Aluminum Extrusion Troubleshooting

Die deflection angularity – thin wall

Problem Description

Thin-wall sections show angular distortion due to die deflection under load.

Cause–Correction Mapping
  • Bearing squareness
    Cause in: Die

      Corrections

    • Correct for square bearing during flow/under pressure

  • Poor die design
    Cause in: Die

      Corrections

    • Change design/replace tool.

  • Poor tooling support
    Cause in: Equipment

      Corrections

    • Increase tooling support before working die.

  • Press alignment
    Cause in: Equipment

      Corrections

    • Correct alignment.

  • Soft die (low Rockwell)
    Cause in: Die

      Corrections

    • Reheat treatment, only when delivery critical; preferably order new tooling.

      Advantage: Better extruded product; less die correction work and die testing.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Die deflection angularity – thin 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.