Indirect Vs Direct Extrusion-FONNOV ALUMINIUM

1. Indirect Extrusion Vs. Direct Extrusion Extrusion is done in different ways. That means different procedures are also followed during these processes. But what makes the difference as to when extrusion is direct or indirect? Here’s the difference! What is indirect extrusion? Normally, during extrusion billet is moved through the extrusion channel under pressure. During indirect extrusion processes, the die is held constant as the billet moves with the container. For this to happen successfully, a stem is applied. One of the stem’s properties is that it must be longer than the container moving with the die. The length of the stem will determine how long the final length of the product being extruded will be. Therefore, manufacturers decide the shape of an extrusion product by cutting the same on the stem. This way, both the extruded Aluminum and stem will share the same length thus determining how long your Aluminum extruded product is. For indirect extrusion to be complete, some requirements must be met. First, the billet must be preheated, although this is a requirement of all extrusion processes. This is then forwarded into the pressure chamber. Again, both direct and indirect extrusion processes happen under pressure. The movement happens as a hollow plunger pushes the billet through a hollow die. At the end of the stem, there’s some blockage of sorts. This allows the billet to absorb pressure and travel back through the hollow die. As this happens, the billet assumes the shape of the die. The extruded Aluminum product that leaves the extrusion unit assumes the shape of the die!

2. When making the decision about which extrusion process to choose, a lot is considered. The advantages of indirect extrusion are considered if one wants to settle for this process. The reverse is true. Manufacturers explore other extrusion options if their benefits outdo the indirect extrusion process, or if the disadvantages of this option are way too many. On that note, let’s consider the advantages and disadvantages of indirect extrusion. Advantages of the indirect extrusion 1. Significant reduction in friction During extrusion, a lot of heat and pressure are involved. It’s also important to note that Aluminum is not easily bendable and stretchable. Therefore, a lot of friction is likely to be experienced. Using indirect extrusion significantly reduces friction by 25-30%. This increases the quality of the final product by a huge margin. Besides, friction reduces the size of the final extruded product. By reducing friction, you allow the process to give larger outputs. That may mean more money for manufacturing companies. Also, you enhance the extrusion speed as well as allow the production of smaller cross sections.

3. 2. Reduced cracks Considering the properties of aluminum, it’s easier to crack under pressure and heat due to friction. Indirect extrusion reduces friction by up to 30%, therefore, you reduce the likelihood of your metal cracking. This means the production of better quality extruded products. Besides, you limit the amount of wastage occurring during the extrusion process. 3. Reduced maintenance fee Another benefit of indirect extrusion is the fact that you will have longer-lasting container liners. This is because of the reduced friction inside the extrusion container. For manufacturing companies, this is a big gain because they’ll be able to save maintenance costs that tend to reduce their profit margin. For the consumer, a reduced cost means the manufacturer reduces the selling price as well. This gives greater value for money. Besides, the quality you purchase is also likely to increase. 4. More flawless extrusion products When you have a well-coursed container, it becomes less likely to have extrusions with defects. And that’s why indirect extrusion may be preferred sometimes. The process produces better products and that explains why some manufacturers opt for this option. While there are many more advantages to this process, it also has some flaws that may prompt some manufacturers to think twice about it. Here are some of the disadvantages of indirect extrusion. Disadvantages of indirect extrusion 1. Cross section limitations

4. The size of the stem limits the cross-sectional area. But this is not a limitation when the goal is to make products with smaller cross-sectional areas. 2. Affected aesthetics Extrusion makes products, some of which require aesthetically appealing looks. Sometimes, there are impurities on the surface of the extruded products. This affects the surface’s final outlook and may have a bad impact on the product. What Aluminum extrusion products are made by indirect extrusion? The aluminum extrusion product is used to make specific products due to the nature of the process. Besides, some products (seamless aluminum tubes, aluminum rods, aluminum bars, etc. ) can only be best produced using this extrusion option. Contact FONNOV ALUMINIUM INDIRECT EXTRUSION (https://www.fonnovaluminium.com/indirect-extrusion.html) for more details. What is direct extrusion? This is the most common type of extrusion and is also referred to as forward extrusion. The process involves placing a billet in a special wall container. The vessel used must be heavily walled for obvious reasons. A lot of pressure is applied during the direct extrusion process and therefore, the heaviness of the wall allows the container to withstand the heavy pressure. After the billet is put in a container, it’s pushed through the container using a ram. The container allowing passage of this billet is commonly referred to as a die. The preheated

