As one of the manufacturing methods of products and components, aluminum extrusion can be classified as “equal material” or forming manufacturing. This manufacturing process is different from 3D printing and CNC machining.It does not increase or decrease raw materials during the manufacturing process. Aluminum alloy is the most common material used for aluminum extrusion, because aluminum alloy is extremely malleable, allowing it to be easily extruded in a variety of desired cross-sectional shapes, and the extruded products and parts can still hold up well its mechanical properties of these extruded profiles can be greatly improved in strength and hardness as well as appearance even after specific surface treatments.
JHMOCKUP is keen to study the aluminum extrusion technology and apply it to low-volume production. Based on the complexity of products and the integration difficulty of the project of customers', we can make rapid response and execution. While ensuring product quality, we will scientifically analyze the entire manufacturing process allows reasonable optimization of manufacturing costs and production efficiency, and ultimately helps customers complete orders.
It is necessary to know about Extrusion in prior to touching Aluminum extrusion.Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work materials that are malleable, because the material encounters only compressive and shear stresses. It also creates excellent surface finish and gives considerable freedom of form in the design process.Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). It can be done with hot or cold material. Commonly extruded materials include metals, polymers, ceramics, concrete, modelling clay, and foodstuffs. Products of extrusion are generally called extrudates. So now we mainly share some knowledge about Aluminum extrusion.
To complete the aluminum extrusion, you need to have the necessary hardware conditions, such as extruding devices/ extrusion machines,dies and raw materials,aluminum alloy that is used to extrude into extrudates. We will spend more time introducing knowledge about extruding equipment/machines later. First of all,we will be aware of what kind of aluminum alloy can be used for extrusion fabrication.
JHmockup adopts three primary aluminum alloy material mainly coming from 6000 series to accomplish aluminum extrusion manufacturing at our rapid prototyping manufacturing center. Certainly there are others alloy materials can be used for extrusion from aluminum family,here we just introduce three key kinds of aluminum:Aluminum alloy 6005, Aluminum alloy 6063 and Aluminum alloy 6463.
Based on greater strength and better durability of structural 6000 series aluminum alloys like Aluminum alloy 6005, there are more and more parts and products have been made by extrusion. The particularity of this aluminum alloy can be employed in designs requiring super quality corrosion resistance and moderate strength. Each alloy has a range of various properties, including its performance during extrusion, machining and finishing. By different elements adding to aluminum, we can be in further prevent corrosion by design and create superior results when choosing an extruded aluminum alloy.
Aluminum Alloy 6005 material has excellent extrusion properties. Because it contains a large amount of silicon element so that it can reduce the melt temperature and improve its extrusion ability. It also has similar minimum tensile and yield strengths to aluminum 6061 alloy, but is easier to be machined and has higher strength properties. Aluminum Alloy 6005 also has certain flexure/bending properties, which makes it not the best choice for applications that may be subject to overload or shock. This alloy can be welded and fabricated by other means, but the heat will reduce the strength, so any unique function is best accomplished through an aluminum extrusion design rather than a secondary operation.
Typical material properties for aluminium alloy 6005 include:
>Density: 2.70 g/cm3, or 169 lb/ft3.
>Young's modulus: 69 GPa, or 10 Msi.
>Ultimate tensile strength: 190 to 300 MPa, or 28 to 44 ksi.
>Yield strength: 100 to 260 MPa, or 15 to 38 ksi.
>Thermal Expansion: 23 μm/m-K.
Common applications for 6005 aluminum alloy include in ladder structures,automotive industry,seamless and structural tubes/pipes,structural applications,etc.,
Aluminum Alloy 6063 is one of the most widely available options for aluminum extrusion, which provides a high-quality finish and is an excellent choice for extrusion. Alloy 6063 is used to design as custom and standard aluminum extrusion, as well as seamless tubes, structural tubes&pipes, radiators/heat-sinks and more.
Due to its electrical conductivity and other properties of aluminum, alloy 6063 is also a great choice for electrical tubing and applications. Aluminum 6063 has excellent resistance to corrosion so it can be engineered to prevent corrosion, in which including stress corrosion cracking, in terms of the heat treated condition.
It is also an excellent candidate for secondary operations and works beautifully with glossy finishing options including color, clear, impregnated/dipping and hard coat. These finishes can be used for aesthetic, functional and protective reasons, depending on the intended use of the finished extrusion profile design.
Typical material properties for aluminium alloy 6063 include:
The mechanical properties of 6063 depend greatly on the temper, or heat treatment, of the material.So here are some typical conditions for reference.
