Industrial aluminum extrusion production process flow

Most of the industrial aluminum profiles are developed according to the existing needs of users. Some industries have strong development capabilities, such as rail vehicle manufacturing, automobile manufacturing, etc., but some small industries lack their own development capabilities or are not aware of the available industrial aluminum profiles. To replace current materials, it is necessary for manufacturers to assist users in developing alternative industrial aluminum profiles. To do this, it is necessary to go out and conduct detailed investigations on the materials used in all walks of life to find out which aluminum profiles are suitable for replacement. Through these developments, the market for industrial aluminum profiles can be expanded, especially the development of large-scale industries, and the increase in market demand can reduce the fierce competition faced by the large and extra-large extrusion lines under construction after the completion. Improve the overall production technology of industrial aluminum profiles. Most of the industrial aluminum profiles have strict requirements on material, performance, dimensional tolerances, etc. Although the profit of industrial aluminum profiles is higher than that of architectural aluminum profiles, its production is relatively difficult, and the technical requirements are also higher, especially complex The production technology of large, flat, wide and thin-walled industrial aluminum profiles still lags far behind foreign countries.

1. Selection of raw materials

Industrial aluminum profile is an industrial frame profile obtained by heating aluminum rods and extruding molds, while aluminum rods are made by melting and casting aluminum ingots, which are called industrial aluminum profile raw materials; and the raw materials will directly affect the industry Aluminum profile product performance.

The production of aluminum rods requires high technical requirements and industry standards to ensure the product performance of industrial aluminum profiles; the production of aluminum rods should pay attention to the following points:

①: The content of active impurities;

②: Alloy composition;

③: Melt overheating temperature;

④: Diversion method;

⑤: The melt moves relative to the crystal plane;

⑥: Cooling rate;

⑦: Casting speed of 6063 aluminum rod;

2. Aluminum rod heating

The heating treatment of the aluminum rod should ensure the temperature control, the temperature of the extrusion outlet, the online quenching temperature and so on.

3. Mold design

Industrial aluminum profile is the final product of aluminum rod extruded through die after heating, while die is a high-precision instrument designed according to demand, used to extrude profile products of required specifications and cross-section; die design And the maintenance should pay attention to the following points:

①: The structure involved in the mold must meet the production requirements and the common sense of physical mechanics to ensure that the products produced can reach the performance used.

②: The selection and hardness of the mold should be appropriate to avoid deformation and scratches during the extrusion process, which will affect the quality of the final product.

③: The mold should be cleaned and inspected frequently, and if there is any problem, it should be repaired in time to avoid scratches, burrs and other hard injuries during the production process of profile extrusion, which will seriously affect the quality of industrial aluminum profile products.

4. Industrial aluminum extrusion

At present, the standard of extruder used in 6063-T5 industrial aluminum profile ranges from 1300 tons to 1600 tons. The above standards can meet the normal production of 6063-T5 series industrial aluminum profiles.

Key elements of the extrusion process of industrial aluminum profile:

①Temperature control: For extrusion production, extrusion temperature is the most basic and most critical process factor. Extrusion temperature has a great influence on product quality, production efficiency, die life, energy consumption, etc.

②Extrusion speed: The extrusion speed must be carefully controlled during the extrusion process. The extrusion speed has an important influence on the thermal effect of deformation, the uniformity of deformation, the process of recrystallization and solid solution, the mechanical properties of the product and the surface quality of the product.

③On-machine quenching: 6063-T5 quenching is to remove the Mg2Si solid-dissolved in the base metal at a high temperature and then quickly cool it to room temperature and be retained. The cooling rate is often proportional to the strengthening phase content. The minimum cooling rate that the 6063 alloy can be strengthened is 38°C/min, so it is suitable for air-cooled quenching. Changing the number of fan and fan rotation can change the cooling intensity, so that the temperature of the product before tension straightening drops to below 60°C.

5. Straightening correction of industrial aluminum profile

After the industrial aluminum profile is extruded, there will be a certain deviation. After the molding, the straightening machine must be used for straightening correction, and the newly extruded industrial aluminum profile must be corrected to the required tolerance range. Straight machine to complete, to ensure its accuracy.

6. Artificial aging

The aluminum profile produced by extrusion has low hardness before aging and cannot be used as a finished product. Therefore, in general, it must be aged to increase its strength.

Control of production process:

①: Ingot temperature control: The temperature of the ingot must be measured before the extrusion machine, and the production can only be carried out after meeting the technological requirements.

