Application of aluminum extrusion profiles in the automotive machined parts industry

1.Aluminum extrusion profiles have high cross-sectional dimensional precision and have different precision due to different production processes. For high vacuum die-casting structural parts, the dimensional deviation is usually large due to the shrinkage and deformation caused by heat treatment of the castings, and the large deviation can reach 1~3mm. For aluminum extrusion profiles processes, the cross-sectional dimensional accuracy is generally higher, the dimensions are more stable and easier to control. Through high-precision mold processing and mold improvement, aluminum extrusion profile parts for automobiles can fully meet the dimensional accuracy requirements of most automotive products. Usually, the dimensional accuracy of the cross-sectional shape of the extruded profile can meet the requirements of product design, and the dimensional precision can be controlled within 1mm. Therefore, in terms of dimensional precision y, the aluminum extrusion process is a mature, excellent and competitive process.

2.Reduce the manufacturing process.Since the cross-section of aluminum extrusion profiles can be complex and varied, and the thickness design freedom is relatively large, the blank of aluminum extrusion profiles can achieve high dimensional precision, thereby minimizing the number of design parts and the manufacturing process from extrusion blanks to final finished parts. It can be delivered for use only through cutting, drilling, punching, machining and bending. If the requirements for mechanical properties need to be adjusted, heat treatment process links can also be added.

3.Good thermal conductivity and seamless properties. In automotive industry, aluminum is widely used to transfer heat for cooling and heating. In terms of thermal conductivity per unit weight, aluminum alloys perform better than most other metal materials. For example, the radiator in the electric drive axle controller, the cooling module at the front end of the car, and the cold water pipe of the air conditioner. Aluminum extruded profiles can be made into hollow pipes to avoid or reduce the risk of liquid leakage. The cooling water circuit of the motor housing, water pipe joints, and battery pack water cooling pipes are all made of aluminum extruded profiles. At the same time, for some areas with electromagnetic compatibility (EMC) requirements, seamless aluminum profiles can also play a good shielding role.

4.Easy to connect and assemble.Aluminum alloy parts can be connected in various ways, such as welding, friction stir welding, mechanical connection (including FDS and SPR), adhesive bonding, embedding and clamping, etc., which are all suitable for connecting aluminum profiles and other material parts. In terms of assembly, the form of fixing with other parts by bolts is more abundant and flexible.

5.Short production cycle. Whether it is to meet the needs of small-batch production of mule cars, soft mold car parts, or large-scale production of hard mold parts, the advantage of short development cycle of aluminum extrusion parts is very obvious. The cycle from mold opening to production of simple aluminum extrusion parts is only 1 to 2 weeks; even some automotive aluminum extrusion parts with complex cross-sections and large sizes, such as motor housings and door sills, only have a mold opening cycle of about 4 weeks. The mold opening cycle of casting and stamping parts is usually 4 to 16 weeks. Although 3D printing rapid prototyping and metal powder sintering have shorter cycles for single part production, they are more expensive and sometimes difficult to meet the requirements of part quantity and performance.

6.Low mold cost. The cost of an extrusion mold for aluminum profile parts is much cheaper than casting and stamping molds. The use of extrusion molded parts can save a large part of the one-time investment cost, and will also reduce the cost of later design changes and increase design flexibility.