Aluminum Extrusion Troubleshooting

Thinning of light areas adjacent to heavy sections, thin wall extremities, screw bosses, etc.

Problem Description

Thin areas near heavy sections become excessively thin, such as near screw bosses or extremities.

Cause–Correction Mapping
  • Inadequate metal flow: Improper flow paths to starving area, Open feed to thing wall areas, Indirect openings to thin walls.
    Cause in: Die

      Corrections

    • ncorporate choke around heavy area; weld restrictions or speed bumps in ports to block or shadow heavy area.

      Disadvantage: Choke may increase extrusion pressure; welding may weaken die.

    • Redesign die to improve flow to thin area.

      Disadvantage: May weaken die, Added cost; time.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Thinning of light areas adjacent to heavy sections, thin wall extremities, screw bosses, etc. 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.