Aluminum Profiles

Aluminum Profiles: An Ultimate FAQ Guide

Aluminum Profiles are a great and advanced substitute for heavy metals that are not just expensive and outdated but also very high maintenance. The former enables you to build sturdy machinery, buildings, clean room equipment, and long-lasting devices.

Equipped with unique and advanced features and having many additional benefits, Aluminum Profiles are a one-time investment since they don’t require expensive assembly and maintenance.

The type and shape can be selected according to the requirement of your application. Customization is also provided to get maximum use out of it. You can use specific tips and tricks to enhance life and the resistance against corrosion and mechanical damage.

To make the best use of these profiles, you must know the components, features, and benefits so that you don’t miss any added advantages and achieve maximum efficiency. This article will help you gain all the knowledge you should have in this regard. So let’s begin.

Aluminum Profile Testing

What are Aluminum Profiles?

Aluminum Profiles are a lightweight and sturdy element extensively used to construct buildings and machines. These are present in various shapes and types that can be used according to your application.

The material is highly durable and allows effortless assembly giving many years of life to the structure in which it is used. There is added protection due to anodizing and powder coating.

They are low maintenance and easy to transport and are a pretty reasonable choice for modern development. You can also obtain corrosion resistance and protection against chemical damage.

The features are unique and quite favorable for a clean room environment. Since the material is non-shedding and smooth, there is no shedding and chipping, thus contributing to maintaining the cleanliness level.

Sunnyda Aluminum Profile

What are the Types of Aluminum Profiles?

Aluminum Profiles are present in different forms depending on their use. They are also known as cross-sections. Since they are made of aluminum, a versatile, malleable, lightweight metal, and have good thermal conductivity, they are very cost-effective. It comes in various thicknesses, which helps in forming multiple structures.

Hollow Beam

The hollow beam Aluminum Profile has no cross-section. It comes in different shapes like rectangular, triangular, or square-shaped beams. It acts as a support framework for bridges, buildings, etc. It is also used in modular installations like a modular clean room.

Square Profile

It is the subsection of the hollow beam type. Both are similar in many ways; the only difference is that they can provide additional stability and support. Both seamless and non-seamless square profiles can be made depending upon their manufacturing.

It is formed by flattening an aluminum sheet, and then corners are joined to form a square. Then a high-pressure piercing is passed through the sheet to smooth the inside of the profile.

SD Aluminum Profile

It is beneficial in both small and large applications. Aluminum is corrosion-resistant and flexible; therefore, it is used in clean room window framing. It helps to fight against harsh weather like dust, rain, and humidity, which affects windows more, and therefore they should be made of good material. It can provide support stability and corrosion resistance and has a sliding function.

RCW Profiles

It is used in curtain walls, mullions, and high buildings. Its function is to prevent the entry of environmental particles like dust or rain droplets from entering into buildings. It is used with other materials to avoid leakage and comes in different sizes.

Door Section

It is also called the ED section. The primary use is in the push and pulls and heavy-duty doors in buildings. The main function is to secure the glass and prevent it from breaking into doors.

Louver Profile

It consists of angled aluminum sheets at a regular interval on doors, windows, and shutters in such a way that it allows the passage of sunlight. Louvers can be made in many forms to prevent the entry of air particles or water according to the structure of buildings. It also aids in the ventilation of rooms and helps in lowering the temperature.

T-Section

This type comes in the shape of a T. This shape enables its usage in the corner, and it increases the support level when attached with fittings. There are different components like horizontal flanges and vertical webs. It can be easily used with other types of Aluminum Profiles.

Aluminum Profiles T-Section

What are the Different Shapes of the Aluminum Profiles?

General Aluminum Profiles are also known as ordinary Aluminum Profiles. They come in many forms like the round tube, square tube, pipe, U Channel, angle corner, and flat bar. They are usually used in civilian construction and decoration.

Aluminum C and U Channel

It is a product of extruded aluminum with radius corners used in structural applications where great strength is required. It is usually used where lightweight and corrosion-resisting material is used.

