| Question: | What size extrusion presses do we have? |
| Answer: | We have one 11" (3000 ton press)and two 7" presses (1550 ton and a 1650 ton) extrusion presses. |
| Question: | What length extrusions can you run? |
| Answer: | The run-out tables are around 140 feet long but we can only handle lengths up to 45 feet or so. This is due to the difficulty in handling soft extrusions. In fact, some small extrusions are hard to handle even in lengths as short as 12 feet. |
| Question: | What size extrusions can you run? |
| Answer: | We can run solid shapes up to a 12" diameter, and hollow shapes up to 6" (round or square). The weight limit is around 7 pounds per foot for 6061 and 8 pounds per foot for 6063. |
| Question: | What alloys do you run? |
| Answer: | We run 6063, 6061, and 6463 on a regular basis and 6105 occasionally. |
| Question: | What tooling is required to produce an extrusion? |
| Answer: | Basically a combination of three tools are required. A Die, a Backer, and a Bolster. The die produces the shape, the backer supports the die and the bolster supports the backer. Hollow dies may not need a backer as they are generally strong enough to support themselves. |
| Question: | What is the cost of the tooling? |
| Answer: | Solid dies can range from as low as $400.00 to around $2500.00 depending on size. Hollows will cost around three times the cost for a solid die of the same size. Backers and bolsters will each be about 70% of the die cost. |
| Question: | Who owns the tooling? |
| Answer: | Our order acknowledgment states that the die charge is a service charge and that the tools are the property of Sapa. |
| Question: | What if the die wears out and has to be replaced? |
| Answer: | Replacement dies are paid for by Sapa. |
| Question: | What is a die line? |
| Answer: | Die lines are caused by imperfections in the bearing surface - ridges or grooves - that translate themselves to the surface of the extrusion. They are removed by polishing the bearing and removing the ridge or groove. Die lines will not be removed by polishing the extrusion unless they are very minor. |
| Question: | What alloy do we use for extrusions that will be Bright Anodized and why? |
| Answer: | We use 6463 alloy because this alloy requires a high copper content and a low iron content both of which contribute to a brighter more consistent finish. |
| Question: | What does the term "Artificial Aging" mean? |
| Answer: | Artificial Aging refers to the heat treating cycle that produces the temper (hardness, strength) required for the extrusion to properly do its job. The reason the term Artificial Aging is used is that Aluminum will get harder over time naturally. We hurry the process by heating the extrusion in an oven to around 380 degrees F and holding it there for a set period of time. Thereby, Artificially Aging the metal. |
| Question: | Why is the metal stretched after it is extruded? |
| Answer: | No extrusion comes out of the die perfectly straight. That being the case, we stretch the profile to straighten it. In the act of stretching we also begin the hardening process by "work hardening" the metal. It is like when you bend a coat hanger enough it will break because you stretched the metal to the point that it will not stretch any more and it breaks. Of course we don't stretch the aluminum that much. |
| Question: | What temperature is the billet when it is extruded? |
| Answer: | Approximately 950 degrees F. |