Aluminum-alloy extrusions form everything from cabinets to car chassis. Here are some ways to join them. 500-hp Ford GT supercars ride on a chassis made almost entirely of welded-aluminum extrusions. Properly designed adhesive joints spread loads over a large area and are oriented to minimize certain stresses Hydro's Rotal hinges bring into mesh two extruded axially aligned gear sets. A third extrusion locks the sections together. The resulting joint is able to swing through 90 and requires no secondary machining. Aluminum extrusions connect four corner castings and one behind the passenger compartment in Ford GT supercars. Some 35 different extruded profiles from form a stiff, strong, and lightweight platform. Chassis are assembled using a combination of robotic MIG and friction stir welding. In addition, bolt-on extrusions add structural support to the engine compartment and also integrate into the bumper assembly. "In all cases, sections are tailored to the specific joining operation," says Hydro Welding Team member, Jim Brown. The ability to quickly modify extruded sections helped Ford go from initial design to production of three prototypes in just one year. The company plans to build about 1,500 of the supercars annually. The capacity to form complex shapes with relatively simple tooling in a single operation makes aluminum extrusions an attractive alternative to machined and stamped components. Throw in a variety of joining methods and the design possibilities grow geometrically. For instance, assemblies of smaller extrusions can replace single, larger units, without compromising structural integrity. Smaller sections are also easier to handle, can be made to tighter tolerances, and may lower die costs in many cases. But choose a joining method when spec'ing dies because sections are often made specifically for it. The elasticity of aluminum makes possible clipped joints, a method of snapping together multiple extrusions that cannot otherwise
Products & Services
Downstream Extrusion Equipment
Downstream extrusion equipment is used to finish and inspect parts once they have been extruded. Post-extrusion processing operations include cooling, cutting, pulling, texturing, embossing and profile inspection.
Metal extrusions are metals or alloys that are extruded into bars, rods, angles, channels, tees, or other profile shapes. Examples of the metals and alloys that can be extruded are lead, tin, aluminum, copper, titanium, zinc, and steel.
Plastic Extrusion Services
Plastic extrusion services suppliers specialize in extruding plastics and polymer compounds into custom and standard profiles and shapes.
Specialty Metal Shapes and Stock
Specialty metal shapes and stock consists of metals and alloys with an unlisted, specialized or proprietary shape or stock form.
Topics of Interest
An extruded aluminum roof rail for a Mercedes car took Grand Prize at a recent competition The Extrusion Technology for Aluminum Profiles Foundation, The rail highlights a new “rounding”...
Friction stir welding joins previously unweldable materials. As the tool moves along, frictional heat plasticizes material from the front of the rotating pin to the back. The material consolidates and...
Space is a premium in the markets for instrument cases. Whether it's a lab,hospital, industrial setting, or on a naval ship, instruments need to be smaller and smaller. In designing instrument cases,...
The purpose of this technical brief is to give the new designer or engineer the basics in the limitations of designing an aluminum extrusion. Extrusions are 2 dimension shapes that can be fabricated...
Extrusion is a bulk forming process in which the material is made to flow using high pressure. The deformation takes places mainly at room temperature cold extrusion as by this means...