Author: Procedure Name: Extrusion defects and

die correction
Procedure #: QP27

1 Document History

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Revision #: 01 Printing Date: 14-4-2008 Number of pages: 1of 12

Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

2 Objective:

 The objective of this document is to list common aluminum extrusion defects, their possible causes and corresponding ways of
correction. It also refers to photos of the defects to making the understanding and imagination of these defects easier.

3 Scope:

 The scope of this documents includes common defects of flat-face and porthole dies that may appear during the initial testing
on the press and also during the actual production.

4 Responsibility:

 Dies correction unit supervisor.

 Dies corrector.

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 2of 12

Author:
# Defect
1 Surface tearing or high surface
thinning
2 The beginning of the profile is
retracted from the middle
3 One side of the profile is advanced Photo 03
more than the other side
Or
Bending in the profile
4 For hollow rectangular shapes,
two opposite angles are less than
90o (acute) and the other two
opposite angles are more than 90o
(obtuse)
Revision #: 01 Printing Date: 14-4-2008
Procedure Name: Extrusion defects and
die correction
Procedure #: QP27
Photo # Cause
Photo 01 - High speed extrusion at certain
bearing surfaces.
- Poor feeding
Photo 02 The bearing length in middle of the
die is higher than required
-Variation in aluminum speed
-Variation in aluminum feed
- Very high difference in the profile
thickness which causes regions to cool
before other regions on the runout
table
Photo 04 Two opposite corners (or at least one
of them) are faster than the others
Number of pages: 3of 12
Correction/ Solutions
Flat Dies:
- Always, reduce the bearing to the
minimum.
- Increase the recess area to increase
aluminum feeding (or reduce feeding
of the other recesses)
- Decrease stem speed.
Porthole Dies:
- Always, reduce bearing to the
minimum.
- Increase the ports or welding chamber
area to increase aluminum feeding (or
reduce feeding the other ports/ welding
chambers)
- Decrease stem speed.
Reduce the bearing in the middle
- Modify aluminum feed by modifying
the recess, ports or welding chamber
- Reduce the bearing in the slow
(retracted) region.
- Polish rough bearings if they slow
aluminum
- Reduce the bearing in slow corners
- Since weld joints are most likely at
the corners, corrector may enlarge the
welding chamber at the slow corners.
- Slightly increasing the front undercut
Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

# Defect Photo # Cause Correction/ Solutions

5 Twisting of the profile (occurs Photo 05
most likely in the semi-hollow
then in the solid then in the hollow
dies)
6 Waviness in a surface (usually Photo 06
occurs in semi-hollow shapes and
tubes)
at the slow corners by making a small
radius in the mandrel.
Portion of the profile is faster than - Reduce the bearing length at the slow
other portions and a choke or relief regions.
exists in such a way that tends to twist - Increase the feeding of the slow
the profile. regions by modifying the recess,
Chock and relief may occur due to the piastrinas, ports, welding chambers or
following reasons: decreasing a bridge height.
1. Deflection in the milling
cutter.
2. Worn EDM electrode.
3. Wire cutting is not vertical
4. Error in manual finishing.
5. Wear of the die bearing.
- A surface is faster than the other - Reduce bearing lengths for the slow
surfaces (and speed difference is not surfaces.
enough to bend the profile or the cross - Increase the feeding of the slow
section is stiff and difficult to bend or surfaces.
the nature of the profile makes
bending difficult to occur like semi-
hollow shapes)

In hollow shapes (tubes), the middle

7 For hollow rectangular shapes,
two opposite surfaces are convex
of the surface is faster than the edges.
Photo 07 Two opposite surfaces are faster than
the other surfaces and therefore
putting them under compressive
stresses and causing them to buckle
and take a convex shape
- Reduce the speed of the fast faces.
- Cut from the bearing beginning of the
mandrel to make it starts with the die
plate bearing beginning
- At the middle of the convex faces (2/3

