Aluminium Section Extrusion Plant
An Aluminium Extrusion Plant is a specialized facility dedicated to the production of aluminium extrusions. Through advanced aluminium extrusion processes, aluminium ingots are transformed into long profiles with specific cross-sectional shapes. These extruded products are widely used across various industries, including construction, automotive, aerospace, electronics, and furniture manufacturing.
HTS-ALU, located in China, serves as an exemplary Aluminium Extrusion Plant, specializing in the production of aluminium profiles for windows, doors, architectural applications, and industrial uses, showcasing the advanced capabilities and extensive applications of aluminium extrusion technology.
Major Process Flow of Aluminium Extrusion Plant
The aluminium extrusion process involves several critical stages, combining advanced technology with precise operations to manufacture high-quality aluminium profiles. Below is an overview of the main process flow:
Aluminium Billet Preparation
The aluminium billet preparation process involves melting raw aluminium, removing impurities through degassing, and casting it into cylindrical billets via advanced Direct Chill (DC) casting technology. The billets are then homogenized to improve alloy uniformity and cut to required dimensions for extrusion.
HTS-ALU is equipped with high-efficiency melting furnaces, rotary degassers, precision DC casting lines, and homogenization systems, ensuring the production of high-quality billets that meet diverse industry demands.
Extrusion
The extrusion process involves heating aluminium billets to a specific temperature and forcing them through a steel die using a hydraulic extrusion press. This process shapes the aluminium into long profiles with a fixed cross-sectional shape, suitable for a variety of applications.
After extrusion, the profiles undergo straightening to correct any deformation and ensure dimensional accuracy. This step requires the use of profile straightening machines, which apply controlled mechanical force to align the profiles properly.
Different tonnages of extrusion presses produce profiles of varying sizes and weights:
- 200–800 tons: Produces small and lightweight profiles with a cross-sectional size of up to 100mm, such as electronic components, LED heat sinks, and decorative trim.
- 1,000–3,000 tons: Ideal for medium-sized profiles with a cross-sectional size of up to 250mm, including window and door frames, curtain wall profiles, and light industrial components.
- 4,000–6,000 tons: Capable of manufacturing larger profiles with a cross-sectional size of up to 500mm, such as structural beams, large tubes, and components for the automotive and construction industries.
- 8,000–10,000 tons: Designed for extra-large profiles with a cross-sectional size exceeding 500mm, used in heavy-duty applications like aerospace, maritime, and railway sectors.
8,000–10,000 tons: Designed for extra-large profiles with a cross-sectional size exceeding 500mm, used in heavy-duty applications like aerospace, maritime, and railway sectors.
HTS-ALU operates 40 production lines with extrusion presses ranging from small to large capacities, with the largest being a 6,000-ton press. This enables a versatile range of aluminium profile production to meet diverse industry needs.
Heat Treatment and Age Hardening
Heat treatment and age hardening are critical steps in the aluminium extrusion process to enhance the mechanical properties of the extruded profiles.
Rapid Cooling:
After extrusion, aluminium profiles are rapidly cooled using water spray quenching units, immersion tanks, or high-capacity air cooling systems. These are essential to stabilize the metal’s internal crystalline structure quickly and uniformly.Heat Treatment:
Based on the alloy type and application requirements, the profiles undergo specific heat treatment processes:- T5: Profiles are rapidly cooled after extrusion and naturally age-hardened. This requires temperature-controlled quenching systems and air circulation systems.
- T6: Profiles are artificially aged after rapid cooling in specialized aging ovenswith precise temperature controls (typically 160–200°C) to achieve maximum strength and hardness.
- T66: An advanced form of T6 treatment, requiring enhanced aging ovens with precise timing and temperature calibration to achieve improved properties like superior strength and toughness.
HTS-ALU is equipped with advanced production equipment for T5, T6, and T66 treatments, including high-efficiency water quenching systems, air quenching systems, and multiple aging ovens with precise temperature and timing controls, ensuring the production of high-quality aluminium profiles tailored to various industries’ requirements.
Surface Treatment
n their raw state, aluminium extruded profiles have a rough surface and lack aesthetic appeal. Surface treatment is essential to achieve decorative or functional requirements, and these processes rely on specialized equipment for optimal results:
Anodizing Tank Anodizing:
This process enhances corrosion resistance, provides a metallic sheen, and allows for coloring options (e.g., silver, black, champagne). It requires anodizing tanks, rectifiers, electrolyte systems, and coloring and sealing tanks to produce high-quality, durable, and visually appealing surfaces.Electrophoresis (Electrocoating):
Electrophoresis creates a smooth, scratch-resistant, and highly durable surface by applying an electrically charged coating layer over anodized aluminium. This process requires electrophoresis tanks, rectifiers, and advanced curing ovens. It delivers excellent weather and corrosion resistance, making it ideal for architectural and decorative applications.Powder Coating:
Powder coating involves spraying color powder onto the surface and curing it to create a protective and decorative layer. It requires electrostatic spray equipment, curing ovens, and pre-treatment tanks for cleaning and preparing the aluminium surface prior to coating. This process is particularly suitable for outdoor applications due to its durability.
