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Notably, extrusion is the primary technique used for making these designs of aluminum profiles.
It is quite a detailed process, which starts with designing every profile.
The designing process involves documenting specific functions of the profiles, shapes, dimensions, and material specifications.
Machinability, finishing, and durability are also other crucial aspects considered during design process.
After completing the designing process using computer software, steel die for producing the design is also produced.
It involves using a hydraulic press to push the billet through the die to create the desired window or door aluminum profile.
The actual extrusion process involves the following details;
A typical extrusion billet comes in form of a solid or hollow cylindrical shape.
In most instances, the billets are cast in an electric arc furnace with aluminum scraps. They are cut into ideal sizes to match the required profile length.
Preheating of the billet and extrusion die takes place before the actual extrusion process starts. The essence is to soften the billet to allow it to be forced through the die?
While at it, you should be careful not to overheat it to a melting point, often about 1200° F. An ideal heating point should be approximately 900° F.
This stage entails actual extrusion process, which begins immediately after the ram starts exerting pressure on the billet. Extrusion machine features a hydraulic press, which can exert pressure of up to 15,000 tons on the billet and die.
Ideally, the more the pressure, the greater the extrusion it can produce. The machine applies the initial pressure crushing the billet against the die.
This die becomes shorter and wider until it can never expand anymore due to container wall restriction. That’s when the aluminum material starts forcing its way out through the die’s orifice and form a particular profile.
Length of an extruded profile is dependent on billet and die opening sizes. There is a runout conveyor, which supports the formed extrusion profile as it comes out of the extrusion press.
Extruded profile may be passed into a cooling bath as it comes out depending on the type of alloy. Cooling is a critical step since it retains adequate metallurgical properties in the metal.
After cooling, you can use the stretcher to stretch these profiles and straighten any twisted part.
These profiles are taken through a special surface treatment module to attain the ideal surface finishing. It varies based on user preference and actual setting of the windows and doors.
After special finishing operations, you may cut the profiles into shorter lengths depending on the actual dimensions of the windows and doors. While at it, you may use special devices to clamp the profiles, cut and transfer them to a conveyor.
This process helps to strengthen the aluminum profiles for windows and doors. You can attain natural aging by exposing the profiles to room temperature.
Alternatively, you can go for artificial aging in an oven. Essentially, the aging process design is to ensure there is uniform precipitation of fine particles through the metal.
It allows the metal to obtain full strength, elasticity, and hardness.