Aluminum Extrusion Troubleshooting

Uneven walls which worsen after each run

Problem Description

Wall thickness inconsistency increases with repeated runs of the same die.

Cause–Correction Mapping
  • Shear edge has dropped below die face, caused by deflection of mandrel (housing face)
    Cause in: Die

      Corrections

    • Redesign stronger, more streamlined die to reduce mandrel deflection if time/budget allows; possibly a larger diameter die.

      Advantage: Less scrap.

    • Cut a small pocket around perimeter of profile on die face to equal the amount of deflection. This will realign the shear edge and die face.

      Advantage: Longer lasting die.
      Disadvantage: Increased die size, more expensive.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Uneven walls which worsen after each run 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.