion resistance, and provides an attractive matte or glossy finish. Anodized aluminum is ideal for applications exposed to harsh weather or moisture, such as construction and transportation sectors.
Powder coating: applies a durable, colored layer to the surface, offering protection against scratches, UV damage, and general wear. This treatment is frequently chosen for architectural profiles and automotive parts, where both resilience and color versatility are required.
Mechanical finishing: includes processes like polishing, brushing, and sandblasting, which refine the surface’s texture and appearance. These finishes add a high-quality tactile feel, ideal for visible components in interior design or consumer products.
Custom finishing solutions: at Profall, profiles can be tailored with specialized finishes to meet unique customer specifications, ensuring compatibility with specific operational or aesthetic demands.

By selecting the right post-extrusion treatment, Profall guarantees aluminum profiles that combine strength, longevity, and a polished look, making them suitable for even the most challenging applications.