ALUMINIUM EXTRUSION

[EIRI/EDPR/3702] J.C.: 1789XL

INTRODUCTION

Extrusion is a plastic deformation process in which a block of metal (billet) is

forced to flow by compression through the die opening of a smaller cross-sectional
area than that of the original billet Extrusion is an indirect-compression process.
Indirect-compressive forces are developed by the reaction of the workpiece (billet)
with the container and die; these forces reach high values. The reaction of the
billet with the container and die results in high compressive stresses that are
effective in reducing the cracking of the billet material during primary breakdown
from the billet. Extrusion is the best method for breaking down the cast structure
of the billet because the billet is subjected to compressive forces only.

Extrusion can be cold or hot, depending on the alloy and the method used. In hot
extrusion, the billet is preheated to facilitate plastic deformation

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Factors Affecting Extrusion

Shape is a determining factor in the part's cost and ease with which it can be
extruded. In extrusion a wide variety of shapes can be extruded, but there are
limiting factors to be considered. These include size, shape, alloy, extrusion ratio,
tongue ratio, tolerance, finish, factor, and scrap ratio. If a part is beyond the limits
of these factors, it cannot be extruded successfully.

The size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap
ratio are interrelated in the extrusion process as are extrusion speed, temperature
of the billet, extrusion pressure and the alloy being extruded.

In general, extrusion speed varies directly with metal temperature and pressure
developed within the container. Temperature and pressure are limited by the alloy
used and the shape being extruded. For example, lower extrusion temperatures
will usually produce shapes with better quality surfaces and more accurate
dimensions. Lower temperatures require higher pressures. Sometimes, because of
pressure limitations, a point is reached where it is impossible to extrude a shape
through a given press.

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The preferred billet temperature is that which provides acceptable surface and
tolerance conditions and, at the same time, allows the shortest possible cycle
time. The ideal is billet extrusion at the lowest temperature which the process will
permit. An exception to this is the so-called press-quench alloys, most of which
are in the 6000 series. With these alloys, solution heat-treat temperatures within
a range of 930°-980° F must be attained at the die exit to develop optimum
mechanical properties.

At excessively high billet temperatures and extrusion speeds, metal flow becomes
more fluid. The metal, seeking the path of least resistance, tends to fill the larger
voids in the die face, and resists entry into constricted areas. Under those
conditions, shape dimensions tend to fall below allowable tolerances, particularly
those of thin projections or ribs.

Another result of excessive extrusion temperatures and speeds is tearing of metal

at thin edges or sharp corners. This results from the metal's decrease in tensile
strength at excessively high-generated temperatures. At such speeds and
temperatures, contact between the metal and the die bearing surfaces is likely to
be incomplete and uneven, and any tendency toward waves and twists in the
shape is intensified.

As a rule, an alloy's higher mechanical properties means a lower extrusion rate.

Greater friction between the billet and the liner wall results in a longer time
required to start the billet extruding. The extrusion ratio of a shape is a clear
indication of the amount of mechanical working that will occur as the shape is
extruded.

Extrusion Ratio = area of billet/area of shape.

When the extrusion ratio of a section is low, portions of the shape involving the
largest mass of metal will have little mechanical work performed on it. This is
particularly true on approximately the first ten feet of extruded metal. Its
metallurgical structure will approach the as-cast (coarse grain) condition. This
structure is mechanically weak and shapes with an extrusion ratio of less than
10:1 may not be guaranteed as to mechanical properties.

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 CONTENTS

INTRODUCTION
FACTORS AFFECTING EXTRUSION
ADVANTAGES OF THE EXTRUSION PROCESS
TYPES OF EXTRUDED PROFILES
CLASSIFICATION OF ALUMINIUM EXTRUSION
(A) DIRECT (FORWARD) EXTRUSION
(B) INDIRECT (BACKWARD) EXTRUSION
(C) HOT EXTRUSION
(D) COLD EXTRUSION AND WARM EXTRUSION
PROPERTIES
PROPERTIES OF ALUMINIUM
WEIGHT
STRENGTH
LINEAR EXPANSION
MACHINING
FORMABILITY
CONDUCTIVITY
JOINING
REFLECTIVITY
SCREENING EMC
CORROSION RESISTANCE
NON-MAGNETIC MATERIAL
ZERO TOXICITY
USES AND APPLICATION
USES
APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS
DESCRIPTION OF PROCESS
MANUFACTURING PROCESS OF ALUMINIUM INGOT
(1) SCRAP PRETREATMENT
METHODS OF PRETREATMENT
(A) COMMINUTION
(B) CLEANING
METHODS OF CLEANING
(I) MECHANICAL CLEANING