Powder Coating lines Brushing & Polishing:
Brushing refines the surface texture, while polishing creates smoother, reflective finishes. These processes use automatic brushing machines, polishing lines, and abrasive equipment to deliver high-end, aesthetically pleasing finishes, ideal for luxury products or premium applications.Wood Grain Transfer:
The wood grain effect is achieved using heat transfer machines, which apply high-temperature technology to transfer patterns onto the aluminium surface. This treatment is especially popular in furniture manufacturing and requires base powder coating lines for primer application prior to wood grain printing.
HTS-ALU is fully equipped with state-of-the-art facilities to perform all the above surface treatment processes, including anodizing, electrophoresis, powder coating, brushing, polishing, and wood grain transfer. The company’s advanced capabilities enable it to deliver high-quality, aesthetically pleasing, and functional aluminium profiles that meet the diverse needs of industries such as construction, furniture, and consumer electronics.
Cutting and Precision Machining
After extrusion and straightening, the aluminium profiles go through cutting and precision machining processes to meet customer-specific requirements and ensure readiness for final applications.
Precision Cutting:
Extruded profiles can be cut to specific lengths according to customer needs (e.g., construction profiles, industrial components, or furniture fittings). This process requires the use of high-speed precision cutting machines or automatic saw linesfor clean, accurate, and efficient cutting. The equipment is capable of producing consistent results even for large-volume production.CNC Machining:
For intricate and complex manufacturing requirements, profiles undergo precise machining to achieve advanced designs or functionality. This includes CNC machining centers equipped for tasks such as drilling holes, tapping threads, milling, or creating other custom shapes. These machines provide high precision and repeatability, ensuring the finished profiles meet exact specifications with minimal deviations.
HTS-ALU utilizes precision cutting machines, automatic saw lines, and CNC machining centers to produce high-quality aluminium profiles for various industries.
Packaging
Packaging ensures aluminium profiles are protected during storage and transportation. Profiles are wrapped individually or in bundles with protective materials such as shrink wrap, foam, protective paper, or stretch film to prevent damage, moisture, or corrosion. Bundles are securely strapped and labeled with specifications for easy identification. Packaging can also be customized based on customer requirements, ensuring the profiles arrive in perfect condition.
Major Product Types of an Aluminium Extrusion Plant
An aluminium extrusion plant produces a wide variety of profiles to meet the needs of different industries. Below are some typical product types and their applications:
Customized Aluminium Profiles
- Features: Designed according to customer-specific cross-section shapes.
- Applications:
- Aerospace components, automotive parts.
- Commercial display racks, medical equipment parts.
Hollow Profiles
- Features: Tubular or profiles with internal cavities.
- Applications:
- Fuel pipelines, exhaust systems.
- Small architectural structures (e.g., balcony railings).
Decorative Aluminium Profiles
- Features: Specially treated surfaces for enhanced visual appeal.
- Applications:
- Home decorations (e.g., skirting boards, ceiling rails, wall edge trims).
- High-end furniture and display applications.
Industrial Aluminium Profiles
- Features: Focused on mechanical strength and durability.
- Applications:
- Frames for automation production lines, equipment frameworks.
- Industrial heat sinks, enclouse.
Customer Base of an Aluminium Extrusion Plant
An aluminium extrusion plant serves a diverse range of industries and customers due to the versatility and wide applications of extruded aluminium profiles. Typical customer groups include:
Construction and Architecture Companies
- Builders, contractors, and architects requiring aluminium profiles for doors, windows, curtain walls, and structural components.
Automotive and Transportation Industries
- Manufacturers of vehicles, trains, and aerospace equipment looking for lightweight yet strong components like frames, panels, and exhaust systems.
Industrial Equipment and Machinery Manufacturers
- Companies needing durable aluminium profiles for machine frames, automation systems, and heat sinks.
Electronics and Electrical Sector
- Producers of electronic devices and power systems, utilizing aluminium profiles for enclosures, heat dissipation systems, and components.
Furniture and Interior Designers
- Designers and manufacturers requiring decorative aluminium profiles for furniture, fixtures, partitions, and interior decorations.
Retail and Commercial Display Businesses
- Companies in need of customised aluminium profiles for display racks, shelves, signage, and advertising stands.
Medical and Healthcare Device Manufacturers
- Producers of medical equipment and devices requiring precision aluminium components for structures, frames, or specialty machinery.
Renewable Energy Sector
- Manufacturers of solar panels and wind turbines using aluminium profiles for frames, mounting systems, and structural components.
