22 02, 2023

Large Aluminum Extrusion Design

2023-02-27T00:40:04+00:00February 22nd, 2023|

Graphic with three photos in sepia tint, with the title of the blog written in white font. The upper left photograph is of a circular building with multiple window frames. The upper right photo is a machine in Taber’s facility. Third photo at the bottom is the interior of the Taber factory.

“Dream big dreams; only big dreams have the power to move men’s souls.”

― Marcus Aurelius

If you think about it, innovation is ingrained in man’s DNA. As humans, we always want to better ourselves and the things that we utilize to improve our way of life. And why stop there? Why not be bigger?

Here at Taber, we continue to raise the bar and enhance our capabilities to help you realize your vision – in all shapes, forms, or sizes. And with that, we pride ourselves in having the only rectangular container in North America. A feat that sets us apart in the aluminum extrusion industry in terms of capabilities. We’ve uniquely positioned our company to have the ability to extrude wide shapes – which is much more comprehensive than the capability of traditional round containers. Our exclusive rectangular container allows us to supply our customers with some of the industry’s widest, most complex multi-void hollows.

Like the great Marcus Aurelius once said, “Dream big dreams; only big dreams have the power to move men’s souls.”  And our large press capability will surely take your vision to reality.

Why Go BIG?

The larger the press, the bigger the extrusion. Assembly techniques can be reduced by eliminating the need to weld in using the largest available extrusions and/or mechanical joints, lowering the cost and time spent in construction.

Mechanical factors such as holes, threads, grooves, and placement of flaw-free welds affect the properties and fatigue-strength of the material. With large aluminum extrusion capability, fusion welds can be arranged in non-critical areas, or broaden the section nearest to a weld to compensate for any losses caused by the welding process.

In structures with complex parts, the use of large-scale extrusions streamlines the design, eliminating strain and possible drawbacks to the structure.

In a rectangular container, there is uniform metal flow in width and thickness of wider bars and profiles and the following is achieved, in contrast to a round container of similar geometry:

Typical flatness can be controlled to within normal AA specifications, multi-void hollow profiles of up to 29” width and solid profiles up to 31” wide. However, at times, profile designers demand flatness profiles outside of AA specifications. In these cases, Taber operates a compliment of secondary roll correction machines that are able to bring the profile into the desired tolerance range. Overall, it is best to consult with Taber early in the design process and we can work with you to design the best profile to meet your specifications and allow the most efficient production.

Graphic with 3 black and white photos with a poem about aluminum in white font printed on the photos. The one on the left is a photo of a high-rise building, the one the top right is a photo of a plane, and the one on the bottom right is a photo of a ship.

The advantages of working with aluminum extrusions in a variety of sizes are endless.

  • High recycling value
  • Reduced cost in tooling/machining
  • Reduced assembly time
  • High strength-weight ratio
  • Long lifespan with minimum maintenance
  • Aesthetically pleasing finishing options
  • Streamlined design possibilities
  • Wide range of large-scale applications
    • Aircraft landing mats
    • Heliport decking
    • Bridge decking
    • Air droppable pallets
    • Shoring planks
    • Loading platforms
    • Airport structures
    • 28” wide rectangular container
    • Superstructure components
    • Military vehicles
    • Shipping containers
    • Rail cars
    • Truck trailers
    • Buses
    • Beverage trucks
    • Light rail systems
    • Delivery vehicles

Are You Ready to Go BIG?

To make your design more efficient, it’s imperative to have a deep understanding of the full scope from alloy properties to material and tooling costs, appropriate tolerancing, and the latest in manufacturing innovation. Taber Extrusion’s talented engineering team is available to assist your design engineers with the details:

  • Wall/material thickness
  • Uniform wall thickness
  • Wall/material variance
  • Radius vs square corners
  • Solid profiles if possible
  • Fewer cavities in hollow profiles
  • Profiles with deep channels and ratios
  • Heat sinks
  • Decorative surfaces run-out surface

We are proud to be set apart as more than just an extruder. Taber Extrusions is a full-service partner, and we have an unwavering commitment to consistently meeting and exceeding customer expectations by providing both products and services of the highest quality. This commitment is at the core of our value-added philosophy.