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(II) PYROMETALLURGICAL CLEANING
(III) HYDROMETALLURGICAL CLEANING
(C) SORTING
METHODS OF SORTING
(I) MAGNETIC SEPARATION
(II) AIR SEPARATOR
(III) EDDY CURRENT
(IV) DENSE MEDIA SEPARATOR
(V) HAND SORTING
(VI) HOT CRUSH
(VII) INNOVATIVE SORTING SOLUTIONS
(D) DECOATING
(2) CHARGING AND FLUXING
CLASSIFICATION OF FLUXES FOR MELTING ALUMINUM
(A) COVER FLUXES
(B) DROSSING FLUXES
(C) CLEANING FLUXES
(D) WALL CLEANING FLUXES
(E) DEGASSING FLUXES
(F) GRAIN REFINERS
(G) SILICON MODIFIERS
(H) DEMAGGING FLUXES
(3) MELTING PROCESS
TEMPERATURE CONTROL
SKIMMING
ALLOYING
(4) DEGASSING (MELT TREATMENT)
(5) INGOT CASTING
(6) QUALITY CONTROL
(5) EMISSIONS AND CONTROLS
(A) SCRAP PRETREATMENT EMISSIONS
(B) SMELTING/REFINING EMISSIONS
(6) SHIPMENT
EXTRUSION PROCESS
(1) BILLET PREHEATING
TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE
ALUMINUM ALLOYS
TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS
(2) EXTRUSION
(3) QUENCHING
(4) STRETCHING
(5) CUTOFF
(6) ARTIFICIAL AGING
TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS

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(7) INSPECTION AND TESTING
EXTRUSION MATERIALS INSPECTION
ALUMINUM ALLOY CHECK
EXTRUSION DYE CHECK
ADDITIVES CHECK
EXTRUSION VISUAL INSPECTION
VISUAL DEFECTS CHECK
COLOR AND GLOSSINESS CHECK
DIMENSIONAL INSPECTION
COATING AND FINISHING CHECK
WEIGHT AND DENSITY CHECK
EXTRUSION PERFORMANCE INSPECTION
TENSILE TEST
WELDABILITY CHECK
WORKABILITY CHECK
CORROSION RESISTANCE
FLAMMABILITY TESTING
HARDNESS TEST
WEATHERING RESISTANCE TESTING
ABRASION RESISTANCE
CHEMICAL RESISTANCE
PLANT AND MACHINERY
EXTRUSION PRESS
DESCRIPTION OF EXTRUSION PRESS
PROCESS FLOW CHART
(A) FOR INGOT
(B) FOR EXTRUSION
MARKET SURVEY
THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS
ALUMINIUM EXTRUSIONS THE PROS AND CONS
THE PLAYERS
THE FUTURE
SPREADING AWARENESS
THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY
FUTURE OUTLOOK
CHALLENGES IN THE INDIAN EXTRUSIONS MARKE
RISKS AND AREAS OF CONCERN
EXPORT DATA OF ALUMINIUM EXTRUSION
IMPORT DATA OF ALUMINIUM EXTRUSION
PLANT LAYOUT
SUPPLIERS OF ALUMINIUM EXTRUSION SECTIONS
SUPPLIERS OF ALUMINIUM PROFILE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM SCRAP

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SUPPLIERS OF SILICON POWDER
SUPPLIERS OF IRON POWDER
SUPPLIERS OF COPPER POWDER
SUPPLIERS OF MAGNESIUM POWDER
SUPPLIERS OF NICKEL POWDER
SUPPLIERS OF ZINC POWDER
SUPPLIERS OF LEAD POWDER
SUPPLIERS OF TIN POWDER
SUPPLIERS OF PACKING MATERIAL
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF OIL AND GREASE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CRUCIBLE FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF SILICON CARBIDE CRUCIBLE
SUPPLIERS OF SHEREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGENETIC SEPARATOR
SUPPLIERS OF CASTING LADDLE
SUPPLIERS OF SPECROMETER
SUPPLIERS OF POROSITY TESTING MACHINE
SUPPLIERS OF ALUMINIUM EXTRUSION PLANT
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 10 MT/Day

Land & Building (10,000 sq.mt.) Rs. 7.38 Cr
Plant & Machinery Rs. 5.94 Cr
Working Capital for 2 Months Rs. 6.52 Cr
Total Capital Investment Rs. 20.48 Cr
Rate of Return 43%
Break Even Point 47%

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