aluminum forming process Archives

The Benefits of Aluminum Extrusions as a Solution to Product Design Challenges

maria2023-03-07T02:09:39+00:00October 3rd, 2022|

Triptych with left image displays 5 samples of Taber’s aluminum extrusion products in varied shapes. Middle image shows a curved exterior of a building with beautifully designed rectangularly framed windows. The last photo on the right is a sepia-toned picture of another building showing staggered rectangularly framed windows.

The benefits of aluminum extrusions as a solution to product design challenges are numerous. Aluminum is an abundant mineral found in the Earth’s crust. It is highly conductive, has low density, has excellent resistance to corrosion, is malleable, and most importantly — it is recyclable! Combined with the process of extrusion, it is the most cost-effective, functional, and efficient way of achieving form and function in design and engineering.

From humble beginnings in 1894, Alexander Dick developed the hot extrusion process allowing non-ferrous alloys to be extruded. The applications for aluminum in architecture, engineering, electronics, transportation, and other industries has grown exponentially since then.

According to Technavio, the aluminum extrusion market share is expected to increase by 8.87 million tons from 2020 to 2025, and the market’s growth momentum will accelerate at a CAGR of 5.02%.

“Form follows function — that has been misunderstood. Form and function should be one, joined in a spiritual union.” — Frank Lloyd Wright

A black and white oval-framed portrait of the great American architect and designer, Frank Lloyd Wright. In line with the portrait, written in bold white font on a blue background is a quote from the late architect, “Form follows function—that has been misunderstood. Form and function should be one, joined in a spiritual union.”

The Benefits of Aluminum Extrusions on Form and Function

What is form and function? It is a principle of design associated with late 19^th– and early 20^th-century architecture and industrial design in general, which states that the shape of a building or object should primarily relate to its intended function or purpose.

This is only a part of how the benefits of aluminum extrusion helps designers, engineers, and industries in building and shaping our world. It is basically all around us, from a simple child’s toy to a medical device that saves lives. From vehicles and infrastructure that transport us by land, sea, and air — to the satellites that connect us seamlessly through technology. This process has changed how we live, thrive, and build our future.

Collage showing the different industries that use aluminum extrusion. The upper left photo shows a beautiful view above the city traffic and skyscrapers with lights on at night. Below that is a photo showing a huge cargo ship leaving the docks with a view of the sunset. Beside it, on the right is a high-speed train with a red roof and aluminum body passing through a modern underground terminal. Lastly, in the upper right corner, is a photo of a satellite orbiting near Earth in space.

Through the years, aluminum extrusion has evolved and grown alongside advancements in technology. These breakthroughs helped the industry improve raw materials with the aid of modern testing and surveying. As the world goes digital, everything is done using a computer and/or smart technology, which means materials that have undergone the process are precise, accurate, and spot on!

Pentaptych image showing the modern ways of how aluminum extrusion is created and used. First left image shows an engineering surveyor working with surveying equipment. Next is a close-up of a circuit board used in modern electronics. Third is a scientist looking through a telescope wearing a white lab gown and mask. Fourth image is a green metal press in a factory demonstrating how materials are processed in a production line. Last photo shows a desktop computer from above with a hand at a keyboard showcasing how aluminum extrusion is designed.

More Benefits of Aluminum Extrusions as a Design Solution

There are many benefits of Aluminum extrusions in terms of strength, resilience, corrosion resistance, and weight. The material itself is lightweight at about 1/3 that of iron, steel, copper, or brass which makes the material ideal for shipping and logistics. The process enhances the strength-to-weight ratio of the material and is applicable to a variety of industries where weight is a consideration in terms of design and capabilities.

One advantage is that it can develop its own inert aluminum oxide film that blocks further oxidation. While other materials get brittle when temperatures are reduced, aluminum gains strength, making it a preferred choice for low-temperature applications. It diffuses heat which allows designers to optimize heat dissipation in electrical housings and other components.

And what about safety? Aluminum is non-sparking making it suitable when combustible materials are present. Aluminum can be substituted for copper in electrical conductors, can help reduce the cost and weight of electrical connectors. As well, It does not burn and does not produce toxic fumes.

Aluminum is widely used in all industries around the world. Combined with the process of extrusion, it will surely be beneficial in terms of alternative materials and processes that will give way to innovation and continue to enrich our lives.

Collage showing the advantages of aluminum extrusion. First photo shows a sheet of metal material covered in rust and deteriorating. Beside it is a photo of a bicycle parked on a sidewalk covered with thick white snow. Above it is a photo of a small scale with blocks of sugar weighing in at ¼ grams. Lastly, a hanging metal chain with links symbolizing strength.

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

A Partner That Understands the Benefits of Aluminum Extrusion as a Design Solution

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

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

Take 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 100 pounds 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 has been a leader in the extrusion industry for over four decades.

