28 02, 2024

Aluminum Casting Services for Aerospace, Marine, and Custom Chemistries for Specialized Industries

2024-02-28T16:18:21+00:00February 28th, 2024|

The most noticeable object in the photo is a massive yellow crane with the name “TABER” on it. The crane is lifting 3 lengthy metallic pipes that measure approximately two feet in diameter. Straps securely attach the pipes to the crane. Other industrial equipment and machinery fill the background of the image. The photo diffuses the lighting, creating a soft glow. At the same time, muted colors add to the overall industrial feel of the scene.

In order to fully grasp the importance of Taber’s aluminum casting services, you must first understand the importance of aluminum billets.

Aluminum billets are the unsung heroes of the industrial world. These unassuming cylinders of aluminum, typically 10-12 feet long and 7-20 inches in diameter, are the raw material from which countless objects are born. From sleek aircraft fuselages to the humble soda can, aluminum billets form the foundation for many products that touch our lives every day.

To begin the journey of an aluminum billet, workers extract bauxite ore and refine it into alumina. During smelting, the process uses a powerful electric current to separate the aluminum metal from the oxygen in alumina. Molds are filled with molten aluminum to create billets, which are then cooled, solidified, and subjected to further processing.

These versatile billets are extruded, rolled, forged, or machined into many shapes and sizes. Manufacturers can transform them into intricate components for airplanes, automobiles, and electronics or use them to create building materials, kitchenware, and sporting goods. The possibilities are truly endless.

So, the next time you hold an aluminum can or admire the gleaming surface of an airplane, take a moment to appreciate the humble aluminum billet that started it all. These unsung heroes of industry are a testament to human ingenuity and the transformative power of raw materials.

Two workers in full safety gear at Taber Extrusions’ brightly lit aluminum cast house in Gulfport, MS.

From Billets to Innovation: Cast Houses as the Crucible of Progress

Aluminum billets, those unassuming cylindrical metal blocks, are the lifeblood of countless industries. Before reaching their final form, they undergo a crucial transformation within the fiery heart of a cast house. These specialized facilities, with their towering furnaces and molten metal, act as the crucible where innovation takes shape.

Within the cast house, billets are heated to extreme temperatures, transforming them from solid to liquid. This molten state allows for precise manipulation and shaping, producing new and innovative products. Advanced casting techniques, such as low-pressure and vacuum, produce high-quality billets with superior strength and consistency.

These improved billets, in turn, fuel the fires of innovation in various industries. Automotive manufacturers utilize them to create lighter and more fuel-efficient vehicles. Aerospace engineers rely on them to construct more robust and more durable aircraft. Even the electronics industry depends on high-quality aluminum billets for producing smartphones, computers, and other devices.

But the role of cast houses extends far beyond mere production. They are also hubs of research and development, where engineers and scientists collaborate to refine existing processes and invent new technologies. From exploring recycled materials to developing advanced casting techniques, cast houses constantly push the boundaries of what’s possible.

Aluminum billets are not just raw materials but the seeds of innovation. Nurtured by the heat and expertise of cast houses, these seeds grow into the products that shape our lives. As technology evolves and industries strive for ever-greater efficiency and performance, the humble aluminum billet and the cast houses that transform them will remain at the forefront of progress.

Aluminum Casting Services: Fueling Innovation Across Industries

Aluminum billet casting is a crucial process that shapes diverse and vital components for various industries. From high-performance aerospace to rugged marine applications and even specialized custom chemistries, aluminum castings are pivotal in driving innovation and progress.

1. Aluminum Casting Services for Aerospace

The aerospace industry demands ultimate strength, lightness, and reliability, and aluminum castings rise to the challenge. Please note that aircraft components utilize them in a multitude of ways.

  • Airframes:

    The primary structure of an aircraft needs to have a high strength-to-weight ratio and excellent fatigue resistance.

