Industry Overview
Aluminium extrusion is a plastic deformation process in which a billet is forced to flow through a die opening having a smaller cross-sectional area than the original billet. It is an indirect-compression process in which the reaction of the billet with the container and die generates high compressive stresses. These forces make extrusion an effective method for breaking down the cast structure of a billet while reducing the likelihood of cracking during primary breakdown.
Extrusion may be carried out by cold or hot processes, depending on the alloy and method used. In hot extrusion, the billet is preheated to facilitate plastic deformation. The success, quality, cost, and ease of extrusion depend on factors including size, shape, alloy, extrusion ratio, tongue ratio, tolerance, surface finish, and scrap ratio. These factors are interrelated with extrusion speed, billet temperature, extrusion pressure, and the alloy being processed.
Extrusion speed generally varies with metal temperature and the pressure developed within the container, while permissible temperature and pressure depend on the alloy and profile geometry. Lower extrusion temperatures can provide improved surface quality and dimensional accuracy but require higher pressures. Consequently, equipment pressure limitations can restrict the ability to extrude certain shapes through a particular press.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 10 MT/Day |
| Land & Building (10,000 sq.mt.) | US$ 7.83 Lac |
| Plant & Machinery | US$ 11.30 Lac |
| Working Capital for 2 Months | US$ 12.67 Lac |
| Total Capital Investment | US$ 33.82 Lac |
| Rate of Return | 33% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- EXTRUSION
- FACTORS AFFECTING EXTRUSION
- ADVANTAGES OF THE EXTRUSION PROCESS:
- TYPES OF EXTRUDED PROFILES
- CLASSIFICATION OF ALUMINIUM EXTRUSION
- TRADITIONALLY, THE PROCESS HAS BEEN DESCRIBED AS HAVING THREE DISTINCT REGIONS
- (B) INDIRECT (BACKWARD) EXTRUSION
- (C) HOT EXTRUSION
- (D) COLD EXTRUSION AND WARM EXTRUSION
- PROPERTIES
- PROPERTIES OF ALUMINIUM
- WEIGHT
- STRENGTH
- LINEAR EXPANSION
- MACHINING
- FORMABILITY
- CONDUCTIVITY
- JOINING
- REFLECTIVITY
- SCREENING EMC
- CORROSION RESISTANCE
- NON-MAGNETIC MATERIAL
- ZERO TOXICITY
- ANODIZING OF ALUMINUM
- WHAT IS ANODISING?
- PURPOSE OF ANODIZING
- TYPES OF ANODISING
- TYPE-I-CHROMIC ACID ANODISING
- TYPE-II-SULPHURIC ACID ANODISING
- TYPE-III-HARD ANODISING
- USES AND APPLICATION
- USES
- APPLICATION
- APPLICATIONS OF EXTRUDED ALUMINUM
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- (A) FOR EXTRUSION
- (B) FOR ANODISING
- MANUFACTURING PROCESS
- (A) FOR EXTRUSION
- DESCRIPTION OF PROCESS
- (1) BILLET PREHEATING
- TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE ALUMINUM ALLOYS
- TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS
- (2) EXTRUSION
- (3) QUENCHING
- (4) STRETCHING
- (5) CUTOFF
- (6) ARTIFICIAL AGING
- TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS
- (7) INSPECTION AND TESTING
- EXTRUSION MATERIALS INSPECTION
- ALUMINUM ALLOY CHECK
- EXTRUSION DYE CHECK
- ADDITIVES CHECK
- EXTRUSION VISUAL INSPECTION
- VISUAL DEFECTS CHECK
- COLOR AND GLOSSINESS CHECK
- DIMENSIONAL INSPECTION
- COATING AND FINISHING CHECK
- WEIGHT AND DENSITY CHECK
- EXTRUSION PERFORMANCE INSPECTION
- TENSILE TEST
- WELDABILITY CHECK
- WORKABILITY CHECK
- CORROSION RESISTANCE
- FLAMMABILITY TESTING
- HARDNESS TEST
- WEATHERING RESISTANCE TESTING
- ABRASION RESISTANCE
- CHEMICAL RESISTANCE
- DESCRIPTION OF EXTRUSION PRESS
- (B) ANODISING
- (1) SURFACE PREPARATION
- TECHNOLOGIES OF SURFACE PREPARATION
- A. MECHANICAL CLEANING
- G. ANODIC ELECTROCLEANING (REVERSE ELECTROCLEANING).
- H. PERIODIC-REVERSE ELECTROCLEANING.
- I. ACID ACTIVATION.
- (2) ANODISING PROCESS
- (A) CHROMIC ACID ANODIZING, I.E., TYPE 1
- A CHROMIC ACID ANODIZING SOLUTION SHOULD NOT BE USED UNLESS:
- (B) CONVENTIONAL SULFURIC ACID ANODIZING, I.E., TYPE 2
- (D) HARDCOAT ANODIZING, I.E., TYPE 3
- ANODIZING EQUIPMENT AND PROCESS CONTROL
- (A) FOR CHROMIC ACID ANODIZING.
