Types of aluminum extrusion: what you must know

Aluminum extrusions are available in a wide range of sizes, from simple square tubes to multiple intertwined and complex parts and profiles. Different types of aluminum extrusions bring different functions to the table, and separating the types of aluminum extrusions helps to achieve optimization of construction projects and effective cost control. Prices of different types of aluminum extrusions vary widely, so how to differentiate them and choose the right kind is necessary for your project.

Therefore, this article will discuss to you in detail the types of aluminum extrusions and the characteristics of each. I am sure you will find the answers you are looking for below:

table of content：

What is Aluminum Extrusion
Aluminum Extrusion Processing
Common Types of Aluminum Extrusion
Types of Aluminum Extrusion Profiles

What is Aluminum Extrusion?

Aluminum extrusions are products made by extrusion. Specifically, aluminum extrusion refers to the application of strong pressure to an aluminum billet placed in a die cavity, forcing the billet to deform and ultimately obtaining the desired aluminum product. It is widely preferred because it can be made in various shapes.

In the 19th century, the demand for aluminum extrusions in industrial and construction projects grew as people discovered this new manufacturing method. It can become strong and lightweight angles, beams, channels and tubes of different sizes. In addition, the complex structure of aluminum extrusions can be interlocked with other steel structures. On modern buildings, extruded aluminum profiles are used as curtain walls and structural materials to help resist hazards.

Properties of aluminum extrusions:

Highly flexible:

Aluminum extrusion allows for highly complex cross-sectional shapes, often allowing for the integration of several different components into a single extruded shape, thereby reducing connections and overall costs.

Lightweight:

Aluminum is lightweight and strong. It is suitable for use in application scenarios where weight reduction is required, such as roofing systems and aircraft with stringent weight requirements.

Corrosion Resistance:

Aluminum has good corrosion resistance, and its surface oxide film protects the workpiece from a wide range of environments.

Excellent thermal conductivity:

Aluminum metal’s thermal performance is second only to copper metal, yet copper is four times more expensive than aluminum, making aluminum thermal materials more popular. Extruded aluminum heat sinks help LED light systems and computers operate at a consistent temperature.

Processing of aluminum extrusions

Aluminum extrusion processing is also divided into three types: hot extrusion, cold extrusion and directional extrusion. The choice of extrusion process depends on the use of the part and the type of product. Hot extrusion is used most often because this process produces aluminum workpieces that are harder and stronger.

So how does aluminum become the part we want in these processes：

1.Aluminum Extrusion Die Design

The nature and function of an aluminum extrusion depends on the design of the aluminum die, as the structure of the die determines the shape and size of the finished product. Therefore, the design of aluminum extrusion dies is also the most critical and beginning step.

All extrusion dies are solid, semi-hollow or hollow. Solid dies produce a shape with no opening in the center, while hollow dies have one or more openings and semi-hollow dies are almost hollow. If we want an aluminum profile with a complex shape, then it may require all three dies to be used together to achieve the result.

2. Heating aluminum billets

Aluminum billets need to be heated prior to extrusion to soften the material and increase its malleability. The heating temperature is determined by the properties of the selected aluminum alloy and the desired product, and is usually performed at a higher temperature.

The heated aluminum billet needs to be kept within a certain temperature range to ensure that it remains sufficiently malleable during the extrusion process.

3. extrusion process

The heated aluminum billet is placed into the extrusion barrel of the extruder. The open end of the extruder (also known as the punch) exerts strong pressure on the aluminum billet, forcing it through the extrusion outlet (extrusion die).

The die’s orifice has the shape and size of the desired product, and the aluminum billet undergoes plastic deformation as it passes through the die, resulting in the desired shape of the extruded part. This process is very important because the temperature and speed of the extrusion affect the quality and shape of the finished aluminum product.

4.Cooling & Cutting

Extruded aluminum parts are usually in a high temperature state and need to be cooled to stabilize their dimensions and properties. Cooling can be natural or forced (e.g. using air or water cooling). After cooling, the aluminum extrusions are cut to length or shape.

5. Finishing & Further Processing

Aluminum extrusions may require further machining or the addition of coatings, depending on your project requirements. Aluminum CNC machining, welding and drilling can all add to the functionality of aluminum parts. And powder coating and anodizing finishes can help it better resist UV rays and corrosion.