  • Wings:

    responsible for lift generation, demanding a lightweight and robust design

  • Landing gear:

    absorbing impact and supporting the aircraft’s weight, necessitating exceptional strength and durability

  • Engine components:

    operating in extreme environments, requiring heat resistance and superior mechanical properties

2. Aluminum Casting for Marine

In the harsh marine environment, aluminum castings offer unmatched resistance to corrosion and fatigue, ensuring the longevity and performance of various components:

  • Hulls and superstructures:

    providing structural integrity and resisting the corrosive effects of saltwater

  • Propellers and shafts:

    wproviding structural integrity and resisting the corrosive effects of saltwater

  • Deck fittings and hardware:

    withstanding constant exposure to saltwater and harsh weather conditions

  • Lifeboats and davits:

    ensuring safety and functionality in emergencies

3. Aluminum Custom Chemistries

Beyond aerospace, firearms, and marine applications, aluminum casting shines in its ability to fulfill specific needs through customized chemistries:

  • Medical devices:

    requiring biocompatible alloys for implants and surgical instruments

  • Electronics:

    demanding high conductivity and thermal management properties

  • Automotive components:

    lightweight and robust parts for fuel efficiency and performance

  • Renewable energy technology:

    tailored solutions for solar panels, wind turbine blades, and other features

Aluminum casting, with its unmatched versatility, strength-to-weight ratio, and sustainability benefits, is poised to continue shaping the future of various industries. As technology advances and new applications emerge, aluminum’s unique properties will ensure its continued dominance as a material of choice for innovative solutions.

Taber Extrusions: where innovation and aluminum meet

Transform Your Business with Taber’s In-House Aluminum Casting Solutions

Taber Extrusions offers in-house aluminum casting solutions, which include manufacturing aluminum billets for specialized industries such as aerospace and marine. Their upgraded, state-of-the-art aluminum cast house, combined with experienced metallurgists and research engineers, enables them to produce high-quality aluminum billets. They offer a full range of aluminum alloys, including custom chemistries to meet their clients’ specific requirements.

Experience Unmatched Purity and Renewability with Taber’s Aluminum Refining Process

Taber utilizes Almex’s liquid aluminum refining system (LARS) to refine and purify the aluminum before casting. This process eliminates impurities such as dissolved hydrogen gas, nitrides, oxides, and alkali metals in a controlled and environmentally friendly manner. Additionally, Taber is committed to renewability and uses 75% commercial and extrusion manufacturing scrap to highlight this dedication further.

From Testing Capabilities to Quick Facts: The Fascinating World of Taber Extrusions

Taber Extrusions offers a comprehensive suite of testing capabilities to ensure the highest quality and consistency in their products. Key capabilities include:

  • On-site alloy verification and certification:

    This ensures that the chemical composition of Taber’s aluminum alloys meet the exact specifications required by their customers.

  • Ultrasonic testing:

    This non-destructive testing method uses sound waves to detect internal defects in the aluminum castings, ensuring they are free of flaws that could compromise their performance.

The infographic features a beautiful gradient background in shades of gold and brown. At the top is crisp white text that reads “CAST HOUSE CAPABILITIES.” Directly below the text, six shapes of varying sizes, with a sleek silver gradient, are arranged in a row horizontally. Beneath the shapes, text reads “Our casting capabilities and cast house information:" followed by a list in white text outlines the impressive capabilities of the cast house, including the latest technology to ensure internal quality, entirely designed and recipe-controlled DC casting, complete alloy family casting capabilities, a homogenization center for controlled heat treatment, and an on-site laboratory for metallurgical testing and ultrasonic lab house metallurgical analysis.

Quick Facts:

  • Recycled content makeup:

    Taber Extrusions is committed to sustainability and uses significant recycled content in its aluminum products. Their billets typically contain 25-30% prime aluminum and 70-75% scrap (a combination of commercial and extrusion manufacturing scrap).

  • Environmental benefits of recycling aluminum:

    Recycling aluminum is an effective way to conserve energy. It helps save up to 95% of the energy required to refine new aluminum. This makes aluminum production more sustainable by reducing greenhouse gas emissions.

  • CO2 emissions reduction:

    Recycling 1 ton of aluminum spares the planet from 9 tons of CO2 emissions. This translates to significant environmental benefits and helps to combat climate change.

