How to make aluminum profiles
Aluminum profile. It is almost always an extruded aluminum profile.. Much less frequently used other types of aluminum profiles, for example, bent or rolled.
Figure 1.7 – The share of finished products and process waste
from extrusion aluminum ingot (column) 
Output of finished products from aluminum ingot-pillar:
- 75 % – ready-made profiles;
- 4,5 % – scrap in the manufacture of aluminum products from aluminum profiles;
- 4,5 % – blanks for heating matrices; matrix crimping, pressing defects;
- 11 % – waste of crumpled ends of profiles after stretching machine;
- 4 % – press residues; 1 % – Waste hot cutting the workpiece to the column
Elements and details of structures, machines and products
Each aluminum profile has its purpose, their properties and characteristics. If it's just a decorative element, the main purpose of which - to be beautiful, looks nice, its main characteristic that - good surface quality, its uniform color decorative coating, powder or anode.
If set for aluminum profile, e.g. - matt colorless anodic coating, it should be a really matt. This is the "haze" must be perfectly homogeneous when viewed from a given distance and at a predetermined angle, without any visible bands, and other visual surface discontinuities. To ensure that all, necessary to apply a special aluminum alloy with a chemical composition, special technology of its manufacture and its special surface treatment technology.
Aluminum profiles, as elements bearing construction or other structures, require special attention to their mechanical characteristics:
- tensile strength,
- ductility limit,
- reduction of area,
- tough properties.
In this case, important to choose the correct alloy, its condition (degree of autofrettage or heat treatment), as well as the required dimensional accuracy during manufacture.
In other types of profiles, we must take into account such properties, as corrosion resistance in the environment, which will work profile, sometimes - conductivity or heat resistance.
Blanks for drawing, cold pressing and forging
Moreover, Extruded aluminum profiles are used as starting templates for such aluminum processing techniques like dragging, cold pressing and forging.
Alloys of aluminum profiles
Extruded aluminum profiles can be manufactured from a large number of alloys in different states in order, to meet the requirements of various fields of application - from household goods to the space launch vehicles.
Basically, from any deformable aluminum alloy (and even casting) one way or another it is possible to extrude an aluminum profile. However, metal flow through the holes and cavities of the matrix at high temperature compression requires special characteristics of the flow, so that the metal:
- filling all holes at the outlet of the matrix with the same high speed,
- I provide the desired microstructure,
- reaches a predetermined strength and other properties,
- shaped optimal surface quality.
Therefore, special aluminum alloys are being developed specifically for pressing (extrusion). The chemical composition of these alloys is optimized in this way., that they are the most suited to the conditions of the process of pressing and ensure the required quality of molded products.
In world practice, aluminum profiles from alloys 6xxx series give more 75 % the volume of all sections.
The most popular aluminum alloy profiles – these are alloys:
- 6060/6063 (AD31) and
gaining popularity “more construction” alloys
- 6005 and
- 6082 (AD35).
Brand series aluminum 1xxx, for example, 1100, used for parts and products, which is no requirement for strength. They are best compacted – They have the highest compressibility.
3xxx series of alloys, for example, alloy 3103 pipe for compressed fluid lines.
other alloys, are more likely to apply for the production of profiles - is “Duran”:
- 7005(1915) and
Alloy Compressibility: Compression Ability
The minimum thickness of the profile wall
Effect complexity cross-sectional profile of the alloy 6063 the normal minimum wall thickness /
Diameter of the circle described Profile
Generalized size aluminum profile is circle diameter, describing its cross-section (figures 3.1 and 3.2). This parameter is called the "circumscribed circle diameter".
The diameter of the circumscribed circle (OCD) is really related to the complexity of extrusion of an aluminum profile. During pressing, the metal tends to flow through different parts of the matrix at different speeds: the farther from the workpiece axis, the slower. therefore, the greater the OED, the harder it is to control the size of the aluminum profile.
When pressing large and thin profiles, special, if these thin wall profiles on the periphery of the matrix, you must take special precautions, to metal flow was uniform around the cross section profile. Therefore, with increasing PEO all standards for aluminum profiles reduce the requirements for tolerances geometrical dimensions.
Figure 3.2 – round billet
Types of aluminum profiles
Existing standards for aluminum profiles – for example, Russian GOST 22233-2018 and GOST 8617-91, European EN 755-9 и EN 12020-2 – subdivide the entire range of aluminum profiles into various types:
- hollow profiles and
- solid profiles, and
- S- and U-shaped profiles, or "open-end".
The hollow profile
By definition, these standards are hollow aluminum profiles - those, which have a cross-section at least one closed cavity.
Solid aluminum profiles do not have closed cavities.
Figure 4.2 – Solid profile 
Solid matrices have one or more holes and intended for the manufacture of extrusions without cavities. The hole in the solid matrix is exactly the same cross-section of the molded article of aluminum.
Profile with an open end
"Open End" can be like a hollow, and have a solid profile. For these three types of profiles are given different requirements for tolerances geometrical dimensions.
Semi-enclosed and semi profiles
Hollow aluminum profiles include, including, and profiles with so-called semi-closed (half-open) cavities. Often profiles of this type are called semi-closed (half-open). They are partially closed cavity, for example, circle or rectangle, with an entrance to it from one side (figure 6).
Not every partially closed cavity transforms the profile from a solid semi-closed one: its area A must be significantly larger than the square of the width of its entrance b (A > b), depending on the width of the entrance - in 2,0-4,5 times (cm. Figure 6).
Hollow and semi-enclosed aluminum profiles are combined in one view, because they are made on the so-called "hollow" dies (figures 7 and 8). Hollow dies are of three types:
profiles, manufactured in such matrices, have one or more longitudinal welds due to the metal flow around the bridges, that support mandrel. The mandrel determines the internal profile contour. After passing these bridges, metal matrix before exiting again welded in the welding chamber. Welding occur due to high pressure and high temperature. Solid profiles are compressed on a continuous matrix - steel rims with one or more holes with the same cross-section, and that the pressing profile.
Figure 7 – Combined die for pressing semi-closed (half-open) profiles
Figure 8- Combined matrix for pressing hollow profiles
Level of difficulty of aluminum profiles
Each type of profiles – continuum, and semi-hollow – They differ in the types of complexity of their cross-section. This complexity is evaluated by the aluminum profile form factor.
Aluminum profile shape factor is calculated as the area of all surfaces, formed in the pressing unit mass of metal. obviously, that this factor is directly proportional to the length of the cross-sectional perimeter. The shape factor affects the performance of the profile molding, as well as the cost of production and maintenance of matrices. Therefore, it is frequently used presser-makers as a basis for setting prices and the profile gives developers profiles specific tool for comparing alternatives developed aluminum profiles.
Classification of complexity of aluminum profiles
Classification of types of extruded aluminum profiles according to the complexity of their manufacture is as follows. Types of difficulty from A to N are arranged in order of increasing complexity. Each type is illustrated by several examples.
The complexity of pressing increases in the following order of profile types:
- Bars – simple or profile.
- Standard aluminum extrusions and simple solid profiles,
- Poluzamknutыe profiles,
- Profiles with complex matrices tongues,
- Simple hollow profiles,
- Complex hollow profiles.
- Wide hollow profiles.
Optimization of aluminum profiles
Figure 10 – Optimization of the cross-section of aluminum profiles 
Price aluminum profiles
Price aluminum profiles usually directly related to its category of complexity. However, at the same time, multi-functional aluminum profiles open up the possibility of more effective technical, and their higher price is often quite justified.