Extrusion & Die Process Application

Craig Werner, Intelligent Extrusion LLC, USA 

The extrusion industry has made huge strides in equipment and collection of critical tooling, recipe, process, and production data over the past decades but too often decision processes have not kept pace. Proper data collection and organization allow for improved historical investigations helping to pinpoint and solve the root cause(s) thus improving future decisions and actions. This also prepares extruders to utilize advanced analytic tools starting with predictive analysis applied through a myriad of key extrusion variables and relationships to dramatically improve quotation accuracy and recipe optimization, which rely on consistent data structures. These in turn are key inputs into dramatically improving yield and productivity and in matching capacity with demand. The authors’ collection of ET ’27 papers are meant to be read or referred to as an overall roadmap and are designed to progressively advance extruders’ capabilities via prediction. 

Shah Imani, Dan Dunn and John Cullum, Castool Tooling Systems, Canada 

Building on our award-winning ET ’22 study on billet geometry, this research advances thermal management in aluminum extrusion by examining the distinct and decoupled roles of billet and container. Contrary to conventional assumptions, findings show billet and container temperatures are not directly correlated; maintaining a stable differential is critical for process scalability. The study evaluates the impact of billet taper, material selection, heating element configuration, and thermocouple placement on thermal gradients, extrusion uniformity, and efficiency. High-fidelity simulations and case studies reveal that billet taper compromises temperature accuracy, reducing productivity and optimization potential. Comparative analysis of center-of-mass versus liner-focused heating strategies highlights their influence on precision control. Results redefine the container’s role from passive heat sink to active thermal boundary, enabling improved billet temperature stability. Measurable gains include enhanced uniformity, reduced cycle times, and improved predictive control — supporting next-generation container systems aligned with industry goals for energy efficiency, thermal precision, and extrusion performance. 

Ajai Pratap Singh, Jindal Aluminium Ltd., India 

Productivity of direct extrusion of aluminum alloys depends significantly on the so-called “back-end” defect which always occurs in the center of an extruded section at the end of one extrusion cycle. This is the most common flaw encountered during aluminum extrusion that compromises product aesthetics and mechanical integrity. In structural sections this defect leads to an unacceptable decrease in product quality and so the length of the extruded section which contains this defect must be scrapped. The length of the scrap due to the back-end defect depends on different process parameters like friction, initial temperature of the billet or tool geometry. This paper explores the root causes of coring, diagnostic techniques, and optimization strategies to minimize its occurrence. Focus centers on controlling the process, improving die design, choosing suitable materials, and regulating temperature. 

Jitendra Rai, Jindal Aluminium Ltd., India 

Impression marks manifest as localized surface depressions or raised outlines on extruded aluminum profiles, typically occurring at abrupt transitions in section thickness. These impressions not only compromise aesthetic quality but can also impair downstream finishing processes like anodizing and powder coating. This study examines the formation mechanisms of impression marks linked to die bearing transitions caused by thickness variation, evaluates the influence of bearing contour design and proposes corrective strategies to mitigate defect occurrence. 

Vinit Jha, Jindal Aluminium Ltd., India 

In today's competitive market, aluminum extruders are constantly seeking ways to maximize the utilization of their existing resources. While simply operating the press for a greater number of days is one aspect, true press utilization lies in achieving maximum output and recovery from the available press capacity without compromising the quality of the extruded product. Optimizing the billet length for each production run is a crucial method to achieve this goal and consistently operate above 90% of the press's capability. This note outlines a step-by-step approach to planning the optimum billet length based on extrusion ratio and other critical factors. 
 

Veerendra R, Jindal Aluminium Ltd., India 

We have observed recurring instances of pitting marks on anodized profiles. These marks, which are difficult to detect in mill finish condition, become prominently visible post-etching during the anodizing process, leading to rework and quality concerns. To address this issue, we have undertaken a series of process modifications aimed at eliminating the root causes. These include optimization of quenching mode, revision of the ageing cycle, adjustment of natural aging duration, enhancement of storage methodology, and reduction in lead time from production to packing. We are currently monitoring the effectiveness of these interventions and are optimistic that they will result in a significant reduction of pitting marks in future shipments. This article discusses the various initiatives taken to minimize such pitting marks. 

