Aluminum defects can significantly impact production efficiency and profitability. Even a small flaw in an aluminum profile can result in the entire length being discarded, leading to waste and increased costs. Given the high value of aluminum profiles, extrusion manufacturers must prioritize minimizing defects throughout the production process.
One key factor is **non-squeeze cycle time**. If an extrusion press produces 30 rods per hour and each non-squeeze cycle saves 10 seconds, this can add up to two extra hours of production daily. This increase translates into over an 8% boost in output, which directly reduces the cost per kilogram of the final product.
**Downtime** is another major issue. In our example, each minute of downtime costs about 48 yuan, not to mention the loss of potential output during that time. Reducing unplanned stoppages is essential for maintaining efficiency and maximizing profits.
The **extrusion speed** also plays a crucial role. High-tech molds can significantly increase extrusion speed, allowing manufacturers to offset their initial investment quickly. For instance, if a mold increases production by 50% and reaches 800 kg/hour, even a small order of less than 10 tons can cover the added cost of the mold.
Using **porous molds** can further boost productivity. A 2-hole mold can increase extrusion speed by 200%, while a 3-hole mold can go up to 300%. These improvements lead to higher economic returns and better utilization of resources.
Modern **aluminum haulers** help reduce waste by ensuring that the extruded profiles are cut at the correct length. This eliminates unnecessary extrusion time and reduces material waste, saving on both transportation and recycling costs.
After extrusion, it's vital to minimize scrap and improve shipment rates. Any waste generated post-extrusion is costly, so focusing on reducing defects in later stages is essential. Cutting at **stop marks**—marks left during the non-extrusion cycle—helps ensure that only the required lengths are used.
Two main technologies enable cutting at stop marks: **flying saw cutting** and **dual-length systems**. Flying saws allow for real-time cutting during the extrusion process, while dual-length systems cut between two profiles after the second one is extruded. Both methods can increase yield by 1–2%, converting waste into sellable products.
In terms of **transportation**, modern systems use tractors to align profiles with the stretcher head, reducing the risk of damage from pushing or pulling on conveyor belts. Proper **clearance** between profiles also prevents scratches and ensures smooth handling.
Manual operations introduce risks. Operators who handle profiles directly increase the chance of damage, especially when loading and unloading from frames. Training and awareness are critical to minimizing these risks.
Regular **maintenance** of extrusion presses is equally important. Poor alignment, worn-out components, or faulty ingots can all contribute to defects. Ensuring that the equipment is well-maintained helps maintain consistent quality.
**Residual air** during the extrusion process can cause bubbles in the final product. Three main causes include gas residue from upsetting, air sticking due to hot shearing, and contamination from spliced rods. Addressing these issues is essential for producing defect-free profiles.
Using **long rod hot saws** instead of hot shears can eliminate air entrapment, though some manufacturers avoid them due to the creation of aluminum chips. However, these chips are low-value and do not affect the value-added processes, making the switch economically beneficial.
For spliced rods, **bar-spinning welding machines** offer a solution by joining short bars to longer ones before cutting, eliminating the risk of air entrainment.
Finally, **solid contaminants** such as dirt or oxides can also damage the final product. Keeping storage areas, heating equipment, and transfer systems clean is crucial. Over-lubrication should be avoided, and operators should be trained to apply just the right amount of lubricant.
By addressing these factors, manufacturers can significantly reduce defects, improve yields, and enhance overall profitability in the aluminum extrusion industry.
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