At LIXIL VINA, we pride ourselves on a state-of-the-art aluminum extrusion process. It is strictly managed at each stage to deliver the highest quality aluminum profiles (extruded aluminum). This process not only guarantees dimensional and shape accuracy but also optimizes the mechanical properties of the aluminum. It meets all stringent market demands.
Let’s explore the professional aluminum extrusion process at the LIXIL VINA factory.
Main Steps in LIXIL VINA’s Aluminum Extrusion Process
The production of aluminum profiles at LIXIL VINA is standardized through multiple stages. These range from raw material preparation to heat treatment and final inspection. This ensures an aluminum extrusion process that is efficient and high-quality.
1.Preparation and Heating of Aluminum Billets
Input Material: We use high-quality aluminum billets produced from the casting process. They are typically around 6m in length.
Billet Heating: The billets are placed in a heating furnace at approximately 450°C. This softens the aluminum and increases its malleability, preparing it for extrusion. This heating step is crucial in the aluminum extrusion process to facilitate shaping the aluminum effectively.
Billet Cutting: After heating, the billets are cut into shorter lengths of about 50cm, suitable for the size of the extrusion container.
2.Extrusion of Aluminum Profiles
Loading into the Container: The cut and heated billet is loaded into the extrusion container.
Extrusion: Under high hydraulic pressure from a large-capacity extrusion press, the billet is pushed through a specially designed extrusion die located at the end of the container. In this aluminum extrusion step, aluminum’s excellent plasticity at high temperatures allows it to flow through the die’s openings. This forms profiles with complex cross-sectional shapes and lengths of up to 50-60m. During the extrusion process, friction and deformation can further increase the temperature of the aluminum profile to around 550°C.
3. Cooling and Stretching of Aluminum Profiles
Initial Cooling: Immediately after exiting the die, the aluminum profile is guided onto a cooling table. It is rapidly cooled using a system of fans or water.
Stretching: After cooling to room temperature, the aluminum profile may have slight distortions. It is then passed through a stretcher. This ensures that the aluminum extrusion process results in products that are perfectly straight and partially hardened. Each of LIXIL VINA’s production lines is equipped with an advanced double puller. This enhances productivity and guarantees product precision.
4. Finishing Cut and Dimensional Inspection
Cutting to Length: In the finishing stage, the straightened aluminum profiles are cut to the lengths specified by the order requirements or product standards.
Shape and Dimensional Inspection: QC (Quality Control) technicians rigorously inspect the shape, dimensions, flatness, squareness, and other technical parameters of each aluminum profile. This ensures high dimensional accuracy, a critical part of the aluminum extrusion process.
Racking: Products that meet the standards are carefully placed on special racks in preparation for the next heat treatment stage.
5.Hardening Heat Treatment (Aging)
Purpose: To enhance the mechanical hardness and other physical properties of the aluminum profiles, the racks of products are moved to a heat treatment furnace.
Aging: Here, the aluminum is “age-hardened” at a precisely controlled temperature and time (e.g., around 180-220°C for several hours, depending on the alloy type and required hardness). Within the aging phase of aluminum extrusion, the precipitation of alloying elements results in products with the desired T5 or T6 temper.
6. Final Quality Inspection
Comprehensive Inspection: After the aging and cooling processes are complete, LIXIL VINA conducts a final inspection. This includes verifying the material’s hardness, dimensional parameters, surface quality, and other technical requirements.
Handover: Only aluminum profiles that meet all strict quality standards are sent to the next process. This typically involves surface treatment (such as anodizing or powder coating) to enhance the product’s aesthetics and durability. In conclusion, our aluminum extrusion is thorough to uphold stringent quality standards.
Superior Features of LIXIL VINA’s Aluminum Extrusion Process
- Latest Technology: Utilization of large-capacity extrusion presses and advanced double pullers.
- Quality of Extrusion Dies: The manufacturing and maintenance process for dies is highly prioritized. This ensures that aluminum extrusion achieves accurate product shapes.
- Optimal Temperature Control: Temperature is strictly managed from billet heating to age hardening.
- High Precision: LIXIL VINA’s aluminum profiles achieve high accuracy in both dimension and shape.
- Standard Hardness: Effective heat treatment ensures products achieve the necessary hardness for various applications.