Industrial aluminum production process
ã€China Aluminum Industry Network】 1. Fusion casting is the initial step in aluminum production:
(1) Raw Material Preparation: Based on the specific alloy composition required for production, the quantities of various alloying elements are calculated and mixed with appropriate raw materials to ensure the desired properties.
(2) Melting: The prepared materials are melted in a furnace following precise process guidelines. During this stage, impurities and gases are effectively removed through degassing and slag removal techniques to improve the quality of the molten metal.
(3) Casting: Once melted, the aluminum liquid is cooled and cast into various round ingots using a deep well casting system under controlled conditions. This ensures uniformity and high-quality structure for further processing.
2. Extrusion: This is a key method for shaping aluminum profiles. First, molds are designed and manufactured according to the desired profile shape. Then, heated aluminum ingots are forced through the mold using an industrial extrusion press. Commonly used alloys like 6063 are typically subjected to air-cooled quenching and artificial aging to enhance their mechanical properties. Different heat-treatable alloys require different heat treatment processes to achieve optimal performance.
3. Coloring (Starting with the oxidation process)
Oxidation: After extrusion, aluminum profiles have relatively low corrosion resistance. To improve durability, surface treatment through anodizing is essential. Anodizing enhances the material’s corrosion resistance, wear resistance, and aesthetic appearance.
The main steps involved are:
(1) Surface Pretreatment: The profile surface is cleaned chemically or mechanically to expose the pure metal base, ensuring a uniform and dense oxide layer forms during anodizing. This step can also create either a shiny or matte finish depending on the desired outcome.
(2) Anodizing: Under controlled conditions, the treated surface undergoes an electrochemical process that creates a thick, porous, and protective layer of aluminum oxide (Al₂O₃). This layer significantly improves the material's durability and appearance.
(3) Sealing: The pores in the oxide layer are sealed to prevent contamination, corrosion, and wear. The oxide film is initially colorless and transparent. However, before sealing, the porous structure allows for the absorption of metal salts, which can be deposited within the pores to produce a variety of colors such as black, bronze, gold, and stainless steel, enhancing the visual appeal of the final product.
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