Common type of aluminum extrusions

There is a wide variety of aluminum extrusions, from simple rounds to complex parts and profiles, and these general types of aluminum extrusions below will be common to us. These aluminum extrusions generally come in standard sizes and shapes, and almost all extrusion manufacturers have these profiles, and you can even use their dies for the desired product.

Aluminum Beams

Aluminum beams are large structural metal members that are made of aluminum alloy and are used as horizontal supports in building construction. A preferred alternative to steel and wood, aluminum beams are stronger but lighter and are suitable for high-rise buildings or private.

Structural aluminum does not corrode and can withstand high and low temperatures without rusting. Extruded aluminum beams last longer and are available in a variety of shapes, such as non-circular and C-channel, H-beam and I-beam.

aluminum channel

Aluminum channel are one of our most common extruded aluminum products, which are aluminum extrusions with a channel type. This workpiece is smooth and linear with internal grooves to provide protection for various sizes of LED strips, wires and frames. Aluminum grooves can also be used as connectors to provide support for glass and handrails using their own channel.

Aluminum channels are good heat conductors and protectors, which makes them ideal for heat transfer and insulation. Industries that use aluminum channels include construction, industrial manufacturing, automotive, medical and automotive.

Some of the common types of extruded aluminum channels we see include: F channel, U channel, J channel, V channel and W channel. Of these, U-channel and J-channel are the most common aluminum extrusions we use to wrap glass or connect two boards.

As with many types of extrusions, the wall thickness and dimensions of aluminum channels determine how they are used, with thicknesses ranging from 0.0625”——0.5”. Widths range from 0.5 inches to 6 inches, and lengths depend on your project requirements. Wanna know more about extruded aluminum channel please contact Hugh aluminum!

Aluminum Trim

Aluminum trim is a long, thin, narrow extrusion that can be used in a variety of shapes for decorative architecture, indoor and outdoor lighting, and architectural and engineering projects. It is weatherproof, resistant to high and low temperatures, corrosion and rust.

Aluminum trim is lightweight and inexpensive, can be extruded into a variety of shapes, and has a variety of surface colors and a unique sheen that can lend a sense of luxury. Aluminum trim can therefore look luxurious and increase the value of your home or commercial building when installed.

Extruded Aluminum Tubes

Extruded aluminum tubing is a hollow linear cylindrical, square, round or rectangular tube used for applications such as downspouts and building supplies. It is formed using hot or cold extrusion methods. Extruded aluminum tubing is widely used due to its flexibility and versatility.

Extruded aluminum tubing can be used in mining equipment, hardware joints, fluid and gas transportation, lightweight building frames, structural applications, and lighting poles.

Extruded aluminum tubes are produced by passing an aluminum bar through a deformation die under pressure. The process improves the microstructure and mechanical properties of aluminum. After forming, the aluminum tubes are hardened and aged to further improve their properties. Extruded aluminum tubes are stronger and harder than welded aluminum tubes. Therefore aluminum extrusion is also the main production process for tubes.

Aluminum Flat Bar & Aluminum Round Bar

Aluminum flat bars and round rods can be obtained by the process of extrusion, as aluminum extrusion solid dies can be designed to extrude these finished products in round or rectangular shapes. However, these products are still semi-finished because they require further processing to become the familiar car doors, medical parts and aluminum tools.

Aluminum Angle

Standard extruded aluminum angles have sharp square corners, and the two extensions of the aluminum angle are called legs because they resemble right-angled structures, even though some angles do not have 90° corners. It is usually made of aluminum grades 6063 or 6061, which are lightweight and strong aluminum alloys.

Aluminum angle extrusions are lightweight but have enough strength to support structural projects, so building contractors use them as building frames and supports.

Aluminum angle has equal or unequal leg lengths with sharp right angles. Of the various types of aluminum angle, some are less than 90°, leaving the legs more open. Some manufacturers use a heat treatment or tempering process in order for the aluminum angle to achieve sufficient strength.
When the aluminum angle reaches the T5 or T6 level, the strength is increased by about 40% but this requires a higher cost.

T-Slot Aluminum Extrusions

T-slot aluminum extrusions are typically shaped in a square, rectangular, or curved radius with a long T-slot on one edge.The shape of the T-slot extrusion allows for the attachment of fittings that fit into the T-slot.

It is a strong, sturdy and robust frame used in the manufacture of 3D printer frames as well as tables and housings. Among other things, the T-slot can be fitted with angle brackets or connectors. As a frame material, it requires no welding, drilling or bolting, and can be easily customized for design and application.