5. billet is pushed into the die and out under intense pressure. This ensures maximum results are achieved. As this activity happens, the ram and billet will likely mix considering Aluminum is in an almost molten form. To avoid the two from mixing, a dummy block is applied. The material works to keep the two separated throughout the billet’s journey. There’s another interesting activity that happens during the direct extrusion process. A part of the billet in contact with the extrusion wall must protect the rest of the billet. As the matter travels through the die, there’s friction happening. Friction destroys extruded material. The billet directly in contact with the container walls shields the rest from destruction through friction. This ensures that the final product is of better quality and flawless. Just like indirect extrusion, this process too has benefits and shortcomings. For manufacturers to opt for this, they must consider the gains rather than the disadvantages. Let’s see the advantages and disadvantages of direct extrusion. Advantages of direct extrusion 1. Longer workpieces Direct extrusion has lesser limitations than indirect extrusion. This is because of the nature and difference between the two processes. With direct extrusion, your product length will be determined by the amount of billet that goes through the die and comes out. Compared to indirect extrusion, where the size of the product heavily relies on the size of the stem. And that brings about limitations in terms of cross-sectional size. 2. Operational flexibility When looking into direct and indirect extrusion processes, you will realize a difference in the operations. In terms of flexibility, direct flexibility performs better than indirect

6. flexibility. While there might be a slight difference in the processes, a bigger one is experienced in terms of operational flexibility and productivity. 3. Low cost per component Direct extrusion utilizes the billet in contact with the die to minimize wastage. That way, most of the other part of the material passes through to the end to form extruded products. When you have maximum output for reduced costs, it lowers further the cost per component during the product manufacturing process. This is a major benefit of the direct extrusion process. 4. Continuous operation Continuity of operations also plays an important role in reducing costs. With every discontinuity and restart in production comes an extra cost. Therefore, direct extrusion helps you reduce costs significantly. 5. Easy modification of products Direct extrusion doesn’t give a final product until you decide so. This means that you can keep directly extruding the metal until you get the shape you desire. This gives manufacturers the freedom to make extruded products of any shape. Besides, the option to modify products as you wish allows the production of a variety of products. Clients today are very specific when it comes to the products they want. When you have the power to modify products, it allows you to not only meet your client's needs but also make proper sales. Disadvantages of direct extrusion 1. More force requirements

7. Direct extrusion requires more force to extrude the metal compared to other extrusion alternatives. This may mean more friction and as a result, the metal may have deformities. More force requirements may also mean that you increase the power needs and that may lead to additional needs. As far as mass production is concerned, this may not be a good idea. What Aluminum Products are made through direct extrusion? A direct extrusion process is a good option for some manufacturing companies sometimes. There are many reasons why this would be preferred instead of the other options. Above all, the process results in amazing products like those below. 1. Solid shaped products A lot of products assume this shape and makeup majority or direct extrusion products. The solid-shaped ones have no spaces in them but are compact and stuck together. 2. Hollow shaped products These have a space in between them and also form equally good products for further processing. Hollow shapes form products like cylinders among others. They can also be connected via junctions to make pipes that can be used to transport stuff. 3. Semi-hollow shapes These shapes fall between solid and hollow shapes. They are also common and have many uses in many industries today. Contact FONNOV ALUMINIUM (https://www.fonnovaluminium.com/) for more details.

8. Conclusion Extrusion is becoming more common every other day. The process assists in the production of amazing Aluminum products that manufacturing companies rely on. According to the benefits and shortcomings of both options, it turns out that direct extrusion is the most common method. But sometimes companies may be forced to opt for indirect extrusion depending on the needs at hand. These processes can be used at the same time in some instances to make more complex products. Manufacturers like FONNOV ALUMINIUM continue to use these processes to make complex aluminum products for their esteemed clients satisfactorily. And that’s why you should try them.