Raghavendra Kulkarni, Jindal Aluminium Ltd., India 

In hot extrusion, streaking and impression marks are some of the common surface defects on architectural extrusion profile used in the building and construction industry. Streak defects are often present on anodized extrusion of 6XXX-series aluminum alloys, increasing the fabrication cost of the products due to the need to additional operations like buffing to minimize the streaks. Moreover, streaking often only becomes visible after etching and anodizing treatments, which makes it very difficult to control at the extrusion stage. An impression mark on the other hand refers to a localized surface defect that appears as a groove or uneven surface usually at web intersections, which becomes predominantly visible after powder coating. The current study talks about our practical experience with these marks and the actions taken with regard to the die design and process parameters, to minimize these marks. 

Pradip Saha, Technical Fellow, USA 

In the aluminum extrusion industry, quality is the basic key factor leading to business success, growth, and an enhanced competitive position. Effective quality-improvement programs can result in increased market penetration, higher productivity, and lower overall costs of extrusion. Extrusion quality is totally dependent on the functions of the process control of each stage of operations, including billet preparation, die design and manufacturing, extrusion press and auxiliary system, extrusion parameters, and the final heat treatment. It is very important to monitor the total process control system, from billet casting to the final heat treatment of soft- and medium grade and hard alloys extrusions. This paper highlights each operational stage with a detailed process-control flow diagram to provide a better understanding and to create a process-control document of each operational process stage. This paper also presents fundamental ideas of a complete process and quality control framework system for an aluminum extrusion plant. 

GNS Narayana, Jindal Aluminium Ltd., India 

In 6061 alloy extruded rods, Peripheral coarse grain( PCG) is a very common defect. PCG will create aesthetic appearance issues in the extruded products after machining process and after the anodizing process. PCG can also significantly affect the fatigue strength of the extruded products. PCG is affected by various parameters like chemical composition, homogenization, press, extrusion ratio, billet temperature, exit temperature, extrusion speed, quenching, die design, heat treatment, etc. While PCG is difficult to eliminate completely, it can be controlled by controlling and optimizing the process parameters. This article discusses our practical experience with PCG and the process being adopted to control it. 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

Die rings are essential components in aluminum extrusion, providing die holding and effective container sealing. Depending on die size, sealing may occur on the die face or the die ring face, making dimensional accuracy critical. To improve sealing consistency and metal flow, baffle die rings with integrated feeders are commonly used. Baffle die rings ensure continuous metal availability at the die face, enabling higher extrusion speeds, improved productivity, and consistent die performance. However, aluminum trapped inside the baffle after each cycle must be removed during die changeover, increasing handling effort and contributing to additional cost as scrap recovery. Residual aluminum left inside the baffle undergoes oxidation and may be carried into subsequent billet cycles, resulting in surface defects that become evident after anodizing. This study concludes that while baffle die rings are effective for maximizing productivity and process stability, their use should be carefully avoided for extrusion profiles. 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

In an era dominated by artificial intelligence and paperless data systems, most manufacturing plants rely on electronic data logging for process monitoring and analysis. At Napco, however, a circular paper chart recorder was innovatively adopted and upgraded to enhance operational effectiveness. Although considered obsolete, the system proved highly effective when redesigned and strategically implemented. The recorder was modified by replacing the rotating mechanism with a wall-clock drive, converting battery operation to a stabilized power supply, and repositioning it near press operators for real-time visibility. These changes resulted in improved productivity and reduced die failures. The concept was further extended to billet temperature recording before press loading, powder coating process monitoring, and packing machine runtime tracking. The system’s key advantage lies in its simplicity and instant visual feedback, enabling shift performance assessment at a glance and promoting operator accountability. 
 