  • Aluminum’s recyclability:

    Aluminum is one of the most recyclable materials on Earth. Roughly 74% of all aluminum produced is still in use today due to its excellent recyclability. This makes it a valuable resource for future generations.

Taber’s Aluminum Casting Revolution: Innovation Forging the Future Tabers

The American aluminum extrusion company Taber Extrusions invested in upgrading its aluminum casting capabilities. Taber’s improved cast house is a testament to their dedication to achieving the broadest capabilities in the aluminum extrusion industry. Taber prefers to keep everything under one roof, from casting to extrusion, machining, and beyond — casting ingots using prime and recycled aluminum to meet the required quality and chemistry specifications.

Unlock The Potential of Your Project: Why Choose Taber?

Taber Extrusions is a full-service partner that delivers high-quality products and services. They are dedicated to meeting and surpassing customer expectations, providing the best possible service. Since 1973, Taber Extrusions has been manufacturing solid profiles as wide as 31 inches and hollows up to 29 inches. In 1995, they expanded with the purchase of an extrusion facility in Gulfport, MS. Today, Taber Extrusions also launched expanded capabilities to include micro-extrusions and 7” billet molds, and shortly thereafter, added a new Hass VF-12 CNC vertical machining center.

Certifications

  • ISO 9001:2008 (technically equivalent to EN9100:2009 and JISQ 9100:2009)
  • AS 9100C
  • ABS QUALITY ASSURANCE Program certificate no. 11-MMPQA-652. ABS Mill has approval to produce extruded aluminum alloy products for marine applications 5083H111, 5086H111, 5454H111, 5456H111, 6061T6, and 6082T6. Maximum diameter: 1.0-inch casting process included.

If you want to learn more about the U.S. aluminum extrusion process and how it can fuel innovation in your industry, consider working with a trusted partner like Taber Extrusions. With decades of experience and a commitment to quality and innovation, Taber Extrusions offers various extrusion capabilities and value-added services to help you bring your ideas to life. If you want to elevate your products to the next level, contact the best aluminum extruder today to explore how they can assist you in leveraging the benefits of aluminum extrusions.

About Taber Extrusions: 

Taber Extrusions is a well-known aluminum extrusion manufacturer serving various industries, including aerospace, infrastructure, transportation, defense, and thermal management. With facilities in Russellville, AR, and Gulfport, MS, Taber Extrusions has provided an extensive range of aluminum extrusions since its inception in 1973. The company’s dedication to delivering exceptional goods and services can be observed by its possession of plate number 1 and AS 9100 certifications.

Taber Extrusions has earned its reputation for working closely with customers to problem-solve through innovation and collaboration. With over four decades of experience, Taber has the broadest capabilities in the aluminum extrusion industry, setting a benchmark for others.

If you have any queries, please visit https://www.taberextrusions.com or call Taber Extrusions at 1-888-984-3795.

28 01, 2024

A Year in Review: Best Aluminum Extrusion Blogs by Taber Extrusions

2024-02-28T16:21:36+00:00January 28th, 2024|

A black paper cutout of the word “BLOG” stands out, with a notebook and pen beneath. In the center, the Taber logo is encircled by L-shaped borders in gold and blue, creating a stylish composition.

Taber Extrusions goes beyond being a premiere aluminum extruder; but serves as a comprehensive resource, offering valuable insights and practical solutions to common industry challenges through providing the best aluminum extrusion blogs possible. Covering everything from news and trends to tips for enhancing extrusion capabilities, Taber ensures that you stay well-informed.

Here’s some of our favorite aluminum extrusion blogs of 2023:

1. Large Aluminum Extrusion Design

Are you ready to go BIG? This blog talks about how Taber elevates aluminum extrusion capabilities to new heights. With an exclusive rectangular container, they lead the industry in producing some of the widest and most complex multi-void hollows. Their large press capability, exemplified by the 8600-ton press, ensures the transformation of big dreams into reality. Explore the advantages of partnering with Taber, from reduced assembly time to streamlined design possibilities. Go BIG with Taber— where innovation meets excellence.