Specifications

Length: 0.2m-14m.

Minimum wall thickness: 0.4mm

Maximum dimension: circumscribed circle.

Diameter: 300mm

Workability: It can be easily welded and cut.

Application: supports frame, braces, trailers, beams, clean room framework

Aluminum Angle or Aluminum L Channel:

Also, a product of extruded aluminum, it is available in 6063-T6. It is an architectural alloy used to protect, reinforce and support clean room window frames, doors, rails, posts, etc.

Specifications:

Lengths: 0.2m-14m

Minimum wall thickness: 0.4

Aluminum Flat Bar:

It consists of different alloys that are easy to cut, corrosion-resistant, and have good weldability and machinability. They have high strength and are used in aerospace applications.

Corrosion-resistant aluminum alloys are used in marine applications. They are obtained from extruded aluminum and have radius corners. The width ranges from 10mm to 60mm.

Aluminum H Channel

Also known as the holy aluminum H channel, it is similar to the aluminum C channel. It is used where greater strength is required and is supplied in two finishes: mill finish or natural anodized surface finish.

Aluminum Rectangular Tube

Present between two types of alloys, 6061 and 6063, rectangular aluminum tubes are beneficial. 6061 Aluminium alloy has more corrosion resistance and weldability than 6063 alloys. It is available in two types, either full-length or half-length. Its primary use is in construction because of its strength and reliability. Other benefits include handrails, fencing, furniture, and frames.

Specifications:

Length: 0.2-14

Diameter: 300mm

Aluminium Round Tube and Pipe

It is also available in two forms of alloys. One is 6061, and the other is 6063. 6061 has more corrosion resistance and has more weldability. The usage is mainly for construction purposes, furniture, and fencing.

Aluminum Square Tube, Bar, and Rods

These shapes have a fine finish and strength-to-weight ratio. Because of these qualities, they are used in architectural trims, frames of doors and windows, safety and deck structures, furniture components, racks, and athletic equipment.

Specifications:

Diameter: 300mm

Workability: it can be easily cut, welded, and machined.

Aluminum Tee and T-Shaped Profile

The most commonly used shape for structural application is the aluminum tee. It is also used in architectural trim, furniture components, athletic equipment, frames of doors and windows, etc.

Specifications:

Length: 0.2m to 14m.

Minimum wall thickness: 0.4mm.

Aluminum Z-Shaped Profile

They are commonly known as the zed section, which is majorly used for structural applications. There are two aluminum alloys, 6061 and 6063. A typical application is creating a display area by providing support for boards and sheets, architectural trim, frames or doors and windows, racks, and athletic equipment.

Specifications:

Length: 0.2m to 0.4m.

Diameter: 300mm

Maximum dimension: circumscribed circle.

Aluminum H Channel

What are the Major Components of Aluminum Profiles?

An Aluminum Profile consists of three parts: the slots, the mounting hole, and the chambers. With the help of a profile cross-section, these parts can be seen.

Slot

It is also called T-slot because of its resemblance with the letter T. The profile wall is divided into equal halves by slots in a cross-section. It is used to connect the profile with other parts or elements with the help of a connector placed between them.

The module or purpose for which the slot is used decides its shape. It consists of three characteristics, outer and inner width and depth, to determine the size and shape of the connector and the purpose of the profile.

The shape and size of the connector are determined by the depth and inner width of slots, whereas the outer width determines the purpose of the profile.

Mounting Hole

It is a round hole that runs across the inside of the whole structure. It is located in the center, and its purpose is to connect the profile with the help of self-tapping screws.

Chambers

In cross-section examination, various polygonal-shaped empty spaces can be seen; these are called chambers. A profile determines what kind, size, and shape of chambers should be used.

What are the Excellent Benefits of Aluminum Profiles?

Aluminum Profiles have many beneficial properties that help in increasing the area of use. Some of these are mentioned here:

Modularity

There are standardized shapes and sizes for each profile that can be used universally in various applications. Since these modules can be separated, they allow a simple construction and can be replaced easily.