Tony Da Silva, XtruAdvance, Canada; and Vinicius Dessotti, XtruAdvance, Brazil 

Xtru-IQ is a press-level extrusion intelligence system developed to support real-time process optimization in aluminum extrusion operations. The system integrates billet thermal history, die pressure demand, and press operating limits to define and continuously update an extrusion limit diagram representative of actual production conditions. By linking die design attributes with measured extrusion performance, Xtru-IQ provides quantitative guidance for billet temperature, ram speed, and pressure management while reducing reliance on operator intuition and highlighting die design improvement potential. Physics-based algorithms monitor and adjust key process variables in real time and generate periodic performance analyses to support operational and management decision-making. In parallel, Xtru-IQ coordinates press-adjacent equipment, including multi-zone billet furnace control and container thermal management, to minimize exposure to metallurgically sensitive temperature ranges without introducing press delays. The objective is to stabilize process conditions, reduce operator cognitive load, and improve overall equipment performance. 

Lei Pan, Paul Rometsch, Nick Parson, Rio Tinto Aluminium, Canada; and Jerome Fourmann, Rio Tinto, USA 

The growing demand for vehicle lightweighting continues to drive the increased use of aluminum extrusion alloys in automotive structures, where reduced mass directly contributes to improved energy efficiency and lower emissions. Among these materials, Al‑Mg‑Si and Al-Mg-Si-Cu alloys provide an attractive balance of formability and strength, but their final performance is highly affected by the processing history. Understanding the influences of natural aging kinetics, forming strain, artificial aging response, and alloy composition is therefore essential for controlling microstructure evolution and ensuring consistent properties in formed components. In this study, several Al‑Mg‑Si(-Cu) extrusion alloys were systematically evaluated under different aging and strain‑forming conditions. Mechanical testing and microstructural characterization were conducted to establish correlations between chemical composition, precipitation behavior, deformation state, and resulting performance. The findings provide practical insights to support alloy selection and heat treatment optimization for the development of reliable, lightweight, high‑performance automotive structural components. 

Walt Sorensen, Bonnell Aluminum, USA 

Every extruder needs to control multiple process variables to produce successful products for their customers. Those process variables hold hidden signals which explain if your extrusion process is, or was, successful yet often remains underutilized in understanding production success. Your process data tells not only the story of your extrusion process but the health of your extrusion equipment. Visualization of your extrusion process data can reveal the hidden reasons for quality issues, find root causes for failures faster, improve die corrections, and develop better best practices. Using visualized process data, you can build a feedback loop between quality, maintenance, extrusion operators, and your die shop to solve the technical process and equipment challenges which otherwise would prevent success. Practical case examples show how data visualization supports improved root cause analysis, improved equipment trouble shooting, better die correction decisions, and targeted corrective actions to improve best practices. 

Lucas Itchue, Bala Jayachandran, Jeffery Victor, and Danni Xie, Hydro Extrusions USA, LLC, USA 

Quench rate and cooling uniformity play a critical role in controlling precipitation behavior, residual stresses, and profile geometry in Al–Mg–Si (6xxx) aluminum extrusion alloys. While quench temperature, pressure, and extrusion delays are routinely monitored in the production environment, the influence of quench water chemical conditions, particularly water conductivity, oil contamination, and dissolved solids are often poorly controlled. Production experience indicates that variations in quench water chemistry are not consistently reflected in average tensile properties, yet strongly influence ductility, especially tight-radius bend behavior as evaluated by VDA 238-100, a key lot-release criterion for automotive applications. Controlled quenching trials are performed using water conditions spanning representative quench water conductivity ranges. Cooling behavior is characterized using quench probes and quench factor analysis. Post-quench properties are evaluated through hardness and tensile testing, complemented by VDA 238-100 bend testing to assess crack initiation, bend limits, and result scatter. 

