Castingin the Aluminium profile manufacturing process
Casting is the first stage in the aluminum profile manufacturing process, where aluminum, typically in the form of ingots or recycled scrap, is melted in a furnace at high temperatures (around 660°C, the melting point of aluminum).
Stages
Raw Material Preparation
- Primary Aluminum: Derived from bauxite, refined aluminum is obtained in its pure form.
Recycled Aluminum: Aluminum scrap is cleaned and sorted before being remelted.
Alloys: Other metals are added to aluminum to enhance its properties.
Aluminum Melting
- Solid aluminum (in the form of ingots, billets, or scrap) is placed in a melting furnace that heats the metal to over 660°C until it becomes liquid.
- Melting furnaces can be electric, combustion, or induction, depending on the factory and production volume.
Pouring of Molten Metal
- The liquid aluminum is carefully poured from the furnace into steel or iron molds. The molds can vary in shape depending on the product to be manufactured.
- In the case of aluminum profile manufacturing, the metal is poured into molds or ingot casters that will later be used in the extrusion process.
Solidification
- The liquid metal begins to cool and solidify within the molds, taking on its final shape. This process can be controlled through natural or forced cooling, depending on the type of product.
Demolding
- Once the aluminum has completely solidified, the molds are opened to extract the formed pieces, ingots, or billets. In some cases, permanent molds or disposable (sand) molds are used.
Finishing
- The solidified pieces may require finishing processes such as trimming burrs, sanding, or polishing. In the case of ingots, they may proceed to a subsequent process, such as extrusion, to create profiles with complex shapes.
Quality Control
- Inspections are conducted to verify the quality of the metal, including strength tests, visual inspections, and assessments for internal or external defects.
Equipment and Capabilities
At Extrusiones Metálicas, we have the necessary equipment to fully carry out the casting process, allowing us to process our products from raw material acquisition to final product delivery. For this first stage, we have in our plants in Guanajuato and Veracruz:
Veracruz
Capacity 3,000 Tons
- 1 Rotary Furnace
- 2 Melting Furnaces
- 2 Homogenizing Furnaces
- 2 Cooling Furnaces
Guanajuato
Capacity 3,300 Tons
- 2 Melting Furnaces
- 2 Homogenizing Furnaces
- 2 Cooling Furnaces
Alloys
An aluminum alloy is a material composed of aluminum as the base metal, to which small amounts of other chemical elements are added to enhance its mechanical, physical, or chemical properties. These elements, such as copper, magnesium, silicon, zinc, or manganese, allow for the modification of characteristics such as strength, hardness, ductility, corrosion resistance, or thermal conductivity.
Aluminum alloys are classified into two main groups:
- Forged Aluminum Alloys: These are used in plastic deformation processes such as rolling or extrusion and are more malleable.
- Cast Aluminum Alloys: These are used in casting, where molten aluminum is poured into molds to manufacture specific parts.
Aluminum alloys are essential in sectors such as construction, automotive, aerospace, and profile manufacturing due to their combination of lightweight and high strength.
Below are the alloys developed by Metal Extrusions along with their respective heat treatments, all strictly adhering to the AA standard.
- 6063
- 6060
- 6005
- 6005A
- 6061
- 6082
If you have any questions regarding these or require a specific alloy not listed, please reach out to your sales representative for guidance from our experts. We have the necessary equipment to assist you with the project you have in mind.