Common sizes of T-slot extrusions are 20×20 (2020), 30×30 (3030), and 40×40 (4040), and this excellent construction allows it to hold up to 2,800 lbs. per sq. ft. The T-slot extrusions are quick-attach using plates or angle brackets, and are secured with T-bolts and nuts.

Fabricated Aluminum Extrusions

In most metalworking processes, secondary operations are performed on workpieces to prepare them for application or further processing. Examples include CNC machining, punching, welding, drilling and further cutting. And there are quite a few aluminum extrusions that need to be machined, so they are also classified into a type.

Machining aluminum extrusions refers to the processes that aluminum extrusions undergo after extrusion. The manufacturing and finishing processes make the extrusions functional components for applications. These aluminum extrusions usually require surface machining and further deep machining.

Machined aluminum extrusions can specifically be: aluminum handles, aluminum handrails, aluminum railings, aluminum enclosures and aluminum roofing. They will typically require surface treatment to increase corrosion resistance and CNC machining. Surface treatments for aluminum extrusions are generally powder coated or anodized, these coatings give the surface a bright color and increase the wear resistance of the extruded aluminum.

Aluminum extrusion profiles

Aluminum profiles are shapes of extruded aluminum products, manufactured in various thicknesses, which are essential to provide proper form and function. The number and types of profiles are endless and growing as new and unique applications continue to be developed. The following aluminum extrusion profiles are some of the common finished aluminum profiles we see.

1. Architectural Profiles

Architectural profiles are used in building and construction for aesthetic and functional purposes. Examples include:

Window and door frames: Extrusions designed for framing windows and doors, providing structural support and housing for glass panes.
Curtain walls: Systems used to create non-structural exterior walls, allowing for large expanses of glass and aesthetic designs.
Railings and balusters: Profiles used in balcony, stairway, and decking applications for safety and decoration.

2. Transportation Profiles

These extrusions are used in automotive, aerospace, and marine industries for lightweight and durable components. Examples include:

Roof rails and crossbars: Used in vehicles for attaching cargo carriers.
Chassis components: Structural parts for vehicle frames and bodies.
Rail car profiles: Used in the construction of train cars and other rail vehicles.

3. Electrical Profiles

Used in electrical and electronics industries, these profiles include:

Conduits: Hollow profiles for housing electrical wires.
Busbars: Solid profiles used for conducting electricity in switchgear, panel boards, and busway systems.

4. Furniture Profiles

Used in the production of furniture and fixtures, these extrusions include:

Frame components: Profiles used to build the frames of tables, chairs, and other furniture.
Decorative trims: Profiles that provide aesthetic finishes to furniture edges and surfaces.

5. Industrial Profiles

Industrial profiles are used in machinery and equipment manufacturing. Examples include:

Guide rails: Used in conveyor systems and machinery for guiding and supporting moving parts.
Structural components: Profiles used in the construction of industrial frames, supports, and housings.

Extruded aluminum Heat Sink

Aluminum heat sinks are key components in thermal management systems designed to dissipate heat from electronic devices, machinery and systems. Their main function is to increase the surface area in contact with the cooling medium (usually air or liquid) to promote efficient heat dissipation.

There are various types of extruded aluminum heat sinks, mainly distinguished by their use and shape. Extruded aluminum heatsinks can be straight, pinned, circular shaped, or folded, and the design of the fins is crucial as they increase the surface area and thus the heat dissipation rate.

Extruded heat sinks can be passive or active. Active heatsinks use a power source, such as an integrated fan with directional fins that direct airflow patterns to help increase the surface area of the aluminum extruded heatsink. Passive heat sinks do not use any mechanical components.

final conclusion

Aluminum extrusions are versatile components used in a wide range of applications from construction to automotive to consumer products. They are produced by extruding aluminum through formed openings in a die, and the types of aluminum extrusions described above do not cover all types. If you want comprehensive information and prices on aluminum extrusions please contact – Hugh Aluminum, a manufacturer specializing in the design and production of aluminum extrusions!

Various types of aluminum extrusions are available here!

If you are looking for aluminum extrusions that can meet your project requirements, but you don’t have a professional team to help you, Hugh Aluminum is here to help! We are a large aluminum extrusion manufacturer with a factory with 600-1800 tons extrusion lines. In addition, we have anodizing, powder coating, CNC machining, welding and heat treatment capabilities. Our high quality aluminum extrusions have won the recognition of our customers, and we have exported to 40+ countries in the past 14 years, completing more than 600 construction projects.

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