Jan-Philipp von Weschpfennig and Werner Hahnel, Kind & Co., Edekstahlwerk GmbH & Co. KG, Germany; and Raymon Fryan, Lake Park Tool and Machine, Inc. USA 

High‑strength aluminum alloys and higher press utilization push extrusion containers and dies into harsher thermo‑mechanical regimes. The traditional U.S. setup, a 4340 outer container with an H13 inner liner, can suffer accelerated abrasive wear, thermal checking, and loss of dimensional stability. This paper describes a three‑piece container architecture that separates structural load and wear functions via a high‑thermal‑resistance (HTR) intermediate liner and a high‑strength Q10 inner liner. Material selection rationale, liner interface considerations, and implications for die steel choice are discussed. The approach targets longer liner life, fewer unplanned stoppages, and more stable process windows for demanding alloys, improving profile consistency at higher throughput. 

Nikhil Yellakara, Hydro Aluminum Metals USA LLC, USA; Adrian Lervik, Hydro Aluminum Metal, Norway; and Charles Wright, International Extrusions, USA 

Effective cooling of automotive aluminum profiles during extrusion remains a significant challenge, as high cooling rates must be achieved while maintaining dimensional stability and meeting stringent strength and crash-performance requirements. Recent advances in quench box (QB) design have raised questions regarding the performance gap between lower-cost and premium quench systems. In practice, extruders often expect high quenching precision from equipment not designed for such demands. At International Extrusions (INTEX) Livonia, an existing quench box was evaluated using the Quench-box audit developed by Hydro Aluminum Metals. The audit assessed equipment design, operational practices, maintenance conditions, and in-line cooling performance. Based on the initial findings, Hydro provided practical recommendations to address INTEX’s requirements for advanced automotive applications. The recommended upgrades required only minor investment from INTEX. This paper presents cooling performance results before and after implementation of the recommended quench system upgrades, highlighting the resulting improvements in quenching capabilities and crash performance. 

Johnny Pangborg, Metalstar Consulting LLC, USA 

In our industry, excellent process control at all points is paramount to quality, cost-effective production. Ultimately, the enemy of a controlled process is process variability. Proper performance of all production equipment is critical to minimizing process variability. One piece often not given enough attention is the heat-treating process, particularly post-extrusion aging. We often rely on the extrusion equipment and quality checks, but variation in the ovens results in variability in the product that is not accounted for in the check process - a higher risk for our customers. In order to avoid treating ovens as a 'black box', several standards have been established for instrumentation of ovens: ASTM, AMS, and AIAG have decades-long history in standards. This paper will provide 1) an overview to survey methodology; 2) a comparison of the three major standards; and 3) application to aging ovens as well as homogenization ovens in the casthouse. 

Lei Pan, Leticia Marin de Andrade and Paul Rometsch, Rio Tinto Aluminium, Canada; and Jerome Fourmann, Rio Tinto, USA 

Intergranular corrosion (IGC) evaluation is essential for many 6xxx‑series aluminum extrusion alloys used in automotive applications, as corrosion performance directly affects long‑term durability and safety. IGC test results are strongly influenced by the testing method, making it critical to select appropriate and consistent test conditions. Furthermore, variations in alloy chemical composition, extrusion conditions and heat treatment history can significantly affect the degree of recrystallization and grain boundary precipitation, and therefore IGC resistance. This study systematically investigates the effects of IGC test parameters within ISO 11846 Method B, alloy composition (especially Cu content), extrusion press quench cooling rate and heat treatment practices on IGC test results. Complementary microstructural characterization was conducted to establish correlations among these factors. The findings provide practical guidance for improving IGC testing practices while informing alloy selection and process design, enabling the development of high‑performance aluminum extrusions for advanced automotive applications. 

