ã€China Aluminum Industry Network】 1. Select the appropriate mold based on the operation plan: flat mold should be set between 460°C and 480°C, while the diverter mold should be maintained at 480°C to 500°C. The mold must remain in the furnace for more than 8 hours. The loading process should be quick and efficient, ensuring that the mold does not cool down during the process.
2. The aluminum ingot must be clean and free from severe wear or damage. Any imperfections can lead to slag or air bubbles forming in the extruded product.
3. Avoid rolling aluminum alloy round ingots on the ground, as they may collect dirt or dust. Before being placed into the furnace, the surface should be cleaned thoroughly.
For heating, the furnace temperature is set in stages: 300°C to 450°C. The temperature of the ingot on the machine should be controlled based on wall thickness—T ≥ 1.4mm requires a temperature range of 440°C to 540°C, while T < 1.4mm should be kept between 400°C and 540°C. Adjustments are made depending on the alloy type, mold structure, and other factors.
4. Before heating, the surface quality of the ingot must be self-inspected by the operator. Any ingot with visible slag, cold shut, center cracks, or bending should not be loaded into the furnace and should be returned to the casting area for further inspection.
5. Warm the ingot gradually using a stepwise temperature increase of 100°C per hour, reaching a final temperature of 380°C to 420°C. The end face of the ingot barrel should be around 280°C to 360°C.
6. Ensure that both the ingot and die ends are smooth and free from damage or adhesion. If not, material may run out 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 maintain optimal extrusion conditions.
7. Monitor the pressure during extrusion. If the pressure remains above 210 kg/cm² for more than one minute, stop the extrusion immediately to avoid equipment or mold damage.
8. Control the extrusion speed according to the alloy type. Low-impurity alloys can be extruded faster, while high-impurity ones require slower speeds. If the ingot temperature is high, reduce the extrusion speed accordingly. To increase speed, lower the ingot temperature.
9. The outlet temperature must be at least 500°C to ensure proper mechanical properties.
10. Inspect the first extruded section: Cut the first 500mm of the profile for mold adjustment. Check the size, shape, and tolerances of the first two sections to confirm they meet design specifications and assembly requirements before continuing production.
11. Apply a small amount of mold release grease to the mold and gasket end faces to prevent sticking. However, avoid over-application, especially on the mold cavity and ingot barrel walls, to prevent contamination of the profile.
12. Use the squeeze gasket properly to protect it from damage. Replace the gasket if it becomes worn or the chamber is not clean. Always check that the gasket is in place before extrusion to avoid equipment failure.
13. Monitor the hydraulic oil temperature during extrusion. When it reaches 45–50°C, extrusion force decreases significantly. Stop extrusion until the oil cools down before resuming.
14. Extrusion press capacity: 80 pieces per die set.
15. To prevent gas entrapment in the dead zone, the pressurization length should be kept between 15–30mm. Avoid excessive thickness or compression.
16. For 6063 aluminum extrusion, T6 quenching uses forced air cooling, while T5 uses natural cooling. The cooling rate should be at least 80°C/min until the temperature drops below 170°C. For 6061, use strong wind, water mist, or direct water cooling, reducing the temperature below 200°C within 2–3 minutes.
17. Cool the aluminum profiles on the cooling bed until below 50°C before straightening. The straightening amount should be around 1–2%, up to 3% for thick profiles. Protect the decorative surface during handling. Place non-decorative sides against the scaffolding whenever possible.
18. Understand the length tolerance requirements before cutting. If no specific customer instructions are given, allow +15mm deviation, and +20mm for full-scale delivery. Ensure the first cut meets specifications with a positive deviation only. Confirm accuracy before proceeding with bulk cutting.
19. Prevent scratches by avoiding folding during sawing. Clean the sawdust off the profile before cutting.
20. Lubricate the saw blade but avoid contact with the aluminum surface. Ensure the cut is perpendicular, smooth, and free from burrs or twists. Keep the blade sharp; replace it when necessary to maintain a clean cut.
21. After cutting, blow off any debris with compressed air before boxing.
22. Inspect all large profiles and sample 10% of medium and small ones. Check for flatness, bending, twisting, opening, closing, and surface quality.
23. Handle the profiles carefully when placing them in the frame. Two workers should lift and position them gently to avoid collisions. Wear clean, oil-free gloves during the process. Place heavy or long profiles on the lower layer and lighter or shorter ones on top.
24. After each layer, insert 4–8 crossbars according to the profile length and tolerance. Avoid vertical bending or stacking.
25. Separate solid aluminum materials that cannot be ventilated vertically. Use small square tubes with ventilation holes to promote airflow and heat dissipation.
26. Ensure the upper layer of the aluminum profile is slightly lower than the frame plane to prevent crushing when stacking.
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