Compatibility

The profiles are compatible with other connecting elements, thus making a sturdy assembly. You can combine them with different shapes as well. The screws allow a more stable adjustment to the slots.

Convenient Assembly

Since they are lightweight and easy to handle, the assembly is quite simple and does not require particular expertise. The profiles can be easily mounted and joined together.

Lightweight

Aluminum is a light metal, and the empty spaces in the profiles also help in this property since they only contain air.

Application Multitude

Aluminum Profiles cover many applications, including work stations, production lines, machines, and load-bearing structures.

High Load Capacity and Strength

Despite being lightweight, the profiles are firm and can bear significant loads.

Corrosion Resistance and Aesthetically Pleasing

They are of the same color, relatively smooth, and look aesthetically pleasing. They can be made more presentable by anodizing.

Lightweight Aluminum Profile

What are the Uses of Aluminum Profiles?

Aluminum Profiles are extensively used in constructing roofs, production of machines, clean room equipment, windows, clean room doors, etc. Some of the prominent uses are listed below:

• Temporary roofing
• Storage halls
• Elements of construction for assembly stations
• Industrial lines
• Advertisement boards and information signs
• Conveyors and manipulators
• Furniture fronts
• Machine parts

Use of Aluminum Profiles

What are the Thermal, Surface, and Fabrication Treatments for Aluminum Profiles?

Thermal Treatments

Aluminum needs heat treatments like nickel and titanium to gain the required mechanical properties. The hardening process is done by aging, and each application requires specific heat treatments to get the desired properties.

Here are some prominent treatments:

T4: Tempered from the solution temperature by forced air with natural aging.

T5: It is tempered from the extrusion temperature using forced air followed by artificial aging. It is the most common heat treatment.

T6: Tempered using the solution temperature through the water along with artificial aging.

Surface Treatments

Here are some of the effective surface treatments that add to the efficiency of your Aluminum Profile.

Polishing

It helps in creating a smooth surface and brings the shine. It can be either obtained by using a chemical agent or directly rubbing it well.

Anodizing

This is to enhance the oxide layer on the surface so that the strength and durability can be increased.

Powder Coating

This process not only makes the surface look presentable but also adds to the strength and corrosion resistance of the metal.

Fabrication

Fabrication manipulates the profiles to obtain the desired structure by punching, cutting, drilling, and machining. This is to match the specification of the application. It is like drilling a hole in one of the pieces to secure a screw and make a stable assembly.

Powder Coated Aluminum Profiles

What are the Alloys Used for Aluminum Profiles?

The physical properties of aluminum can be enhanced by alloying it with other metals like copper, zinc, silicon, magnesium, etc. alloying helps to increase corrosion resistance, formability, tensile strength, and load capacity. The ratio and proportion of the alloying metals are adjusted according to the application.

This technique also helps in improving flexibility and weldability. The fabrication of alloys becomes more accessible, and the resultant profile is ultra-lightweight. Some of the alloys are listed below:

6060

Medium strength and heat treatable

6063

It has medium strength but is commonly used.

6005A

It is a versatile alloy paired with other alloys to produce desirable products.

6105

It is very similar to 6063 and bears medium strength.

6061

It is most commonly used because it’s more affordable and has considerable strength.

6060 Aluminum Alloy for Aluminum Profiles

What are the Terminologies Related to Aluminum Profiles?

The common terminologies include the following:

Aging

It refers to the change in internal crystalline structure with time. There are two types, natural and artificial aging.

Alloy

It adds one or more metallic substances to metal to enhance its characteristic properties.

Anodising

It is an electronic treatment for the Aluminum Profile surface that adds to the stability and corrosion resistance.

Burr

A rough and irregular edge is left after drilling or cutting.

Circumscribing Circle Diameter

The circle corresponds to the size of the profile which is housed inside.

Container

A cylinder that extrudes the billet in an extrusion press.