Craig Werner, Aaron Williams and Miguel Santana, Intelligent Extrusion, USA 

Extruders’ team experience/training and results vary dramatically. Many extruders rely heavily on a few talented team members to make critical decisions. Recipe and quotation decisions often rely on simplifying heuristics which have proven useful. These exceptional team members simply do not often have sufficient time to calculate the thousands of “what if” inputs possible and, of course, many of these experts are retiring. Using properly structured data to feed proven advanced analytic techniques improves the decision process and dramatically bridges the gaps that become evident upon retirement of these key team members. These techniques are even more critical for new facilities but are also effective for legacy systems with older equipment and data systems. The authors’ ET ’27 papers are designed to progressively advance extruders’ capabilities via use of their actual data to provide predictive capabilities and should be referenced for further understanding. 

Craig Werner, Aaron Williams and Miguel Santana, Intelligent Extrusion, USA 

Extruders rely heavily on key team members to make critical decisions. Retirement of these team members risks losing key decision processes, but even without retirements, the evaluation of hundreds or thousands of possible tooling decisions, extrusion press assignments and backups are too time-consuming requiring the use of heuristic techniques which are not sufficient for the complexity of multi-press operations. With proper data structuring and use applied extrusion analytics can be used to drive better decisions for recipes, quotations and specifically for evaluating thousands of “what if” cases automatically to supplement heuristic decision processes. The authors’ ET ’27 papers are designed to progressively advance extruders’ capabilities via use of their actual data to provide predictive capabilities and should be referenced for further understanding. 

Craig Werner, Intelligent Extrusions; Johnny Pangborn, Metalstar Consulting LLC; Jerome Fourmann, Rio Tinto, USA; and Richard Dickson and Danny Dunn, Castool Tooling Systems, Canada 

Four authors previously worked together on what became the Keynote paper in the published ET ’24 proceedings, covering What and Why so many aspects of the extrusion process are critical to long term success. Using this paper as the basis, this follow-up ET ’27 paper will focus a bit on “what and why” but will delve much more deeply into specifically how extruders should make and implement decisions from various perspectives: operations focused (Part I) and management focused (Part II) to drive sustainable success. “Connecting the Dots to Approach Optimization, not just Efficiency - An Excellent Resource to Gain Impressive Productivity and Capability Improvements”. 

Arif Hussain, Gulf Extrusion LLC, United Arab Emirates 

The increasing demand for sustainable manufacturing has accelerated the use of recycled aluminum in structural and automotive applications. However, concerns remain regarding the corrosion performance of recycled billets compared to primary aluminum, particularly under varying extrusion parameters that influence microstructure and surface integrity. This study presents a comparative investigation of the corrosion behavior of recycled and primary aluminum with different extrusion temperatures, and ram speeds. Primary and recycled billets were homogenized prior to extrusion. The extruded profiles were characterized by grain structure, surface quality, and defect formation using optical microscopy and SEM/EDS. Corrosion performance was checked by salt spray testing, ECP, and immersion testing in chloride environments. Results indicate that extrusion parameters significantly influence corrosion resistance by altering grain. By optimization of temperature and ram, narrowing the gap between recycled and primary. The findings show that when controlling processing parameters, recycled aluminum billets can achieve corrosion performance comparable to primary aluminum. 

Leo Hendriok, Fabian Esterl, Benjamin Klusemann, and Noomane Ben Khalifa, Institute for Production Technology and Systems, Leuphana University Luneburg; and Benjamin Klusemann and Noomane Ben Khalifa, Institute of Material and Process Design, Helmholtz-Zentrum Hereon, Germany 

The aluminum sector is responsible for approximately 3% of greenhouse gas (GHG) emissions worldwide. This enforces transformative innovations towards clean production processes. Solid-state recycling by hot extrusion proves to be a promising approach to produce recycled parts with good mechanical properties while maintaining a high material throughput and significantly reducing GHG emissions. This study aims to optimize the pre-processing of the chip material to improve the mechanical properties. By applying different pre-compaction processes prior to hot extrusion, the oxygen-exposed surface of the chip material will be reduced before high-temperature processing, thereby improving bond quality. The resulting extrudates will be evaluated regarding their mechanical properties, and the respective microstructure development will be analyzed by SEM measurements. The goal of this study is to advance the solid-state processing chain for aluminum chips by hot extrusion towards industrial implementation. 

