High-Performance Aluminum Extrusion
Extrusion is a versatile process that transforms heated aluminum billets into precisely shaped profiles by forcing them through a die. At Regal aluminum, this is our core competency. Our facility operates two imported 1150 US Ton extrusion presses, giving us a rated capacity of 12,000 tons per year to handle projects of any scale. Each press is synchronized with a PLC-controlled puller to produce exceptionally straight, twist-free products. We deliver high-tolerance extrusions with an excellent surface quality, suitable for a vast range of architectural and industrial applications.
The Extrusion Process: Step-by-Step
Billet Pre-Heating
A solid aluminum billet, typically 5 inches in diameter for our presses, is heated in an induction furnace to a precise temperature of around 450-500°C, making it malleable but not molten.
Loading the Press
The heated billet is transferred to the extrusion press and placed into a container. A lubricant is applied to prevent it from sticking to the ram or the die during the high-pressure process.
Extruding the Profile
A hydraulic ram applies immense pressure (up to 1150 US tons) to the billet, forcing the softened metal to flow through the shaped opening in the steel die, emerging as an elongated profile.
Quenching & Cooling
The hot profile is guided onto a run-out table where it is rapidly cooled, or "quenched," using air or water. This process locks in the material's metallurgical properties developed during extrusion.
Stretching & Cutting
After cooling, the profile is moved to a stretcher and pulled from both ends to straighten it and relieve internal stresses. It is then cut to specific, marketable lengths as per customer requirements.
Aging (Heat Treatment)
Finally, the cut profiles are placed in an aging oven for a specific time and temperature. This precipitation hardening process brings the material to its final temper (e.g., T5 or T6), giving it maximum strength and hardness.
The Regal Advantage
- High-tolerance profiles meeting exact specifications .
- Superior, scratch-free surface finishes from automated handling .
- Consistently straight, twist-free products via PLC-controlled pullers .
- Wide range of commercial alloys, including 6061 and 6063 .
- Both custom and standard shapes available from our die library
- On-time delivery and consistent lead-times