Etching

Give a uniform and matt finish by using an acidic or alkaline treatment.

Porthole Die

It contains a mandrel as an essential part of its structure. It is for hollow profiles.

Press Force

The extrusion press has a very high pressure that forces the aluminum through the die. The average pressure range is between 1000 to 2000 tones when measured in tons per square inch.

How to Obtain Aluminum Profiles?

The extrusion process obtains Aluminum Profiles. Direct or indirect extrusion presses can be carried out with different power levels. The basic steps of this process are six, but they can be modified according to customers’ requirements.

Before starting the extrusion process, Aluminum rods are cut into small pieces called billets. It ensures that each extruded bar length will be the same and material wastage minimum.

Step 1: Specified temperature preheating of aluminum billet and steel die:

Induction of heat furnaces is used to heat billets from room temperature to extrusion. Different temperatures are used to heat other alloys. Billets should be heated enough to be molded into the desired shape but still retain their shape during transportation. The push bat applies pressure on the billet, and it is pushed towards the opening of the die.

Step 2: Loading of billet into the steel extrusion press container:

Billets are transported quickly from the furnace into the press to avoid heat loss. After transportation, they are prepared to be extruded by loading a billet into the recipient.

Now the ram applies pressure on the heated billet and is pushed towards the die’s opening.

Step 3 Extrusion:

Different openings make different shapes and sizes. The heated aluminum billet is pushed through those openings. Bars are extruded to the desired form when they exit the press. It is similar to a cookie press where different shapes and sizes of cookies are made through other discs.

Step 4 Controlled Cooling:

When extruded bars/tubes/profiles exit the press, they are further pushed into the water bath for controlled cooling. It ensures uniform extinguishing of heated aluminum; it is called the quenching process.

It is done to check the mechanical properties of aluminum that are required and the material’s microstructure. The cooling process should be carried out immediately after the extrusion process to prevent material deformation.

Step 5:

Extruded bars are cut into desired interphase lengths right after the quenching process. Then they are laid all over the runout table by the puller to cool down further. Extruded bars are stretched in the stretching process, and their internal tension is removed to check mechanical properties.

Step 6: Cutting and Final Packaging:

Now, after all the quenching and straightening, bars are cut according to the customer’s desire. T1/T4 temper properties are usually found at this stage in Aluminum Profiles. To require T5/T5/T66 temper mechanical properties, profiles are aged artificially. This artificial aging makes aluminum more robust and ensures that they possess the required mechanical properties.

Aluminum Profile Cutting

What are the Factors Affecting the Manufacturing Process of Aluminum Profiles?

Aluminum extrusion for obtaining Aluminum Profiles is a complex process that needs various parameters to be appropriately regulated. These parameters are called TST, which stands for temperature, speed, and time.

It is a highly automated process that must be monitored carefully, and the following factors shall be kept in mind:

• The temperature of the tool being used.
• Quench delay and extrusion rate of the process.
• The speed of the extrusion process.
• The temperature of the container.
• Quench media temperature.
• Tool dimensions and final products.

Temperature

It is the most sensitive parameter, and it must be maintained according to the requirements throughout the process. It also determines the shape of the product. The average temperature for the aluminum alloy biller is 300 to 595 degrees celsius.

Quenching

Right after exiting the dye, the Aluminum Profiles are quenched immediately. It is essential to cover all the structural parts with the correct amount of water. It needs to be soaked for the right amount of time.

The purpose is to cool down the product and bring it down to room temperature. This step enables the profiles to retain the highest mechanical properties regardless of the shape. The faster ye quenching, the greater will be the strength, toughness, and microstructure.

After the quenching, the following factors shall be checked closely:

• Finish of the surface
• Macrostructure of the profiles, tubes, and bars
• Make sure there are no defects
• Tolerance and dimensions of the product
• Mechanical properties
• Ductility and malleability

Aluminum Profile Quenching Process

What are the Tips for Designing Aluminum Profiles?