Graphic with a background of 3 black and white photos. A poem about aluminum in a white font is printed on the photos. The one on the left is a photo of a high-rise building, the one on the top right is a photo of a plane, and the one on the bottom right is a photo of a ship
A portrait slide containing Tabers’ seven types of alloys and their descriptions.

2. Which Aluminum Alloys are Best for Welding?

Welding joins two or more metal pieces, creating a permanent and robust bond. Various welding techniques, including GTAW, GMAW, FSW, and laser welding, can be used for welding aluminum metals. However, welding aluminum can be challenging because of the oxide layer on its surface and its high thermal conductivity. The aluminum must be appropriately cleaned and decreased beforehand for a successful welding. Furthermore, you should use the appropriate welding technique and filler material.

If you’re curious about welding aluminum and want to know more about the different techniques and materials, you should check out this helpful blog post. It’s written in an easy-to-understand manner that’s perfect for anyone who interested in learning about welding, aluminum alloys, and metals joining.

3. Aluminum Extrusions for Military & Defense

Aluminum extrusions offer a lightweight yet sturdy framework, enabling easy customization into diverse shapes. In this blog by Taber, the focus is on the extensive application of aluminum extrusion in the aerospace industry, where it plays a pivotal role in reducing the weight of aircraft, enhancing fuel efficiency, and ensuring structural strength. Armored vehicles similarly leverage aluminum extrusions to fashion lightweight armor capable of withstanding gunfire, explosions, and fire.

: A collage of five applications of aluminum extrusions in the military and defense sector.

This article also underscores Taber’s steadfast commitment and continuous supply of aluminum extrusions to the military and defense sectors.

The top of the Statue of Liberty is on the left with the Taber logo below it. The headline to the right of the Statue of Liberty says, “The Shape of Endless Possibilities — Taber Extrusions” above a collage of four images of Taber Extrusions’ equipment and their warehouse.

Read the full blog here.

4. BABA-Certified: Aluminum Extrusions Manufacturer Sourced in the USA

The Build America, Buy America (BABA) Act is a set of rules that requires the government to buy things made in the USA for government-funded projects. Taber Extrusions is a company that proudly manufactures aluminum parts to supply America’s military and defense sectors – committed to sourcing all parts in the USA responsibly and with top quality in mind. Aluminum is a versatile metal that offers benefits such as resistance to rust, good strength-to-weight ratio, and malleability for shaping. Taber offers many kinds of traditional aluminum extrusions and related processes, such as aluminum casting, fabrication, friction stir welding, and precision extruding.

5. Aluminum Extrusions: Material Comparisons

This blog post centers on the revolutionary impact of aluminum extrusions in modern construction, emphasizing Taber’s ability to intricately shape structures with precision. It underscores how aluminum outperforms alternative materials like wood, plastic, steel, and other metals. The article further highlights the diverse variations in aluminum materials, showcasing aluminum is a wise choice across various applications in the extrusion process.

If you’d like to explore more of Taber Extrusion’s aluminum extrusion blogs, visit taberextrusions.com and follow them on social media so you can receive new blog alerts!

Aligned on the left is the blog title, “Aluminum Extrusions: Material Comparisons,” which is written in a bold black font with a dark and light grey transparent background and the Taber logo beneath it. On the right, are a bunch of aluminum pieces that are unevenly, yet elegantly stacked vertically, showcasing different shaped profiles on a clear white background.

More about Taber Extrusions

Taber specializes in creating aluminum products in unique shapes and sizes to various industries such as aerospace, automotive, marine, infrastructure, and sporting goods.

Founded in 1973, Taber Extrusions has expanded its markets beyond the military and has become a leader in the industry. Working with various tools and capabilities to create custom solutions for their customers, Taber features micro-extrusions in precise shapes and sizes, friction stir welding services, and offers a wide array of aluminum alloy options. Taber also has a CNC machining line that allows them to create custom aluminum components serving a diverse range of industries. Taber offers value-added machining services and can provide raw materials to customers throughout North America.

Interested in becoming a part of the Taber team? Submit your resume to careers@taberextrusions.com. You can also visit taberextrusions.com or call Taber Extrusions directly at: 1-888-984-3795.

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