>Un-heat-treated 6063 has maximum tensile strength no more than 130 MPa (19,000 psi), and no specified maximum yield strength. The material has elongation (stretch before ultimate failure) of 18%.
>T1 temper 6063 has an ultimate tensile strength of at least 120 MPa (17,000 psi) in thicknesses up to 12.7 mm (0.5 in), and 110 MPa (16,000 psi) from 13 to 25 mm (0.5 to 1 in) thick, and yield strength of at least 62 MPa (9,000 psi) in thickness up to 13 millimetres (0.5 in) and 55 MPa (8,000 psi) from 13 mm (0.5 in) thick. It has elongation of 12%.
>T5 temper 6063 has an ultimate tensile strength of at least 140 MPa (20,000 psi) in thicknesses up to 13 millimetres (0.5 in), and 130 MPa (19,000 psi) from 13 mm (0.5 in) thick, and yield strength of at least 97 MPa (14,000 psi) up to 13 millimetres (0.5 in) and 90 MPa (13,000 psi) from13 to 25 mm (0.5 to 1 in). It has elongation of 8%.
>T6 temper 6063 has an ultimate tensile strength of at least 190 MPa (28,000 psi) and yield strength of at least 160 MPa (23,000 psi). In thicknesses of 3.15 millimetres (0.124 in) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%.
Common applications for 6063 aluminum alloy include:construction materials like frames of window and door structures,heat-sinks,irrigational system pipe and tube,hand rails and furniture,electrical conduit and other components,architecture products etc.,
Al-6463 is an aluminum alloy wrought aluminum magnesium silicon series (6000 or 6xxx series). It's related to the 6063 aluminum alloy (the Aluminum Association's name differs only by the second number, a variation of the same alloy), but unlike 6063, it doesn't usually use any process other than extrusion. It is usually heat treated to produce a temper with higher strength but lower ductility. Like the 6063, it is often used for architecture or building applications.
When alloy 6463 extruded, the extrudates can be into bars, rods, tubes,wire, and others profiles according to the desig purpose.Composed of approximately 98% aluminum and small amounts of copper, iron, magnesium, manganese, silicon, and zinc, the properties of 6463 aluminum alloy include high density and yield strength, as well as a fair amount of tensile and yield strength.
Typical material properties for aluminium alloy 6463 include:
>Density: 2.69 g/cm3, or 168 lb/ft3.
>Young's modulus: 70 GPa, or 10 Msi.
>Ultimate tensile strength: 130 to 230 MPa, or 19 to 33 ksi.
>Yield strength: 68 to 190 MPa, or 9.9 to 28 ksi.
>Thermal expansion: 22.1 μm/m-K.
There are three main categories of extruded shapes:
The design of the extruded profile has a large impact on the ease of extrusion. The maximum size of the extrusion is determined by finding the smallest circle that fits the cross-section, which is called the circumcircle. This diameter, in turn, controls the size of the die required, which ultimately determines whether the part will fit in a given press. For example, a larger press can handle 60 cm (24 in) diameter outer circles of aluminum and 55 cm (22 in) diameter round steel and titanium.
The complexity of an extruded profile can be roughly quantified by calculating the form factor, which is the surface area produced per unit mass extruded. This affects tooling costs as well as production speed. Thicker slices often require increased slice size. In order for the material to flow properly, the length of the legs should not exceed ten times their thickness. If the sections are not symmetrical, the adjacent sections should be as close to the same size as possible. Sharp corners should be avoided; aluminum and magnesium should have a minimum radius of 0.4 mm (1/64 in.), steel corners should be 0.75 mm (0.030 in.), and rounded corners should be 3 mm (0.12 in.). The table below lists the minimum sections and thicknesses for various materials.
In a word,Aluminum Extrusion plays an important role of manufacturing process and is also a significant technique in terms of forming products and parts production, JHmockup welcome you bring design and demands via submitting technical files or details information on our website in 24 hours.
In this new era of great changes, many things around us are constantly improving and perfecting. Only technological products that are constantly innovating and changing are more popular. That is to say, our product technology rapid prototyping has a very high speed and efficiency, product production effect is very good. Ming, do not stick together, so how does this rapid prototyping technology compare to traditional technology? Today we’ll take a look.
The rapid prototyping technology adopted by the rapid prototyping device can adapt to the difficulty of manufacturing and processing of various materials in our life, and can obtain excellent materials and structural properties of parts.
