Essential Tips for Working with Square Aluminum Extrusions

Working with square aluminum extrusions offers numerous advantages, including their durability, light weight, and customizable shape. However, understanding the unique properties of aluminum extrusions is crucial to ensure precise and efficient fabrication. Here are some essential tips for working with square aluminum extrusions:

Machining Square Aluminum

Cutting, drilling, and milling aluminum extrusions require specialized techniques to prevent damage. Use sharp carbide-tipped tools designed for aluminum machining. Set the cutting speeds and feed rates according to the extrusion’s thickness and alloy composition. Use a coolant or lubricant to reduce heat and extend tool life. Avoid excessive cutting forces that can cause bending or deformation.

Welding Aluminum Extrusions

Welding aluminum extrusions can be challenging due to their thin walls and high thermal conductivity. Choose the appropriate welding process, such as TIG or MIG welding, based on the extrusion’s thickness and desired joint strength. Use a filler metal compatible with the aluminum alloy. Prepare the joint surfaces by cleaning and removing any oxidation. Use a backing plate to prevent warping or buckling during welding.

Bending Aluminum Extrusions

Bending aluminum extrusions requires careful planning and precision. Determine the minimum bend radius based on the extrusion’s thickness and alloy. Use a bending machine with a die that matches the extrusion’s profile. Heat the extrusion to a specific temperature to enhance its ductility and reduce the risk of cracking. Apply bending force gradually while monitoring the extrusion’s shape to prevent overbending.

Finishing Aluminum Extrusions

Surface finishing of aluminum extrusions enhances their appearance and protects them from corrosion. Sandblasting can create a matte or textured finish. Anodizing forms a protective oxide layer on the surface, improving resistance to wear and corrosion. Painting provides a wide range of color options and additional protection. Follow the manufacturer’s instructions carefully to ensure proper adhesion and durability.

Handling Aluminum Extrusions

Due to their lightweight nature, aluminum extrusions can be easily damaged during handling. Use proper lifting equipment and secure them during transportation. Avoid dropping or bending the extrusions to prevent deformation. Store them in a dry, temperature-controlled environment to prevent oxidation and corrosion.

Additional Tips

Use gloves and eye protection when working with aluminum extrusions to avoid injury.

Consult with experienced professionals for complex fabrication processes or specific alloy requirements.

Maintain proper ventilation to remove welding fumes and cutting dust.

Regularly inspect aluminum extrusions for signs of wear, corrosion, or damage to ensure long-term performance.