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 4of 12

Author:
# Defect
8 Convexity in the base of the U-
channels
9 Concaved surfaces
Note: it is recommended to keep
some concavity for the following
reasons:
1. For tubes, to protect the
surface from scratching on
the runout.
2. For U-channels, to
compensate for convexity
that appears in the surfaces
after stretching.
Revision #: 01 Printing Date: 14-4-2008
Procedure Name: Extrusion defects and
die correction
Procedure #: QP27
Photo # Cause
Photo 08 Wrong speeds
Photo 09 - In U-channels with embranchments
in the middle, the embranchments are
slow
- The mandrel bearing is longer than
needed at the exit side or the die plate
(CAP) bearing is shorter than needed
at the exit side
- In semi-hollow flat dies, the tongue
deflection is high and therefore the
deflection made a relief. This relief
orients the aluminum in a way that
causes bending and hence, concaved
Number of pages: 5of 12
Correction/ Solutions
the length in the middle), the corrector
may make a choke in the die plate
(CAP) to push (orient) aluminum
toward the center of the profile and
therefore causing a bending stress that
makes a counter effect against the
convexity.
- Increase the speed of the legs edges
- At middle of the base (2/3 the length
in the middle), make a choke to push to
inside and at the edges of base, make
chokes to push to outside. As a result, a
bending effect will develop to
eliminate the convexity.
- If there are embranchments in the
middle, slow them down and make
chokes to push the side legs out.
- Increase the speed of the
embranchments by reducing the
bearing length
- Increase the speed of the
embranchments by working in the
recess.
- Cut from the exit-side of mandrel
bearing to make it:
Case 1: new dies,
BM = BC + 1 and sometimes BM = BC + 0,
Case 2: old dies (deflection in the mandrel),
Weld on the entry side of the mandrel bearing
to increase it by about 1mm, and cut from the
Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

# Defect Photo # Cause Correction/ Solutions

surface. exit side of the mandrel bearing to reduce it by
- Feeding of a certain surface is not about 1mm.
Or
enough. Cut from the entry side of the die plate bearing
to reduce it by 1mm.
- For hollow rectangular profiles,
reduce bearing length of the slow
surfaces or increase aluminum feeding
by working in the ports and welding
chambers or increase feeding by
reducing bridge height.
- For the semi-hollow flat dies:
If the a/ b ratio < 2.7, make a choke in
the tongue.
If the a/b ratio > 2.7, do one of the
following:
1. Increase the thickness to reduce
the load and therefore reduce
deflection.
2. Make a taper in the tongue to
orient the aluminum in the
opposite direction.

- If feeding of the surface is not

10 Profile thickness is less than
required (for semi-hollow flat
dies)
Photo 10 Deflection in the tongue causes this
reduction in thickness
enough, increase feeding.
- Increase the die opening thickness.
- Reduce the tongue height to reduce
the direct load on the tongue.
- Feedback to the design department to
modify the design or use other design

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 6of 12

Author:
# Defect
11 In multiple-mandrel porthole dies,
tearing of the surfaces between
mandrels
12 Streaking (profile lines)
If it affects profile quality
Revision #: 01 Printing Date: 14-4-2008
Procedure Name: Extrusion defects and
die correction
Procedure #: QP27
Photo # Cause
Photo 11 - Since aluminum feeding is indirect,
feeding is poor
- Deflection of the mandrels toward
each others is high.
Photo 12 - A small burr in the bearing region
causes this streaking.
- The bearing is rough (the wire
cutting parameters was not suitable,
EDM was used to open the bearing
such as in bridge dies, …)
- Bad case hardening which leads to
high friction after extruding a certain
weight of aluminum profiles.
- If streaking appears in two or more
subsequent dies, oxides in the
container may exist.
- In case a high finish of the profile
(mirror image) was required and the
usual conditions in heating the die
were used (long heating period),
resulting in an oxide layer on the
bearing surface.
- Nitride layer thickness increases as a
Number of pages: 7of 12
Correction/ Solutions
types such as shut-off dies.
- Check bearing length and roughness.
If suitable, increase the size of the
welding chamber.
- Increase the feeding angles of the two
opposite surfaces that feed the required
region
- Check the surface roughness of the
ports, mandrel core and the welding
chamber. If rough, grind or polish it.
- Polish or file the bearing
- Repeat nitriding process (if not
suitable)
- Clean the container using the cleaning
disk.
- In case “mirror image” is required,
reduce heating duration of the die in
the oven or cover the bearing surface
with a graphite layer (spray, liquid)
before putting the die in the oven.
- After a certain number of extrusion
processes, polish the surface and re-
nitride the die.
- make the back undercut 90o and finish
it.
- Lubricate the right surface of the
shear knife and use the right amount of
lubricant and never use a lubricant
when high finish is required.
Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

