Aluminum Extrusion

 
 

High-tech aluminum extrusion presses

After our engineering team has optimized the custom aluminum extrusion design, the next step is automated, high-quality direct custom aluminum extrusion.

  • In-house die modification and maintenance allow Gordon Aluminum to efficiently meet customer needs — from small, custom aluminum product runs to high volume stock runs.

  • Aluminum extrusion takes place on three electronically controlled and monitored press lines. These diverse presses allow us to produce a variety of aluminum extrusions — from large heavy-walled profiles, to small thin-walled profiles — based on a specific tolerance, size, shape, wall thickness and profile weight.

  • We maintain precise pressures and temperatures to ensure consistent quality control, surface quality and proper tempering of the aluminum.

  • Every aspect of the extrusion process is electronically monitored and controlled — from billet temperature and hydraulic pressure, to ram speed and extrusion exit temperature.

 

Gordon Aluminum's aluminum extrusion equipment:

  • 7-inch 1250-ton Loewy Hydro Extrusion Press
    • Our original extrusion press has been extensively re-furbished, including the addition of state-of-the-art computer systems. These modifications have kept the extrusion press efficient, effective, and reliable.

  • 7-inch 1650-ton Loewy Extrusion Press 
    • This press received a complete overhaul and update in 2000 and 2001. It includes a linear motor puller and a conveyor run-out to aid the extrusion process and reduce surface damage.

  • 10-inch 2750-ton Sutton Extrusion Press
    • Bigger billet and higher pressure allow more robust extrusions up to 15 pounds per foot with diameters up to 10 inches. A water quenching system cools these larger sections to ensure we meet proper aluminum temper specifications. (This press will soon be converted to an 8-inch press following installation of the Danieli press below.)

  • 10/12-inch 4500-ton Danieli Extrusion Press (in production December of 2014)
    • We are currently installing state-of-the-art Danieli press.  This press will be capable of extrusions with diameters up to 12" and widths up to 17".  It will be run as a 10-inch press in the short term, but it is also configured to convert between 10 and 12 inch billet in a matter of hours if necessary.  This press will also have a state-of-the-art Granco Clark handling system with intensive quench and completely automated handling to ensure the highest possible material quality.

  • Single Cell Extrusion Die Ovens
    • Dies are heated to about 850 degrees Fahrenheit before placement in the press. Proper pre-heating improves custom aluminum extrusion consistency and quality, and extends die life.

  • Billet Ovens
    • To achieve proper aluminum tolerances and temper, the 6000 series billet is precisely pre-heated before being extruded to ensure the combined heating effects of pressure and friction during the extrusion process allow the aluminum to reach the exit temperature necessary to achieve proper molecular homogenization (about 950 degrees Fahrenheit). This also ensures the aluminum is not over-heated during the extrusion process, which can cause serious surface defects and tolerance issues.

  • Pyrometric Equipment
    • Pyrometers are installed on all three presses to accurately measure the exit temperature of our precision aluminum extrusion. This allows press operators to modify press speed, pressure and billet temperature to produce proper temper and a smooth finish.

  • Cooling Systems
    • Each press is also equipped with extensive air- and water-cooling systems to quickly bring aluminum extrusions down to proper post-extrusion temperatures. As with proper exit temperature, proper cooling is essential to achieve proper temper.

  • Aging Ovens
    • Material temper may be increased after extrusion by solution heat treating or "aging".  This involves "soaking" the aluminum at approximately 400 degrees Fahrenheit for up to eight hours. This aging process allows the aluminum alloy's grain structure to convert to a stronger state after being homogenized and frozen there during the extrusion and cooling processes. Custom extrusions ordered in low temper states and material slated for bending may follow special aging cycles, or may skip this process altogether and then be aged in their bent state.