②: On-line quenching process: solution quenching is the basic prerequisite of aging, without solution quenching aging is meaningless. Therefore, at the discharge port of the extruder, the online quenching process (air quenching, wind-mist quenching, water quenching, etc.) should be selected according to the ingot brand, profile wall thickness, extrusion speed and quenching equipment conditions to ensure the quenching cooling rate Meet the quenching sensitivity requirements of the alloy.

③: Setting and control of the aging furnace temperature: Generally, there is a certain error between the aging furnace temperature and the apparent temperature of the aging furnace. When setting the surface temperature, set it according to the actual temperature of the furnace, and pay close attention to the temperature of the aging furnace. Fluctuations.

④: Aging heat preservation: Aging should be carried out in strict accordance with the process requirements, and the heat preservation time should be appropriate to prevent insufficient hardness due to underaging or overaging.

Frame and furnace loading of blanks:

①: The extrusion frame should not be too dense, and there should be a gap between the material and the material, especially the small and thick materials that are not ventilated. The material is placed below this is conducive to the aging cycle air supply.

②: Before the furnace is installed, the 6063 special alloy and the ordinary 6063 alloy shall be installed separately for aging. When the aging is done in the same furnace due to production reasons, the special alloy process shall be used for aging.

7. Sandblasting + oxidation treatment process

After the industrial aluminum profile is extruded, there will be obvious stretch marks on the surface, and the surface has large micropores and is relatively rough. It must be sandblasted. The impact of the emery during the sandblasting process will cause the surface of the aluminum profile. The change of the organization structure, accompanied by the slip of the crystal during the plastic deformation process, leads to an increase in the density of dislocations in the sub-grain, and the surface of the profile becomes smoother.

The surface treatment of industrial aluminum profiles goes through the following steps:

①: Surface sandblasting treatment;

②: Surface pretreatment;

③: Degreasing process for industrial aluminum profiles;

④: Acid etching process for industrial aluminum profiles;

⑤: Alkaline etching process for industrial aluminum profiles;

⑥: Neutralization process;

⑦: Industrial aluminum profile oxidation process;

⑧: Sealing process of industrial aluminum profile;

At present, many industrial aluminum profiles on the market reduce the cost and reduce the surface oxidation treatment process of industrial aluminum profiles. They directly use silver-white oxidation treatment, the surface is bright silver, and the plating layer is generally between 5μ-6μ, which is far from reaching the industry standard (industry Standard plating 10μ-12μ).

8. Packaging

Because the quality requirements of industrial aluminum products are very high, and the overall aesthetics of the appearance are very particular, the requirements for later packaging are very strict. The overall packaging process is divided into the following categories:

①: Film on the surface of the profile to avoid scratches.

②: Pearl cotton wrap;

③: The outermost layer is wrapped with a layer of kraft paper to avoid scratching with hard objects;

9. Operational requirements for aging and framing of industrial aluminum profiles

1. When hoisting the material into the furnace, the end of the aluminum profile and the air duct are controlled within 80-100mm.

2. Heat-insulating curtain wall aluminum profiles and heat-insulating point window profiles must be aging in the same aging furnace. The temperature in the furnace is controlled within the scale of 180℃±3℃. After reaching the temperature, the temperature is kept for 3 hours and the furnace is turned on. Cooling, the quality inspector checks the hardness;

3. It is not allowed to mix heat insulation profiles and ordinary profiles in the confrontation frame.

4. Aluminum profiles for heat-insulating curtain walls and popular window profiles must be divided and installed in rival frames.

5. For small materials with wall thickness ≥ 2mm, 80mm ventilation ducts must be left at both ends of each frame.

6. If the aging heat insulation profile does not like the furnace, put about 1 to 2 frames of mediocre profiles (the wall thickness is below 2.0mm) for aging in the same furnace, and the aging performance should be tested according to the heat insulation profile.

7. Ordinary curtain wall profiles, ordinary door and window profiles, and domestic products must be aging in the same aging furnace. The temperature in the furnace should be within the range of 195℃±5℃. After reaching the temperature, it will be held for 3 hours and be released. After the furnace is released, the fan will be blown for 20 minutes. Cooling, the quality inspector tests the hardness.

8. Flat mold materials with wall thickness ≥ 4mm are not allowed to be stacked (only 1 per layer is allowed).

9. When the temperature in the furnace reaches the required temperature for singing, the aging worker uses a glass tube thermometer to measure the actual temperature in the furnace every 30 minutes, and make original records.

10. Ordinary curtain wall aluminum profiles, ordinary door and window profiles, architectural profiles, must be separately installed in the counterbalance frame.