# Defect Photo # Cause Correction/ Solutions

result of the repetitive nitriding. - Call maintenance department to align
Because of the speed variation (wear stem and liner (if needed)
rate variation) at different locations in
the bearing, the thickness of the layer
varies also. This results in a sharp
edge between the two layers which
may cause streaking or if it breaks
may cause streaking.
- Back undercut is not 90o or not
properly finished after the EDM
process.
- lubricating the wrong surface of the
butt shear knife, or using a large
amount of lubricant or using lubricant
when high finish (mirror image) is
required.
- Misalignment (eccentricity) of the
stem and liner which causes oxides to
enter inside the die.
13 Knob Photo 13 - At the joint in T-junctions, taper is - Increase the taper length if it is not
not gradual enough.
- the apparent surface was hit during - Try to make the knob gradual as
finishing. much as possible. (when finishing the
- The technician selects the wire die, polish the apparent surface last.
cutting initial point on a visible - Always make the wire cutting initial
surface point at a corner or internal (hidden)
- The wire breaks during wire cutting. surface
- A 90 degrees angle is less than 90 - If angle change is responsible for the
and thus making a knob at the knob, make a tapered recess or choke

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 8of 12

Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

# Defect Photo # Cause Correction/ Solutions

junction.
- Speed difference between the two
surfaces at the joint due to:
1. Wear in the die which
increases the thickness of a
certain surface.
2. Tongue deflection which
reduces the thickness of a
certain surface
3. ….
14 ‫عروق‬ Photo 14 If there is a groove in the design of the
(no mandrel of a porthole die:
available) Case1: lack of aluminum feeding of
the groove.
Case2: the groove is very thin or
bearing is longer than required and
therefore the groove is slow
15 Speed cracking Photo 15 Very high extrusion speed (high stem
speed)
16 )‫تنتيش (عادة يف منطقة الفرشاي‬ Photo 16 - Crack in the die
- Very sharp taper.
17 Disconnection of two subsequent Photo 17 - Bad welding in the recess because of
profiles on the runout (not the following:
available)  Depth of recess is not enough
 Billet temperature is not
enough for welding
 Butt thickness is high. This
stiff butt tends to snatch some
aluminum from the recess
& relief to orient aluminum, …
- If the thickness increases because of
wear in the mandrel, weld the region,
file and polish it (if possible)
- Reduce bearing length (to increase
speed).
- increase the front undercut (to
increase feeding)
- As the last solution, increase the
groove dimensions. (take the written
approval of the customer)
- reduce extrusion speed
- Close the crack
- Make the taper gradual
- Feedback to billet manufacturer
- Increase Recess depth
- Increase billet temperature
- Reduces butt thickness
- Feedback to die designer

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 9of 12

Author: Procedure Name: Extrusion defects and
die correction
Procedure #: QP27

# Defect Photo # Cause Correction/ Solutions

during shearing and therefore
reduces the aluminum depth in
the recess
- Press operator orders the billet early
or some problem causes delay (the
billet cools)