More About Taber Extrusions

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 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, microextrusion 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 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 is proud of its friction stir welding capabilities, and 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. If you have any questions, please visit taberextrusions.com or contact one of our Regional Sales Representatives.

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The Gift of Aluminum Extrusion: How Extrusion Technology Shapes Our World

Cara2022-02-03T22:57:53+00:00December 3rd, 2021|

An photograph of extruded aluminum pieces with a white graphic rectangle that reads “The Gift of Aluminum Extrusion: How Extrusion Technology Shapes Our World.”

Technology is commonly defined as the application of scientific knowledge to the practical aims of human life, or, as it is sometimes phrased, the change and manipulation of the human environment. Aluminum extrusion technology is one such innovation that continues to change the world for the better. Before we bring light to this time-honored approach to aluminum processing, we should first know where it all began.

The Beginnings of Aluminum Extrusion

Before 1825, the complexities of refining aluminum from ore made aluminum a rare and precious metal that was more valuable than silver and gold. Thanks to a successful smelting process invented by Charles Martin Hall and Paul Heroult, aluminum paved its way into the commercial sector. The invention of smelting gave rise to better technology that could fully take advantage of the unique attributes of aluminum. In 1894, Alexander Dick achieved just that when he developed the hot extrusion process. This process allowed non-ferrous alloys to be extruded, and the first aluminum extrusion press was in production by 1904. Over the years, with modern technology, extrusions can now be more precise and accurate.

A picture of a child’s generic plastic playdough-style extruder squishing out a red textured noodle-like log (or “billet”) of modeling clay next to 2 containers filled with blue and red “dough.”

Aluminum Properties Made Simple

In essence, aluminum extrusion technology can be compared to popular child’s modeling clay. Playdough can be smashed, folded, and molded into any shape. The material can also be squeezed through an extrusion-type machine passing through various-sized and shaped holes (just like die casts!) to become an entirely different shape destined for a brand-new use. The possibilities are only limited to one’s imagination. A young scientist at work…

In the world of aluminum extrusion technology, the process of forming aluminum begins with a raw aluminum. While this metal is the most abundant on Earth, it rarely comes in its pure form. Alumina is made from bauxite. After that, the material must undergo smelting and an alloying process involving many alloying elements such as copper, magnesium, silicon, and manganese. Finally, the aluminum is ready for the extrusion process. An aluminum billet is preheated then forcibly compressed through a smaller opening. Besides the aluminum alloy combination, many factors determine the quality and properties of the final product, such as the billet length, the billet heat, aluminum profiles, and the extrusion speed. Despite varying results, a freshly made aluminum extrusion is hardly ever used in a real-world commercial application. Most aluminum extrusion products adhere to specifications which meet the needs of each industry.

Among the many reasons of how aluminum extrusions shape our world, aside from being incredibly strong, aluminum weighs only a third of other common commercial metals like iron, steel, and copper. This makes aluminum more economical in applications where fuel economy is an important factor such as in the transportation sector. Additionally, this metal is exceptionally resilient, allowing it to bend and spring back after substantial impacts, making it a top choice for automotive crash management systems.

A photograph of a modern building made entirely of a reflective metal.

Remember that playdough analogy? Well, aluminum’s malleability makes this metal easy to work with throughout the design and extrusion process. An aluminum extrusion can be tailored to meet all possible needs in terms of function and aesthetics.

Aluminum Extrusions and Energy

Photograph of mounted solar panels in a field of green grass.

Aluminum extrusions also play a role in energy generation. Compared to other metals, aluminum has high electrical conductivity, making it preferential for energy distribution. Aluminum is also essential in structural and racking solutions for systems that collect solar power when generating green energy. Aluminum, and by extension, aluminum extrusions, is one of the most sustainable metals out there. The icing on the cake? Aluminum is infinitely recyclable without losing any of its above properties.

The aluminum industry has had to evolve to accommodate the growing needs of various industries that utilize aluminum extrusions. Within the United States’ aluminum industry, Taber Extrusions is a leader in quality products and customer satisfaction, firmly believing in collaborative work with customers to find unique solutions to queries that our ever-changing world presents. Taber’s extensive aluminum extrusion capabilities allow the creation of all kinds of designs for a variety of industries.

ABOUT TABER EXTRUSIONS

Taber Extrusions, located in Russellville, AR and Gulfport, MS, is highly regarded as a 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. The most recent expansion was the addition of the new Haas VF-12 CNC machining line. Taber continues to extrude billet in a wide range of alloys and sizes and has diversified its markets beyond 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 full offering of extruded aluminum components, value-added machining services, and raw material supply to the North American market.

Follow Taber Extrusions

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

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

TWITTER: https://twitter.com/taberextrusions

Are you interested in joining the Taber Team? Send your resume to: careers@taberextrusions.com

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