With the proper designing techniques, there can be increased light weightedness, higher functionalities, and more straightforward assembly. The right design can be affordable too.

The Right Wall Thickness

The wall thickness of your Aluminum Profile is determined by the requirement of your application, strength, and cost-efficiency. It is easier to produce profiles with uniform wall thickness. However, it can be altered as well.

Other important factors that affect wall thickness are:

• The right choice of alloy for a specific application
• Extrusion speed and press power
• Required tolerance
• Required shape of the profile
• Shapes with rounded corners are considered more efficient.
• Sharp corners are difficult to obtain through this process.
• The radius range should be 0.5-1mm.
• A hole radius is a solution for designs that need sharp edges.
• If there are variations in the thickness, the cooling process is uneven, becoming more visible during anodizing.

Add Decoration or Pattern

A pattern, engraving, or decoration brings excellent value to cost-effectiveness and functionality as well. It also helps in the following factors:

• To hide the imperfections.
• The decoration helps in protection against any damage that can be caused through processing and handling
• The shadowing can be overcome.

Achieving Cost-Effective Production

The design shall be such that it is convenient to implement so that there is less making cost and require less making technique.

Here are some points for easy to extrude profiles:

• Symmetry must be followed.
• There shall be no narrow and deep channels.
• Variation in the wall thickness
• Materials and alloys being used
• Simple round shapes with curved corners are easy to make.

Decorative Aluminum Profiles

How to Assemble Aluminum Profiles?

The assembly and arrangement of Aluminum Profiles are pretty simple and can be done without any professional help. There are special hangers or dowels for fastening the structural profiles. The hangers can be easily bent to adjust according to your settlement.

The profiles are connected without glue or adhesive. There are special connectors for this purpose. The parts can be tightened together by a handheld crimper, but there is no need for a specialized tool kit. Mount the assembly on the desired spot, and the correctness of the mounting should be checked by leveling.

What are Assembly Tips for Aluminum Profiles?

Following are some tips that will help you assemble your Aluminum Profiles more conveniently:

• Always follow the manufacturer’s instructions.
• Handle the profiles carefully and check each one for defects before assembling them.
• Use suitable quality screws and connectors that the manufacturer provides. A faulty or substandard screw can compromise the corrosion resistance of the whole assembly.
• Take proper measurements for precise results.

What are the Precautions for Drawing Aluminum Profiles?

Described below are some of the necessary precautions that must be taken for drawing Aluminum Profiles:

• The first and most important thing is to check the shape of the profile. See if there is any distortion, bump or defect in appearance. There should be no cracks, scratches, or bubbles and eleven areas.
• Check the surface colors of the profile and see if there is any variation in the color throughout the body. If there is any color difference, it indicates that the product is substandard and does not meet the quality criterion. It is not safe to be used for construction because of compromised quality.
• Check the thickness of the profile. Make sure it is even unless it is the requirement of the design.
• The stretching shall be carried out when the profile is cooled below the temperature of 50 degrees celsius. Any temperature higher than this can be harmful since it can burn humans in contact and result in more incredible waste.
• There is only 1% control of stretching amount. If it is too high, there is an increased chance of dimensional errors and other defects like water steaks, hardness, and brittleness.
• The accurate clamping method and appropriate clamping pads are necessary for controlling tensile deformation.
• For uniform heat dissipation, the profiles shall be turned up and down at all angles so that no spot is left untreated. The uneven dissipation can affect crystallinity for shapes with significant thickness and increased length.
• There shall be no stacking, overcrowding, tangling, or mishandling of the profiles that can cause damage. There shall be a fixed distance between each.
• A deformed or twisted profile shall be discarded.

Conclusion.

Aluminum Profiles are perfect for constructing buildings, clean rooms, and industries because they are lightweight materials that require minimum maintenance.

It’s not just pocket-friendly but a very convenient and efficient option since it provides excellent strength, sturdiness, stability, and higher efficiency.

100% Quality Tested Aluminum Profiles