- Bad weldability of the aluminum

allow
18 Disconnection of the profile to Photo 18 - High working temperature - Reduce working temperature
small particles at the runout (not - Very high stem speed - Reduce stem speed
available)
19 Splitting of two perpendicular Photo 19 - Sharp angles - Make a radius and give feedback to
surfaces during shearing. - Anodizing chemicals dissolves the design department to modify similar
Note: customer may perform some existing radius designs
working operations on profile
including shearing
20 Sharp profile edges (safety issue) Photo 20 - Sharp edges in die design. - Increase radius
(not - Small radius in die design - Close cracks (if possible)
available) transforms into sharp edges because - If the problem cannot be solved, the
of die wear. die shall be scrapped (safety issue)
- Cracks formed at the sharp edges
21 Closeness of die opening for wide Photo 21 - Since the die is under compression - Increase the die opening thickness
profiles (high CCD) (in the longitudinal direction) and give feedback to the designer
deformation occurs in the lateral
direction. This deformation tends to
close the die opening because
deformation is restricted in the other
radial directions by the die ring.

Revision #: 01 Printing Date: 14-4-2008 Number of pages: 10of 12

Author:
# Defect
22 Deflection of mandrels’ heads in
multi-hole porthole dies
23 Delay in press pressure (load)
drop, &
The amount of the drop (in the
steady-state region) is less than
expected [as shown in the
load/pressure – ram displacement
curve]
24 Blisters (usually appears after
anodizing)
25 Bad weld joint in porthole dies
26 Difference in profile speed (length
on the runout) between die
openings
Revision #: 01 Printing Date: 14-4-2008
Procedure Name: Extrusion defects and
die correction
Procedure #: QP27
Photo # Cause
Photo 22 - Aluminum flow (speed) in the die
centre is higher which tends to deflect
the mandrels toward the die perimeter
- The high pressure on the mandrel.
Photo 23 - Long bearing
- The areas of the ports, recesses are
small
- Die internal surfaces are rough
- The mandrel is very thick and
therefore the contact area with
aluminum is high which increases the
friction
Photo 24 - Aluminum Oxides in the container
Photo 25 - Welding is not effective in the
welding chamber
- Bad weldability of the aluminum
alloy.
Photo 26 - Difference in aluminum flow
- Misalignment between the container
and die.
- The distance of the opening centroid
Number of pages: 11of 12
Correction/ Solutions
- Compensate for die deflection (by
welding on the centre side of the
mandrel and machine the other side)
- Increase the front undercut of the
mandrel in the outside portion to
increase flow of aluminum.
- Feedback to design department
- Reduce bearing
- Increase ports, recesses areas
- Grind and polish the die internal
surfaces
- Reduce Mandrel thickness to reduce
friction force and increase the backer
thickness to retain the total thickness
- Remove the oxide layer from the
container using the cleaning disk
- Increase the depth of the welding
chamber
- Increase the bridges (left and right)
angles and reduce nose radius
- Return the die to die manufacturer to
increase the welding chamber width
using the EDM machine.
- Reduce the bearing of the slow
opening
- Increase the feeding of the slow
openings
- Grind and polish for fine tuning of
Author:
# Defect
27 Aluminum flare between the die
stack and the liner (container) face
28 Bubbles inside the extrusion
which may split the profile into
two pieces
Revision #: 01 Printing Date: 14-4-2008
Procedure Name: Extrusion defects and
die correction
Procedure #: QP27
Photo # Cause Correction/ Solutions
from the die centre is not the same for speed difference.
all openings.
Photo 27 - Deformation in the die needs high - Improve flow smoothness, increase
force because of the nature of recess/ port area, grind and polish, …
deformation. This high forces retracts - Surface grinding to improve die face
the container and therefore aluminum straightness
flows outside (between the container - Put spacers between die components
and the die ring face) to reach the total thickness required
- a problem in die face straightness. - Maintain the liner
- Total die thickness is less than - Increase the sealing pressure
required - Feedback to billet supplier to improve
- Cracking of the liner or the liner face the billet quality.
straightness is not as needed
- Low sealing pressure (a problem in
the sealing pump)
- Very soft aluminum
- A problem in the pressure pad/ plate
- press misalignment
Photo 28 Entrapped air in the aluminum profile - Maintain the liner
during extrusion due to:
1. Wear in the internal surface of - Maintain the gas cycle system
the liner.
2. The gas cycle system used to
remove entrapped air is not
working properly.
Number of pages: 12of 12