Aluminum profile production process

Author: Hou

Jun. 19, 2024

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Aluminum alloy profiles have the characteristics of environmental protection, stability, easy processing and decoration, and are widely used in the construction and home furnishing industries (glass curtain walls, sliding doors and windows, etc., all-aluminum home furnishings, etc.). Aluminum profiles are divided into substrates, anodized profiles, electrophoretic painted profiles, powder sprayed profiles, fluorocarbon paint spraying profiles, strip insulation profiles, glue injection thermal insulation profiles, etc., and its production process and process also involve many complex links.

1. Mold making

Mold design: CAD SOLID WORK software is used to produce accurate drawings.  

Machining: according to the drawings, the mold steel blank is processed into a suitable diameter and thickness on the lathe, and the welding chamber and shunt hole are processed in the machining center;  

Heat treatment: heat treatment of the mold in a vacuum quenching furnace with the aim of strengthening the hardness of the mold;  

Wire cutting: the size of the die hole is processed by wire cutting;

EDM: EDM processes the mold working belt;

Polishing: After the whole model comes out, the mold is polished, and a smooth working belt is polished, so that the profile with a smooth surface can be extruded, and it is also convenient for the next inspection and mold trial;

Nitriding: Strengthen the strength of the mold working belt to reach 53-54 degrees, which is more durable.

2. Melting and casting

Batching furnace: According to the corresponding proportion, it is equipped with aluminum ingots, master alloys and other raw materials, and the aluminum ingots are put into the smelting furnace.

Melting: Melting the aluminum ingots by burning natural gas, stirring to make their composition and temperature more uniform, and raising the temperature of the molten aluminum to prepare for adjusting the composition and refining;

Compound gold: adjust the proportion of molten aluminum composition according to the alloy requirements;

Refining and slag discharge: slag and gas removal of molten aluminum to improve the quality of molten aluminum;

Standing: for precision filtration;

Casting: continuous casting, producing aluminum rods of various specifications;

Homogenization: Aluminum rods are homogenized in a homogenization furnace to eliminate the residual stress of the ingot, improve the processing performance, increase the extrusion speed, and finally complete the production of aluminum rods.

3. Extrusion

Aluminum rod heating: controlled between 410~500 degrees.

Extrusion: According to the principle of "high temperature and low speed, low temperature and high speed", extrude the profile;

Straightening: Through cold-formed shape correction, the defects such as bending and twisting of the profile are eliminated after straightening, and at the same time, orange peel and uneven surface can not be produced;

Artificial aging: Aging treatment is carried out in strict accordance with the aging process system to improve the strength of the alloy;

Packaging and warehousing: Aluminum profiles that do not need surface treatment are packaged and warehoused after a series of measurements such as length and strength.

Aluminium T-slot Profile.jpg

Fourth, surface fluorocarbon treatment

The surface fluorocarbon treatment sprays difluoride on the aluminum alloy and its surface through electrostatic action, which has uniform color, fading resistance and excellent anti-fouling ability.

One-time shelf: Put the extruded aluminum alloy on the shelf.

Pre-treatment: In the pre-treatment area, the material is cleaned multiple times according to the regulations to thoroughly wash the surface oil;

Chromization: Chromization in the chromium pool will generate a fine and stable chromium film on the surface, and good adsorption capacity can improve the adhesion of the coating;

Drying: The chromed aluminum is placed in the drying oven;

Secondary shelf: local grinding before spraying to ensure that the material is smooth and ash-free;

Paint coating: two coats and one baking, "primer, topcoat" coating, three coats and one baking need to carry out "primer, topcoat, varnish", four coats and two baking need to carry out "primer, isolation paint, baking, topcoat, varnish".

After baking and curing, it can be packaged and put into storage.

Additional reading:
Everything you need to know about aluminum profiles
The difference between industrial aluminum profiles and architectural aluminum profiles

5. Powder coating

Powder coating is a powder coating on the aluminum alloy and surface through electrostatic action, which has strong adhesion, wear resistance, peeling resistance and ultraviolet resistance.

Shelves: put the extruded profiles on the shelves;

Pre-treatment: Chromization is carried out after thoroughly washing the oil stain on the surface of the material according to the regulations in the pre-treatment area;

Drying: The chromed aluminum is dried in a furnace;

Spraying: enter the spraying area for powder coating;

Curing: Let the powder cure at 200 degrees;

After drying, the material is off the shelf, and after the inspection is passed, it can be packaged and put into storage.

6. Oxidation

Aluminum alloy will be electrolyzed on the surface during the anodizing process to form an alumina film, and the oxidized aluminum alloy can be electrolytically colored to produce a variety of colors.

Racking: Putting it on the conductive rack;

Pre-treatment: In the pre-treatment area, the material is cleaned multiple times according to the regulations, and the oil stain on the surface of the material is thoroughly cleaned;

Anodizing: The Custom Aluminum Profile is placed in an electrolyte solution, and the surface of the aluminum oxide film is formed by electrolysis;

Coloring: The oxidation profile that needs to be dyed can be electrolytically colored, and the color can be changed from light to dark over time, and a variety of colors can be produced;

Sealing: sealing the oxide film;

Off the shelves: Aluminum profiles are removed from the shelves for drip drying testing, and packaged into warehouses.

7. Electrophoresis

On the basis of oxidation, through electrophoresis, the oxide film is covered with a layer of water-soluble acrylic paint film, and the profile will have stronger water resistance, wear resistance, wear resistance, and a smoother and more beautiful surface.

Shelf: Rack the material to the vertical conductive rack;

Pre-treatment: In the pre-treatment area, the material is cleaned multiple times according to the regulations, and the oil stain on the surface of the material is thoroughly cleaned;

Anodizing: The aluminum profile is placed in an electrolyte solution, and the surface of the aluminum oxide film is formed by electrolysis;

Coloring: electrolytic coloring in the coloring pool;

Electrophoresis: The profile is placed in an electric pool and covered with a layer of water-soluble acrylic paint film on the oxide film through electrophoresis;

Curing: enter the curing oven and cure the film at 180 degrees Celsius; After drying, the material is taken off the shelf, and the packaging is put into the warehouse after passing the inspection.

8. Broken bridge

The surface-treated aluminum profile is treated with low thermal conductivity aluminum insulation between the inner and outer high thermal conductivity materials for bridge breaking, which can make the product meet the thermal insulation requirements, and there are two ways to break the bridge, namely "strip type" and "glue injection type".

1. Wear strip type

Tooth opening: The aluminum profile is toothed to improve the resistance of the profile after compounding with the heat insulation strip; Stripping: inserting a thermal insulation strip between the two profiles; Rolling: Rolling makes the two profiles composite with the heat insulation strip to form a new type of aluminum profile; Inspection: sampling to check shear resistance; After passing the inspection, the packaging is put into the warehouse.

2. Glue injection type

Glue injection cavity sealing: seal the glue injection cavity of the profile;

Preparation for start-up: After the test of the American Asun A and B glue mixed and stirred samples, the temperature of the profile and the rubber tank is controlled at 20-30 degrees to ensure that the temperature is not too low and the colloid becomes brittle; Cutting bridge: cutting the base material at the connection points on both sides of the profile, that is, cutting the bridge, so as to form a new type of profile that meets the requirements of heat insulation; Inspection: Sampling to check the shear resistance, packaging and warehousing after passing the inspection.

 


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