ã€China Aluminum Industry Network】 1. Select the appropriate mold according to the operation plan. For flat molds, set the temperature between 460°C and 480°C, and for diverter molds, set it between 480°C and 500°C. Ensure the mold remains in the furnace for more than 8 hours. The loading process should be quick and efficient, and the mold must be kept warm to avoid cooling down.
2. The ingot must be clean and free from damage or wear. Any imperfections can lead to slag or air bubbles in the final extruded product.
3. Avoid rolling aluminum alloy round ingots on the ground, as dirt and dust may accumulate on the surface. Clean them thoroughly before placing them into the furnace for heating.
The heating temperature of the aluminum rod furnace is set in stages, starting at 300°C to 450°C. The temperature control depends on the wall thickness: for T ≥ 1.4mm, maintain a temperature between 440°C and 540°C; for T < 1.4mm, keep it between 400°C and 540°C. Adjust based on the alloy type, mold structure, and other factors.
4. Before heating, inspect the surface quality of the aluminum ingot. This responsibility falls on the operator. Any ingot with visible defects like slag inclusion, cold shut, center cracks, or bending must not be placed in the furnace and should be returned to the casting area.
5. Use a stepwise heating method, raising the temperature by 100°C per hour until reaching 380°C to 420°C. The end face of the ingot barrel should be maintained at 280°C to 360°C.
6. Ensure the end face of the ingot and die are smooth and free from damage or adhesion. Otherwise, material may escape during extrusion. The team leader should measure the temperature of every 10–20 ingots using a portable thermometer and record the data to monitor temperature changes and ensure proper extrusion conditions.
7. Monitor pressure during extrusion. If the pressure is below 210 kg/cm² and gradually decreases during normal extrusion, it’s acceptable. However, if the pressure does not drop within one minute after being applied, stop the extrusion immediately to prevent equipment and mold damage.
8. Adjust extrusion speed based on the alloy type. Low-impurity alloys allow faster extrusion, while high-impurity alloys require slower speeds. If the aluminum rod temperature is high, reduce the extrusion speed accordingly. To increase speed, lower the rod temperature.
9. The temperature at the exit must be at least 500°C to ensure proper mechanical properties.
10. Inspect the first section of the extruded profile. Cut a 500mm segment from the upper die for mold repair. Check the first two pieces for size, shape, and dimensional tolerances to confirm they meet design requirements and determine if the mold can continue production.
11. Apply a small amount of mold release grease on the end face of the mold and the gasket to prevent sticking. Do not apply it to the mold cavity or the inner walls of the ingot barrel, as this could contaminate the extruded profile.
12. Properly use the extrusion gasket to protect it from damage. Replace the gasket if it becomes worn or the clear cylinder is not clean. Always check that the gasket is in place before extrusion to avoid equipment accidents caused by missing components.
13. Monitor hydraulic oil temperature during the extrusion process. When the oil temperature reaches 45–50°C, extrusion force will decrease significantly. Stop the process and wait for the oil temperature to drop before resuming.
14. Extrusion press tonnage: 80 pieces per die set.
15. To prevent gas from the dead zone from entering the profile, the pressurization length should not be too thick or too thin. Keep it between 15–30mm.
16. For 6063 aluminum extrusion, use forced air cooling for T6 quenching, and natural cooling for T5. Cool the profile at a rate of no less than 80°C/min until it reaches below 170°C. For 6061, use strong wind, water mist, or direct water cooling, and cool it below 200°C within 2–3 minutes.
17. Allow aluminum profiles to cool to below 50°C before straightening. Control the straightening amount at about 1–2%, allowing slightly more for thicker profiles but not exceeding 3%. Protect the decorative surface from scratches and place non-decorative sides on the conveyor.
18. Understand the length tolerance requirements before cutting. Follow customer specifications if provided; otherwise, control to +15mm. If full-length delivery is required, the total deviation should be +20mm. Ensure the first cut meets the requirements with a positive deviation only.
19. Avoid folding the profile when sawing. Clear sawdust from the aluminum swarf before advancing the profile.
20. Lubricate the saw blade with oil, but avoid contaminating the profile surface. Ensure the cut is perpendicular to the axis, free from burrs, flashes, or twisting. Maintain a sharp blade for a clean cut and replace it when necessary.
21. After cutting, blow off any aluminum debris using compressed air before framing.
22. After fixing the length, inspect all large pieces and sample 10% of medium and small pieces. Check for flatness, bending, twisting, opening, closing, and surface quality.
23. When handling and placing the profile in the frame, two people should lift it gently. Place it neatly without collisions. Wear clean, oil-free gloves to avoid damaging the surface. Place heavy and long pieces on the lower layer, and lighter, shorter ones on top.
24. After laying each layer, insert 4–8 crossbars depending on the length and tolerance. Stack layers carefully to avoid vertical bending or over-stacking.
25. Separate solid aluminum materials that cannot be ventilated vertically. Use small square tubes with ventilation holes to improve airflow and heat dissipation.
26. Ensure the top layer of aluminum is slightly lower than the frame plane to prevent crushing during stacking.
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