Aluminium Extrusion Die Technical Manual

Die Correction For Aluminum extrusion die

During EXTRUSION(Billet-Section),billet suffer frictions from container/dummy

block/diversion holes/welding chamber and bearing,result in aluminum flow in each point
cause difference.For irregular sections(Asymmetric and big thickness difference),aluminum
flow difference is bigger.
The theory of die correction is adjust aluminum flow speed of each area,to balance
aluminum flow. Common die correction ways:
1,Adjust length of bearing; 3,Add block angle;
2,Change friction force of aluminum 4,Adjust size of diversion holes;
alloy flow; 5,Lapping and polishing.
1、Notes for die correction

1.1、Understand design of the die,communicate with die designer before correction;

1.2、If strength of the die is enough,we consider ways of increase aluminum flow first,to
reduce extrusion pressure well.Large-scale of welding is inadvisable.(See figure below)

Prior to increase aluminum flow Large-scale of welding is inadvisable

1.3、Die corrector must observe extrusion condition by himself（See figure below）

1.4、 Increase aluminum flow speed and reduce bearing,give priority to EDM,then can
consider reduce bearing via diamond milling cutter.(See above right)
Do not reduce bearing from welding chamber.
1.5 、 In non emergency situations,please do not remove die carrier.(For multi-cavities
dies,do not allow to change die carrier)
1.6 、 Think before correction.Combining theory with practice, in order to achieve the
effect of twice the result with half the effort.

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 Aluminium Extrusion Die Technical Manual
1.7、Please do not correct too much,should set aside some for next correction.(see below
left)

1.8 、 If we need to weld,the better preheat the die (To 400 ～ 500 ℃ and keep 2
hours),thus can avoid problem of angle crack, bridge crack.(see above right)
1.9 、 The better track&correct one die by same person,thus can avoid mistake and
increase die correction experience well.

2、Common ways for die correction

2.1、Ways for increase aluminum flow:（see below）

Increase depth of run-out area Reduce thickness of inlet area Increase area of inlet holes 2.2、
Ways for reduce aluminum flow:（see below）

Block angle(1-3) Choke block Bearing difference

2.3、Ways for modify chamber are increase and reduce size of chamber.
2.3.1 If thickness or shape size of profile less than drawing,we need to increase size of
chamber.Also we should inspect and measure the die before operation,first test bearing
angular surface,second test size of incongruent part,then decide if use this method.
2.3.2Reduce chamber is much difficult than increase chamber.Normal correction method
is welding,that is heat the operated part,then welding use electrical welder or argon arc
welder,then repair with file.

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 Aluminium Extrusion Die Technical Manual

3、 Common problems and Solutions for extrusion

1、Surface scratch of profile（see below）

Description Analysis of causes Solution

There are rough Magnetic metal adhesion or EDM slag Polish die bearing,run out
residue；
longitudinal or part on time；
transverse Die displacement due to improper bolster Choose suitable bolster；
or pin loose；
grooves,scratche Bearing or run out part is not smooth；
s on the surface Besides,should replace
of profile Profiles from multi-holes die collision； graphite plate, roller on time
Profile abrasion

Surface scratch Hard spots

2、Hard spots（see above）
Description Analysis of causes Solution
Check and repair the
Some part of extrusion die hardness is not bearing of the die in
There are
enough,then stink aluminum; time；
continuous white Bearing is too long or too rough,then stink Grind the choke block;
points on the
aluminum; Formulate and execute
surface of
Temperature of container and billet is too reasonable extrusion
profile,and
high,lead to aluminum flow too fast; process according to
change to hard
Aluminum is not uniform,or oxide coating different alloy material;
spots after
on the surface of aluminum billet is too Use high-quality
surface treatment
thick; aluminum billets.