For us, unique, customized capabilities are key. Taber’s specialty is manufacturing complex and intricate extrusions that competitors consider difficult or even impossible. Our full range of extrusion presses, from 1800 and 3000 tons to our impressive large 8600 tons, gives us unmatched flexibility and profile capabilities.

Graph showing the three kinds of extrusion presses that Taber Extrusion has. Specifications are for an 8600-ton, 3000-ton, and an 1800-ton press. The Taber logo is placed at the lower right corner of the image.

One of the largest extrusion presses in the United States—our 8600-ton press—can extrude both 16- and 20-inch round billets, and 10” x 28” rectangular billets with a maximum circle size of 31” and up to 140 lbs. per foot. With the ability to extrude large, intricate configurations, such as lightweight but strong one-piece extrusions, the customer can incorporate whole assemblies of small components into one extruded part.

We’ve established notoriety for the highest levels of quality and responsiveness over four decades, and proudly hold the title of broadest capabilities in the aluminum extrusion industry.

About Taber Extrusions

Taber Extrusions is located in Russellville, AR, and Gulfport, MS, and is a highly regarded provider of aluminum extrusions to various industries including aerospace, infrastructure, transportation, defense, and thermal management. ISO 9001 and AS 9100 certified, Taber’s present and future customers can expect to see increased supply opportunities with the expanded set of extrusion solutions, programs, and services.

To learn more about how we can be of service visit: https://taberextrusions.com/

For inquiries or quotes visit: https://taberextrusions.com/contact-us/

Follow Taber Extrusions

LINKEDIN: https://www.linkedin.com/company/8843183/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

Interested in becoming a part of the Taber Team? Submit your resume to

careers@taberextrusions.com.

3 11, 2022

Aluminum Extrusions Key Design Considerations

2023-03-07T01:48:18+00:00November 3rd, 2022|

Collage of 3 photos with the words, “Key Design Considerations/taberextrusions.com” Two photos show an array of finished aluminum extrusion profile samples hung on a grey wall. Lower right corner is the gold inverted triangle logo of Taber Extrusions.

Aluminum is becoming more and more popular in the building and manufacturing industries because of its rich and useful properties, giving rise to aluminum extrusions’ key design considerations. When aluminum extrusion was discovered, it allowed the material to be transformed into almost any shape, size, and form imaginable making engineers and design professionals achieve both form and function.

Although aluminum extrusion presents flexibility in terms of design, we also know that there can be limitations as with all manufacturing processes. However, understanding these design challenges can improve the functionality of your design and help reduce production costs and time.

Our goal here is to determine the best design for your project and with aluminum extrusion, it is equally important to understand the function of your profile as well as its appearance. That being said, we’d like to share with you key things to consider when designing your next aluminum extrusion profile with us.

A couple aluminum extrusions key design considerations to start with:

WALL THICKNESS

Wall thickness can be cost-efficient depending on the requirements of your project. Having a uniform wall thickness and minimal aluminum thickness on your profile is efficient both in cost and production time.

Removing uneven wall thickness during your design process is beneficial as it eliminates problems during the extrusion and cooling process. It ensures that the end product is clear of uneven finishes, cosmetic issues, and is structurally sound. It also eliminates high production costs due to potential difficulties during production.

Some of the factors that influence wall thickness are:

  • The choice of the alloy
  • The shape of the profile
  • Extrusion press power and speed
  • The desired surface treatment
  • Desired tolerances

TOLERANCES

Profile tolerance is a key consideration and is critical to the design profile. It is applied to the physical dimensions of a part during manufacturing. Depending on its intended application, there are standard tolerances that are published and are important to consider. Among them are wall thickness, dimension size, location, profile type (solid or hollow), alloy used, cross section, and the parts application. To learn more, you may reach us here.

Various samples of aluminum extrusions from Taber Extrusions on an off-white background. A gold inverted triangle Taber logo is at the lower right corner in a brown triangle graphic.

A few more aluminum extrusions key design considerations:

SHAPE

In line with wall thickness, simple shapes are also efficient in terms of cost and production time. Yes, aluminum extrusion can produce a range of shapes and designs to meet the aesthetic and structural requirements of a designer; but razor-sharp corners and the extrusion process don’t go well together as they tend to bend and become uneven. Also, complicated shapes in turn will need to have complicated dies resulting in higher tooling costs.

