Capabilities

Futura Industries has two aluminum extrusion presses in its facility. Our extrusion presses are positioned to efficiently support our lean manufacturing processes; allowing us to provide you with some of the most consistent lead-times in the industry, and on-time delivery performance. Our range of extrusion press sizes can produce everything from the most common large extruded profiles, as well as thin-wall extruded profiles. We have a “no-minimum” requirement, which means you can get the quantity you need, when you need it.

Extrusion press selection is determined by the required tolerances, wall thickness, circle size for each shape, and order quantity. Maximum circle sizes are directly related to the billet diameter used for each press. The billet diameter generally equals the maximum circle size that each extrusion press can produce, although special tooling may be designed to extrude shapes larger than the billet diameter.

Artificial Aging

Magnesium and silicon are the major alloying elements in 6xxx series alloys. These elements combine to form magnesium silicide. The artificial aging process produces fine grain magnesium silicide precipitates that will increase the strength of the 6xxx alloys. Due to the effects on the magnesium silicide precipitates, this process can also be called “precipitation heat treatment”. The aging process also occurs naturally (uncontrolled) over time. However, by controlling the times and temperatures in the artificial aging ovens, maximum strength and benefits can be realized.

Tempered aluminum ranges from T1 / T4 / T5 / T52 / T6 can be achieved. T52 temper is associated with alloy 6063 and this temper is usually associated with aluminum that is going to be bent is some fashion.

Tolerances

Profile tolerances can be an important consideration when designing extrusions. Factors affecting profile tolerances include wall thickness, profile circumscribing circle size, location of dimension on the profile, type of profile (i.e. solid, semi-hollow, hollow) the extrusion press size (i.e. 1200 ton press versus 2100 ton press).

Design Considerations

One of the advantages of the aluminum extrusion process is the freedom to design profiles to meet your exact needs. We can offer design recommendations that can save you time and money. Understanding the fit, form, and function of your design allows us to work with you to meet today’s tough design challenges.

Choosing the right alloy
6063 is the most common alloy in use today. It offers a wide range of benefits that include good formability, surface finish, and medium strength when aged. 6005A and 6061 are a good choice when added strength is required. 6005A provides a slightly better surface finish while maintaining the same minimum tensile and yield properties as 6061.

Surface finish
Uniform wall thickness is ideal, but gradual transitions from a thick wall to a thin wall will also help to minimize streaking of a cosmetic surface. Generous radii at the point where walls intersect can also minimize surface imperfections. Designing ribs or grooves into a surface can add strength as well as enhance the surface appearance by blending the modified surface with the extrusion process flow lines.

Tolerances required
Standard Aluminum Association tolerances should be used as guideline, but with today’s advanced technology in die building and extrusion controls, much tighter tolerances are attainable.

Circle size
The billet diameter generally equals the maximum circumscribing circle that an extrusion press can produce. Special tooling may be designed to extrude shapes larger than the billet diameter. Each shape that is larger than the billet diameter must be reviewed to determine if this special tooling is a good fit with your application.

Screwbosses
You may want to consider incorporating a screwboss into your extrusion profile, instead of a fully encapsulated hole. Extrusions with holes, such as a round tube, are considered a “hollow die” and require more costly extrusion tooling. Screwbosses avoid this hollow condition, and usually reduce the metal content of your part while providing the same benefits of a hole.

Lean EXTRUSION Activities

Futura's Lean Manufacturing philosophy begins with our raw material, or billet. We receive frequent shipments of billet to meet our daily manufacturing requirements, thus minimizing inventory carrying costs and floor space requirements. Our billets come to us in full length, and we optimize the size of each billet we extrude utilzing an in-line billet saw that cuts the billet to the best size to extrude in our press. This process increases the extruded product yield per pound with less aluminum scrap generated.

Extrusion die preparation is also an important step in Lean Manufacturing. Extrusion dies must be pre-heated in ovens prior to extruding. We use state-of-art equipment and this results in fast die changeover times, another key to Lean Manufacturing.

Smaller lot sizes and “no-minimum-pound” requirements demand more frequent tool changes. Keeping these die change times to a minimum allows us to keep our presses operating at peak efficiency levels. State-of-the-art, infra-red, single-cell die ovens result in a die being being ready for production in as little as 1-½ hours.

Aluminum Extrusion Alloys

6063 - Most economical. Excellent extrudability. Good corrosion resistance, surface finishing response, machinability, formability and weldability.

6463 - Produces a bright, mirror-like, high quality surface finish, good machinability and formability.

6005 - Excellent extrudability and strength, low impact resistance, good surface finishing response, machinability, formability, and weldability.

6061 - Excellent strength, corrosion resistance and machinabilty, poor surface finishing response, good formability and weldability.

6050 - Excellent strength, stronger than 6063, with better surface finish response than 6061