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 Aluminium Extrusion Die Technical Manual
3、Bubble phenomenon
Description Analysis of causes Solution
Division hole of the die is too big,equal or Control the temperature
bigger than billet diameter; and extrusion speed
Container inner wall has abrasion,so there during extrusion
is space between billet and container,thus reasonable and choose
air will enter profiles as extrusion; high quality billets；
There are convex Container and bolster have water stains Detect container,bolster
bubbles on the and oil; and shear’s wear
surface of profile Exhaust system of the container has condition,and replace
problem,cause air can not be drained; them if possible;
Surface of the billet is too rough,will bing Use the lubricating oil
air into container; in a reasonable way；
The material and inner structure of Adjust the exhaust
aluminum billet is very bad; system;

Bubble Wrinkled skin

4、wrinkled skin
Description Analysis of causes Solution
Use good tracking force
of puller;
There will be Tracking force is too big,improper Ensure straight the
adnexed layer operation of puller； profiles after
called wrinkled High temperature straightening； cooling,and control
skin straight force to fit
different size of profiles

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 Aluminium Extrusion Die Technical Manual

5、Wrong dimension and tolerance

Description Analysis of causes Solution
Size of profile is Due to design or processing mistakes, the Aluminum flow speed of
too small size of the chamber is not accurate.; each part is uneven,we can
Because aluminum will rub with inner use ways that pick up speed;
surface of container,the flow will slow Choose suitable extrusion
down,so parts that far away from center press and bolster for different
will be thinner and smaller; sections;
Some of the profiles have related Control die’s heating
problems,such as heat sink,external part is treatment process；
thin and small,inner part is thick and big; Control die’s preheating time
Strength of the die is not enough,cause size and using time；
difference during extrusion；
Size of profile is Due to design or processing mistakes, the Adjust the design；
too big size of the chamber is not accurate;
Large gap of the bearing（As below
picture）

Large gap of the bearing Overdose

Strength of the die is not enough Thickness of inner part is too small
Due to underfeeding of aluminum

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 Aluminium Extrusion Die Technical Manual

6、Wave, twisting, bending of profiles（As pictures below）

Description Analysis of causes Solution
Extrusion temperature and speed are Improve the technology
not suitable will lead to waves; of die design,processing
Wall thickness difference of profile is and die correction;
Wave:There are too big,when we cool the profile, Control the extrusion
continuous waves different size will cause different temperature and speed
on the surface; cooling speed; strictly according to the
Twisting Bolster is not reasonable; requirements;
Bending Choose suitable bolster;
Choose appropriate
quenching process;
Use puller.

Wave Twisting Bending

7、Shrink tail(As pictures)

Description Analysis of causes Solution
Adjust the thickness of
the discard;
There will be
structural defects All of the surface of billet will flow to Require high quality
and clean billets;
at the end of end,then it will cause shrink tail;
Using lubrication oil
profile(Test with Some dirty aluminum flow to end;
reasonable;
low Bad welding line for poor extrusion force;
Choose suitable
magnification)
extrusion press and
increase extrusion rate;

Shrink tail Extrusion lamination

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 Aluminium Extrusion Die Technical Manual
8、Extrusion lamination（As above）
Description Analysis of causes Solution
Division hole of the die is too big,equal or
bigger than billet diameter;
There will be Container inner wall has abrasion,so there Test and replace
is space between billet and container,thus
lamination at the unqualified container
air will enter profiles as extrusion;
end of and bolster on time;
profile(Test with Oxide skin on the surface of billets is too Select high quality
thick,with biggish segregation
low aluminum billet and
accumulation metal tumor;
magnification) keep clean;
There are oil and dirt on the surface of
billet;
Billets have lamination or bubble;

9、Bad welding seam（As below）

Description Analysis of causes Solution
Optimize design of the
Aluminum flow through die bridge and
die;
then weld with a strip or line;
Clear strip or Extrusion rate is too small,cause aluminum Use suitable extrusion
linear defect of process;
supply is not enough;
hollow dies Mill and sharpen the
Extrusion temperature is too low;
bridges to speed up
Extrusion speed is too fast;
aluminum flow;

