Learn about the different types of fabrication techniques for aluminum. These include Extrusions, Drawing, Forming and Casting. Each of these processes focuses on a specific process and can be done in different ways. Learn about the different methods for creating aluminum products to maximize your design and fabrication capabilities. These aluminum fabrication techniques will help you create beautiful, functional and lightweight products for a variety of applications.
Extrusions
Extrusions in aluminum fabrication can be used to create a variety of components. The process is relatively simple, and the resulting aluminum product has a uniform shape. The aluminum is pushed through a die and emerges along a runout table in a similar shape. The pressure applied to the metal during the extrusion process is comparable to the force required to squeeze a toothpaste tube. The opening in the tube serves the same purpose as the extrusion die, and the end result will be a long solid extrusion.
Extruded aluminum products can be polished, painted, powder-coated, electroplated, laminated, or finished in a variety of ways. Some of the standard finishing options for aluminum extrusions are mill finishing and sandblasting. Anodizing is another option that can be used to provide a high-quality finish. Common anodized finishes are black and clear, but custom colors are also available.
The first step in the aluminum extrusion process is to heat the aluminum billets to about 800 degrees Fahrenheit. This prevents the aluminum from melting or undergoing recrystallization. It also prevents the aluminum from work hardening, which would otherwise make it difficult to form. Another important step is the cooling process. A cooling cycle is necessary to achieve the desired mechanical properties.
Drawing
Drawing aluminum is one of the many aluminum fabrication techniques that can be used to create products of any shape and size. This process involves the application of heat to the metal to make it soft and malleable. After that, it is forced through a die to create the desired shape. The end result is aluminum tubing that is shaped and molded in the desired way. A good example of this process is the creation of a tube of toothpaste.
Another method for producing aluminum products is deep drawing. This process is typically used for making aluminum cans. This process requires high forces to draw a soft alloy, and is a multi-stage process that requires a lubricant. When done properly, this process can produce seamless products. Common aluminum alloys used in deep drawing include 3003, 5005, and 5052.
Drawn aluminum is a more complicated fabrication technique than extrusion. It requires a larger tool set and more materials. However, it is faster and produces less waste. Compared to extruded aluminum, the cost is significantly less. However, depending on the shape and size of the product, this process is not suited for all applications.
Forming
There are a variety of processes that form aluminum during aluminum fabrication. These processes are known as extrusion, casting, rolling, and forging. Extrusion involves the use of a powerful ram and die to create a complex shape. In many ways, it resembles play-dough or a toothpaste tube.
Aluminum forming operations produce stock that will be used for subsequent fabricating processes. The aluminum alloy blank is rolled into a three-dimensional form. Once this process has been completed, it is heated to a pre-ageing temperature of 50 to 250oC. After it cools, it is then exposed to a paint bake cycle.
Depending on the type of aluminum alloy and the type of aluminum fabrication process used, certain alloys are more suitable for certain applications than others. For example, the 3XXX series is more suitable for welding applications than the 6XXX series. However, the 7xxx grades are not recommended for welding. The exception to this rule is the 2219 alloy.
Castings
One of the main advantages of castings is the ability to produce complex shapes. This is especially advantageous for the manufacture of automotive parts. Other processes are unable to produce parts with such tight tolerances. In addition to that, castings can accommodate both large and small parts. Consequently, casting is the perfect choice for a wide range of fabrication needs.
Casting aluminum is more expensive than casting bronze, but is less expensive than other metal fabrication techniques. There are two types of aluminum casting: permanent mold casting and expendable mold casting. Casting aluminum is usually performed on a permanent mold. For small daily production, you can use an old electric furnace to melt the metal.
The 8000 series alloy is a common primary alloy and contains small amounts of copper and nickel. While this alloy has relatively low strength, it is machinable, wear resistant, and ductile. The specific alloy configuration depends on the intended use and will determine the metal’s temperature performance, density, and stiffness. For this reason, it is important to choose the proper alloy for a given application.
Forging
Forging aluminum fabrication techniques are a common and effective way of manufacturing a variety of aluminum components. In a typical forging process, two pieces of aluminum stock are heated and then pressed together. This process uses a two-sided press and secondary processes to ensure a seamless finish. The finished product is typically resistant to corrosion and has high performance characteristics.
A key advantage of forging is the deformation energy it produces, which enhances the metallurgy of a metal part. This deformation energy drives the recrystallization of the metal, which creates better strength and durability. While this process can increase the overall cost of forgings, the increased durability, reliability, and safety benefits often outweigh any extra cost.
The process can be applied to a variety of aluminum alloys. The aluminum die base material can be made of 0.5% to 3.0% Mg. The total amount of other elements is usually less than 500 ppm. The aluminum alloy rod material prepared by this process has a tensile strength of 460MPa and a yield strength of 400MPa. In addition, the elongation percentage is greater than 10%.
Machining
Aluminum is one of the lightest metals in the world and can be easily machined. This makes it an ideal material for machinists. Aluminum alloys are also cleaner to work with because they do not contain oil, scale, or other materials that can mar the surface. Additionally, aluminum is the least dense of all metals and is incredibly ductile, making it easier to work with.
While aluminum is a light and durable metal, it can still present certain challenges when machining. Different types of machines are used to achieve different results, which means a variety of methods must be used. CNC milling and turning are two of the most common methods for processing aluminum. Other techniques include grinding, honing, and polishing. Some companies also utilize electrochemical or electrical discharge machining processes.
Another way to process aluminum is by investment casting. Investment casting uses wax patterns to create metal parts. This process produces parts that are extremely accurate and have an excellent surface finish. Moreover, cast aluminum parts can be post-machined, and some companies will even coat the parts with coating for further refinement. In addition to investment casting, pressure die casting is another common process for manufacturing aluminum. This technique is used to create larger batches of parts. The dies used for pressure die casting are made of tool steel.
Waterjet cutting
Waterjet cutting is an efficient aluminum fabrication technique that is suitable for a variety of industries. It produces a smooth surface without burn marks, cracks, or excess burrs. Unlike other cutting methods, waterjet cutting does not involve heat, which makes it an excellent choice for sensitive materials. This process is also easy on the environment.
Waterjet cutting produces less waste and produces very little secondary finishing after the cut. This technique saves time because it is not necessary to refine edges, which is a common problem with other cutting methods. It also yields a high degree of accuracy and is ideal for internal cut outs. It is also an ideal choice for custom patterns, logos, and artwork.
Modern waterjet cutting machines are capable of cutting a variety of parts. The multi-axis design gives the operator true three-dimensional control. These cutting machines can cut multiple parts with one pass and feature a very narrow kerf. Advanced models can handle large production runs and provide high repeatability and uniformity.
MIG and TIG welding
MIG and TIG welding are two different welding processes used in aluminum fabrication. These processes use different types of electrodes and shielding gases. MIG welds use a tungsten electrode, which is more reactive to reactive gases than TIG electrodes. The arc gas used in TIG welds is usually pure argon, although argon blends with other gases are often necessary for special applications.
To properly weld aluminum, the work area should be thoroughly cleaned before the welding process begins. The work area should also be heated to between 175 degrees Fahrenheit and 347 degrees Fahrenheit. This preheating process improves penetration and travel speed. It also removes any oxide layer present on the base material.
The MIG and TIG welding processes are similar, but the MIG process is faster and easier to use. MIG welder is also easier to operate than TIG, as it can be operated with one hand. The MIG welding process is also quicker than TIG and produces quality welds in a shorter time. However, TIG welding is slower and more expensive than MIG, visit website for best aluminum fabricator.