- (B) FOR SULFURIC ACID ANODIZING.
- (C) FOR HARD ANODIZING.
- POWER REQUIREMENTS FOR THE PRINCIPAL ANODIZING PROCESSES ARE AS FOLLOWS:
- (A) FOR CROMIC ACID ANODISING
- (B) FOR SULFURIC ACICD ANODISING
- (C) FOR HARD COAT ANODISING
- (3) RACKING PROCESS
- (4) SEALING PROCESS
- (5) COLOURING PROCESS
- MARKET POSITION
- THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS
- ALUMINIUM EXTRUSIONS - THE PROS AND CONS
- THE PLAYERS
- THE FUTURE
- SPREADING AWARENESS
- FUTURE OUTLOOK
- THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY
- FUTURE OUTLOOK
- CHALLENGES IN THE INDIAN EXTRUSIONS MARKE
- RISKS AND AREAS OF CONCERN
- PRESENT MANUFACTURERS
- ALUMINIUM EXTRUSION SECTIONS
- SUPPLIERS OF ALUMINIUM PROFILE
- PLANT LAYOUT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ALUMINIUM ALLOY BILLET
- SUPPLIERS OF DEGREASING CHEMICAL
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF OIL AND GREASE
- SUPPLIERS OF ANODISING MATERIAL
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF HYDROCLORIC ACID
- SUPPLIERS OF ZINC AMONIUM CLORIDE
- SUPPLIERS OF SULFURIC ACID
- SUPPLIERS OF CHROME SALT AND CHROMIC ACID
- SUPPLIERS OF PLANT AND MACHINERY
- CHINA SUPPLIERS FOR ALUMINIUM EXTRUSION AND ANODISING PLANT
- INDIAN SUPPLIERS OF ALUMINIUM EXTRUSION PLANT
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium extrusion is a metal forming process in which an aluminium billet is forced through a die to produce a profile with a defined cross-sectional shape. The process uses compressive forces to deform the billet plastically and is suitable for producing a wide variety of sections. Extrusion can be carried out using different process conditions depending on the alloy, profile geometry, temperature, pressure, and required dimensional and surface characteristics.
The aluminium extrusion process is affected by profile size and shape, alloy, extrusion ratio, tongue ratio, tolerance, surface finish, scrap ratio, extrusion speed, billet temperature, and extrusion pressure. These variables are interrelated. For example, lowering the extrusion temperature can improve surface quality and dimensional accuracy but may increase the pressure required for extrusion. The practical operating range is also influenced by the capabilities of the extrusion press and the characteristics of the alloy being processed.
Hot extrusion is performed with the billet heated to facilitate plastic deformation, whereas cold extrusion is carried out without heating the billet to the hot-working temperature. The appropriate method depends on the alloy, profile requirements, deformation characteristics, and process conditions. The report also identifies warm extrusion as a separate process category. Temperature selection influences extrusion pressure, surface quality, dimensional accuracy, material behaviour, and the operating limitations of the extrusion equipment.
The main extrusion stages described in the report include billet preheating, extrusion, quenching, stretching, cutoff, artificial aging, and inspection and testing. Each stage contributes to the dimensional, mechanical, and surface characteristics of the finished profile. Quality checks can include alloy verification, dimensional inspection, visual examination, tensile testing, hardness testing, corrosion resistance, abrasion resistance, chemical resistance, and other performance-related assessments depending on product requirements.
Aluminium anodising is an electrochemical surface treatment used to modify the surface of aluminium products. The report covers surface preparation, anodising, racking, sealing, and colouring processes. It identifies chromic acid anodising, conventional sulphuric acid anodising, and hardcoat anodising among the principal types discussed. Process control and equipment requirements vary according to the selected anodising method and the required characteristics of the finished aluminium profile.
Inspection is important because it verifies that extruded aluminium profiles meet specified material, dimensional, surface, and performance requirements. The report covers material and alloy checks, die checks, visual inspection, colour and glossiness, dimensions, coating and finishing, weight and density, tensile strength, weldability, workability, hardness, corrosion resistance, weathering, abrasion, chemical resistance, and other tests. The selection of tests depends on the intended application and applicable product requirements.
An aluminium extrusion plant may require extrusion equipment together with supporting utilities, material-handling systems, and finishing facilities. The report includes suppliers and equipment categories covering extrusion and anodising plants, EOT cranes, power transformers, electrical panels, cooling towers, effluent treatment plants, air pollution control equipment, air conditioning equipment, air compressors, platform weighing machines, material handling equipment, fire-fighting equipment, and shot blasting machines. The exact equipment configuration depends on the process route, product range, capacity, and quality requirements.
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