Bad welding seam Coarse grained structure

10、Coarse grained structure

Description Analysis of causes Solution
Optimize die design;
Choose suitable press
There will be Design of the die is unreasonable;
and control extrusion
coarse grained Temperature of quenching is too high;
process well;
structure of Quality of the billets is bad;
Control quenching
profile(Test with Inappropriate extrusion press,extrusion
process；
low force is too small;
Choose high quality
magnification)
billets that with
homogeneity;
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 Aluminium Extrusion Die Technical Manual

11、Rabbet opening and closing (As below)

Description Analysis of causes Solution
Optimize die design;
Groove shaped Die design is not good.(Ex.Bearing size is Use suitable extrusion
and angle shaped not reasonable); process;
profiles' rabbet Bolster is not good; Adjust height of choke
size is not same Extrusion temperature is not good; block;
as drawing Adjust aluminum flow
speed of each area

open

Rabbet colsing Rabbet opening

Slub phenomenon of pipe Slub phenomenon of plate

12、Slub phenomenon (As above)

Description Analysis of causes Solution
Optimize bearing
design of the die;
There will be
Die design has defect such as too long Increase space of
some small
bearing; welding chamber;
waves on the
Space of die welding chamber is not Operate in strict
surface of
enough; accordance with the
profiles when
Periodicity waves for excessive billet extrusion
extrude mild
temperature; process,choose low
alloy profiles
temperature and high
extrusion speed;

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 Aluminium Extrusion Die Technical Manual

13、Big hat phenomenon (As below)

Description Analysis of causes Solution
Optimize die design to
Extrusion pressure is too high;
reduce pressure;
Usage time of the die is too long that there Replace or repair
is abrasion at feeding side;
Aluminum container;
Billets temperature is too high;
leakage at the Clean the container
Thickness of die ring is bigger than die;
interface between There is gap between container and die regularly and use
container and die lubricating oil
because of working area of container is not
reasonable;
flat;
Adjust locking force of
Locking force of the press is not enough;
extrusion press;

Big hat phenomenon Peeling phenomenon

14、Peeling phenomenon of die (As above)

Description Analysis of causes Solution
Use high quality die
Material composition and organization steel;
structure is unqualified; Strict implementation
There will be Carburization or decarburization of the die of heat treatment
peeling when on heating treatment; process;
phenomenon at Long time work without nitridation; Avoid over extrusio;
the interface Bad nitridation operation; Strict implementation
between die and The die is not dry before nitridation; of nitriding process,and
aluminum alloy Preheating time of the die is too long; polish the die before
Clean the die with too high nitriding;
temperature;(exceed 100℃) Clean the die with room
temperature;

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 Aluminium Extrusion Die Technical Manual
15、Surface arch,surface concave (As below)
Description Analysis of causes Solution
Design of division holes and bearing is not Optimize die design;
reasonable; Check if there are
There are processing problems of the die; assembly errors;
Surface of
There are using problems of the die,for Repair the worn
hollow profiles
example,after many times bearing;
begin arch or
extrusion,bearing will wear and cause Adjust the division
concave
aluminum flow is uneven; holes to uniform
Strength of the die is not enough,and aluminum flow;
bearing change shape as extrusion;

图 37
Surface arch Surface concave
16、Crack Bridge (As below)
Description Analysis of causes Solution
Material composition and organization
 Choose high quality steel;
structure is unqualified;
 Strict implementation of
Design of die is not reasonable;
right heat treatment process;
Heat treatment process is not reasonable;
Improper maintenance of the die will cause  Prohibition of over
extrusion;
There is crack in steel annealing;
 Control nitrding&heating
the bridge of the Long time work without nitridation;
time of the die;
die Small die extrude big profile will cause
 Choose suitable press;
crack too;
 Priority to speed up flow;
Extrusion rate exceed 100;
 Clean the die with room
Wrong die correction;
temperature;
Clean the die with too high
temperature;(exceed 100℃)
Brittle rupture Ductile fracture

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