[China Aluminum Network] The aluminum production process involves several key stages, starting from the casting of aluminum ingots, followed by extrusion of billets, and finally surface treatments such as oxidation and sandblasting. Each step plays a critical role in ensuring the final product meets high-quality standards. This article highlights important considerations at each stage to help achieve superior aluminum manufacturing results.
Aluminum production typically consists of three main phases: casting, extrusion, and oxidation.
1. Casting: The first step in the aluminum production process is casting. It includes the following key steps: (1) Alloy preparation: Based on the desired alloy composition, the correct amounts of each element are calculated and mixed with raw materials. (2) Melting: The prepared materials are melted in a furnace, and impurities and gases are removed through degassing and refining techniques. (3) Casting: The molten aluminum is cooled and cast into round ingots using a deep well casting system under controlled conditions.
2. Extrusion: Extrusion is used to shape the aluminum into specific profiles. Molds are designed according to the required profile dimensions, and the heated ingots are pushed through the mold using an extruder. Commonly used alloys like 6063 are often subjected to air-cooled quenching and artificial aging to enhance their mechanical properties. Different heat-treatable alloys require different heat treatment schedules. After the process, hardness can be measured using a W-20 Vickers hardness tester.
3. Oxidation: After extrusion, the aluminum profiles need surface treatment to improve corrosion resistance, wear resistance, and aesthetics. Anodizing is the most common method. The process includes: (1) Surface pretreatment: The surface is cleaned chemically or physically to expose the pure metal, allowing for a uniform and dense oxide layer. Mechanical methods can also be used to achieve a glossy or matte finish. (2) Anodizing: Under controlled conditions, the aluminum is anodized to form a porous and durable aluminum oxide layer. (3) Sealing: The pores in the oxide layer are sealed to prevent contamination and increase durability. The oxide film is transparent and colorless, but during sealing, metal salts can be absorbed to create various colors, such as black, bronze, gold, and stainless steel finishes.
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