Have you ever wondered how rails, tracks and mullions with intricate designs are made? Have you seen a building with impressive metal window frames that made you wonder how they were able to carve such a beautiful design in that hard metal? No, they did not hire hundreds of blacksmiths and commissioned them for a decade just to decorate the entire building with fancy window frames. Most of the time, these items are produced by metal extrusions.
Metal extrusion is the process of producing long objects, especially those with intricate profile designs. This technology was developed initially for making lead pipes in the late 18th century. The basic process remains the same today. It involves pushing a round billet through a die. The die is shaped according to the desired design. The raw material passes through it and emerges on the other side shaped like the die. The process is similar to wire drawing. Aside from the fact that wire drawing is used for smaller sections, it differs from metal extrusion in the way the metal is forced through the die. In drawing, the metal is pulled rather than pushed.
Today’s industry uses metal extrusion for various purposes. These include aluminum extrusion profiles for frames, tracks, mullions, and rails. The process is also used in producing copper tubing and pipes for plumbing. Steel rod and track productions also benefit from this system. This process is also employed in making titanium aircraft components such as engine rings, seat tracks, and other structural parts.
Softer metals like copper, zinc, and aluminum are commonly used in metal extrusions. In fact, if you want a more intricate profile design or a more complicated shape, the softer the metal, the easier the process will be. The process is very useful for long thin metal parts with a cross-section. These cross-sections usually measure less than 100mm across.