As mentioned above, the rapid prototyping technology of materials involves materials, forming methods and structural forms of parts. The essence of rapid prototyping mainly includes the chemical composition of the forming material, the physical properties of the forming material (such as powder, wire or foil) (melting point, thermal expansion coefficient, thermal conductivity, viscosity and fluidity). Only by recognizing the characteristics of these materials can we choose the right material compared with the traditional rapid prototyping technology. What are the characteristics of rapid prototyping technology?
3d printing material rapid prototyping technology mainly includes material density and porosity. In the production process, can meet the performance requirements of molding material microstructure, molding material precision, parts precision and surface roughness, molding material shrinkage (internal stress, deformation and cracking) can meet the specific requirements of various rapid prototyping methods. The precision of the product will directly affect the structure of the product, the roughness of the surface of the product will affect whether there are some defects on the surface of the product, and the shrinkage of the material will affect the precision requirements of the product in the production process.
Rapid prototyping technology for the products produced. It also ensures that there is no big gap between what is produced and what is put on the market. Material rapid prototyping technology mainly includes material density and porosity. In the production process, can meet the performance requirements of molding material microstructure, molding material precision, parts precision and surface roughness, molding material shrinkage (internal stress, deformation and cracking) can meet the specific requirements of various rapid prototyping methods. The precision of the product will directly affect the structure of the product, the roughness of the surface of the product will affect whether there are some defects on the surface of the product, and the shrinkage of the material will affect the precision requirements of the product in the production process.
Mold manufacturing rapid prototyping technology also plays an important role in the increasingly competitive market economy, mold manufacturing rapid prototyping technology also plays an important role, is an important part of the advanced manufacturing technology group. It focuses on computer aided design and manufacturing technology, laser technology and material science and technology, in the absence of traditional mold and fixture, quickly create arbitrary complex shape and have a certain function of the 3D entity model or parts, about the cost of new product development and mold manufacturing, repair. Section is used in aviation, aerospace, automotive, communications, medical, electronics, household appliances, toys, military equipment, industrial modeling (sculpture), architectural models, machinery industry and other fields. In the mold manufacturing industry, the rapid prototyping made by rapid prototyping technology is combined with silica gel mold, metal cold spraying, precision casting, electrocasting, centrifugal casting and other methods to produce molds.
So what are its characteristics? First, it adopts the method of increasing materials (such as coagulation, welding, cementation, sintering, aggregation, etc.) to form the required parts appearance, because of the RP technology in the process of manufacturing products won’t produce waste cause the pollution of environment, so in today’s modern pays attention to the ecological environment, this also is a green manufacture technology. Secondly, it has solved many problems in traditional processing and manufacturing for laser technology, numerical control technology, chemical industry, material engineering and other technologies. The wide application of rapid prototyping technology in China has played a supporting role in the development of manufacturing enterprises in China, enhanced the rapid response ability of enterprises to the market, improved the competitiveness of enterprises, and also made a significant contribution to the national economic growth.
Advantages of 3D printing prototypes
1. With good complex manufacturing capability, it can complete manufacturing difficult to be completed by traditional methods. The product is complex, and only through multiple rounds of design – prototype machine production – test – modification design – prototype machine reproduction – re-test process, through the prototype machine repeated test can timely find problems and correction. However, the output of the prototype is very small, and it takes a long time and high cost to adopt the traditional manufacturing method, resulting in a long development cycle and high cost.
2. Low cost and fast speed of small batch manufacturing can significantly reduce the development risk and shorten the development time. 3D printing ingot casting with planks do not need to traditional manufacturing mode, system, mold and die forging process, can rapid prototype production, low cost, and digital, the entire production process can be modified at any time, at any time, in a short time, a large number of verification test, thus significantly reduce the risk of developing, shorten the development time, reduce the development cost.
3. High material utilization, can effectively reduce the production cost. The traditional manufacturing is “material reduction manufacturing”, through the raw material billet cutting, extrusion and other operations, remove the excess raw materials, processing the required parts shape, the processing process of the removal of raw materials difficult to recycle, the waste of raw materials. 3D printing only adds raw materials where it is needed, and the material utilization rate is very high, which can make full use of expensive raw materials and significantly reduce the cost.
Customized service of products design and manufacturing is our key core capability. Different product customizations have different customization standards, such as partial product customization, overall product customization, partial customization of product hardware, partial customization of product software, and customization of product electrical control. The custom manufacturing and fabrication service is based on a comprehensive understanding of the customer’s product function, material strength, material processing technology, surface treatment, finished product assembly, performance testing, mass production, cost control and other factors before comprehensive evaluation and program design. We provide a complete supply chain solution. Probably your product does not use all the services at the current stage, but we will help you consider the scenario that may be needed in the future in advance, which is what differentiates us from other prototype suppliers.