Aluminum Extrusion Troubleshooting

Waving/light wall

Problem Description

Waviness combined with localized thin wall sections, either along the full length or partial areas.

Cause–Correction Mapping
  • Die or tool deflection
    Cause in: Equipment

      Corrections

    • Redesign backer/bolster to provide maximum support.

  • Excessive flow
    Cause in: Equipment

      Corrections

    • If along entire length of extrusion:
      1. Increase flow to slow area by adjusting ports.
      2. Decrease flow to fast area by welding restrictors (bumps).
      3. Decrease billet temperature.

    • If along portion of extrusion length:
      1. Increase/decrease entire billet temperature as required.
      2. Use shorter billet.
      3. Achieve uniform billet temperature.
      4. Check and adjust putter tension.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Waving/light wall in aluminum extrusion. However, it is important to note that the specific cause and correction of any particular defect will vary depending on the specific extrusion process, alloy, and other factors. Therefore, it is important to consult with an experienced and professional engineer to ensure that the correct diagnosis is made and the most suitable correction is chosen.