There are three general classifications of extruded shapes: solid, semi-hollow, and hollow.

Solid shapes have a cross-section that does not have any voids. They are cheaper to make because they are less complex. Semi-hollow profiles are defined by the tongue ratio (width of the gap vs. its depth). A larger ratio is classified as semi-hollow while a smaller ratio is considered as solid. Hollow profiles contain a void or maybe even multiple voids on a single profile.

SURFACE FINISHES

When exposed to the elements in our atmosphere, different materials can be vulnerable, and aluminum is no exception. Aluminum naturally forms a thin oxide layer on its surface and serves as protection against the elements.

However, aluminum extrusions can be finished with a variety of paint, anodize, or mechanical treatments when additional surface protection or an enhanced appearance is desired. One factor to be considered about finishing is the in-use environment that your profile needs. There are, however, other reasons for treating aluminum surfaces such as color, hardness, better resistance to wear and corrosion, reflectivity, electrical insulation, and enhancements to the surface structure.

It is important to remember that the dimensions that were added to a finished profile are often overlooked. Although these changes can be minor, there can be critical impacts caused by these changes that may be troublesome to your projects. You can reach us here to know more about the finishing options and considerations for your profile.

ALLOY SELECTION

A wide selection of alloys and tempers are available depending on your profile’s needs and use. Aluminum is alloyed with other materials to enhance strength and/or attributes to cater to most applications. Therefore, you initially need to determine the function of your profile to determine the best alloy to use for your profile.

In addition to alloy selection, temper — the hardness and strength imparted to the metal by mechanical or thermal treatment — determines the ultimate physical performance of an aluminum extrusion.

To know more about this, click here so we can guide you on the best alloys to use for your profile.

So, what’s next? Find the right company that specializes in aluminum extrusions, billet casting, fabrication, microextrusions, friction stir welding, and design assistance.

Who can help with aluminum extrusions key design considerations:

Taber Extrusions is a full-service partner, and we have an unwavering commitment to consistently meeting and exceeding customer expectations by providing both products and services of the highest quality. This commitment is at the core of our value-added philosophy.

For us, unique, customized capabilities are key. Taber Extrusions’ specialty is the manufacturing of complex and intricate extrusions that competitors consider difficult or even impossible. Our full range of extrusion presses, from 1800 and 3000 tons to our impressive large 8600 tons, give us unmatched flexibility and profile capabilities.

For example, one of the largest extrusion presses in the United States, our 8600-ton press, has the capability to extrude both 16 and 20-inch round billets, and 10” x 28” rectangular billets with a maximum circle size of 31” and up to 140 lbs. per foot. With the ability to extrude large, intricate configurations, such as lightweight but strong one-piece extrusions, the customer can incorporate whole assemblies of small components into one extruded part.

Our value-added philosophy, along with our custom capabilities and top-tier customer service, is why Taber Extrusions has been a leader in the extrusion industry for over four decades.

More About Taber Extrusions – Company History

Taber Extrusions, located in Russellville, AR, and Gulfport, MS, is a highly regarded provider of aluminum extrusions to a wide variety of industries including aerospace, infrastructure, transportation, defense, and thermal management. ISO 9001 and AS 9100 certified, Taber’s present and future customers can expect to see increased supply opportunities with the expanded set of extrusion solutions, programs, and services.

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS in 1995 which houses a new state-of-the-art cast house and two additional presses, micro-extrusion capabilities, and the fabrication area has been expanded multiple times.

Taber continues to extrude billet in a wide range of alloys and sizes and has diversified its markets beyond the military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies cast and extruded products in a variety of soft and hard alloys.

Today, Taber Extrusions is proud of its friction stir welding capabilities, and a full offering of extruded aluminum components, value-added machining services, and raw material supply to the North American market.

Thank you for your continued support of Taber Extrusions, LLC. If you have any questions, please visit taberextrusions.com or contact one of our Regional Sales Representatives.

Follow Taber Extrusions:

LINKEDIN: https://www.linkedin.com/company/taberextrusions/
FACEBOOK: https://www.facebook.com/taberextrusions/
TWITTER: https://twitter.com/taberextrusions

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