Aluminum Extrusion Troubleshooting

Thin walls or mandrel shifting toward outside on multi-hole dies

Problem Description

In multi-hole dies, mandrels shift outward, producing thin walls in outer cavities.

Cause–Correction Mapping
  • Balanced porting and flow
    Cause in: Die

      Corrections

    • Use larger ports toward outside of die to encourage more flow to the outside and balance mandrel (if unsuccessful revise die design).
      Design die with offset walls.

  • Check Rockwell of tooling
    Cause in: Die

      Corrections

    • Reheat treat, or replace tool.

  • Inadequate support tooling
    Cause in: Die

      Corrections

    • Design better support tooling.

  • Measure area of the ports to evaluate consistency
    Cause in: Die

      Corrections

    • Use larger ports toward outside of die to encourage more flow to the outside and balance mandrel (if unsuccessful revise die design).

  • Support tooling flatness
    Cause in: Die

      Corrections

    • Correct flatness/check hardness of tooling; reheat treatment and grind flat or replace.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Thin walls or mandrel shifting toward outside on multi-hole dies 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.