Gautam Wagle, Sumit Gahlyan, Raviprasada Kasat, Dhurandas Fulzele, Sudharshan Ravichandran, Hindalco Industries Limited, India 

Aluminum extrusions are widely used in automotive applications for front and side crash assembly components considering the capability of high energy absorbance and high strength-to-weight ratio. These extrusions are designed to be multi-hollow to allow for higher energy absorption in the event of a crash. However, these features also limit the design of the extrusion process for achieving consistent material performance throughout the section since the internal webs of the profile are subjected to varied cooling rates during the quench. Hence localized microstructural changes become pronounced such as abnormal grain growth. This work covers the design of alloy and the extrusion process including post-extrusion quench to control the microstructural for improved performance of extrusion in side-crash sill component. These effects are numerically and physically validated during the extrusions. Additionally, the effect of artificial aging to achieve the desired material toughness across the profile cross-section is also presented. 

Gautam Wagle, Aakansha Mhatre, Kuldeep Patidar, P Mohanraj, Jaison George, Ritesh Warange, Sumit Gahlyan, Hindalco Industries Limited, India 

Surface quality is a critical requirement for niche anodized, extruded products where microscopic features can strongly influence post‑anodizing appearance. Control of microstructural constituents depends on every processing stage—from alloy chemistry, homogenization, die design, extrusion, and ageing. Among these, die design remains highly influential even when all other parameters and profile dimensions are fixed. Subtle design variations can modify metal flow, altering grain evolution and alignment of intermetallic particles in the extrudate. This study examines two die designs with minor geometric differences that produced significant changes in intermetallic alignment and the density of these aligned features. Increased concentration aligned particles resulted in visible stripping‑line defects on the anodized surface. The die design concepts were based on extrusion simulations while the microstructural defects were characterized using optical and SEM microscopy. The findings highlight the capability of simulation tools to predict metal flow and the sensitivity of anodized quality to small die design modifications. 

Esma Senel, Randi Morkrid, Anders Nordeide, Hydro Aluminium Metal, Technology Development, Norway; and Micah Lobdell, Hydro Aluminum Technology Center, USA 

Quality issues in extrusion can be difficult to diagnose, as their origins may lie in billet microstructure, extrusion parameters, or downstream processing. Resolving such cases requires metallurgical insight, structured analysis, and close collaboration across the value chain. This paper presents illustrative cases where supplier and customer jointly troubleshoot challenges, by integrating analytical expertise, alloy knowledge, and process understanding from casting through extrusion and surface finishing. Selected cases will be presented, including  stabilizing of extrusion performance, clarifying mechanical‑property variability during new‑product implementation, and conducting failure analysis after multi‑step downstream processing. The findings highlight that close technical cooperation between supplier and extruder strengthens process robustness, reduces variability, and improves predictability. 

Rolf Beckert, WEFA Inotec GmbH, Germany; Jan Svoboda, WEFA Bohemia, spol s, Czech Republic; Dawid Wanat, Grupa Kety SA, Poland 

This work focusses on high volume production of profiles with multi cavity extrusion dies. Especially in the current market conditions, all extrusion companies are under high pressure to improve productivity. Besides, material properties and surface quality shall be maintained. By means of the newly developed “High Precision Insert Technology” (HPIT) extrusion dies, longer extrusion runs with less tool changes can be established. Additionally, a CVD coating protects the die bearings in terms of wear and by specific pre- and post-treatment the profile surface finish can be improved. One invention of this new die concept is the easy to replace mandrel and plate inserts and its overall reduced maintenance efforts such as eliminating the nitration cycles. Dimensional stability of small details in the profile section was improved in a way no polishing is required. The paper will compare current standard dies with the new HPIT concept using specific profile examples. 

Johnny Pangborn, MetalStar Consulting LLC; Richard Dickson, Dickson Kingdom; and Matt Wille, Alexandria Industries, USA 

Die technology has improved over the last decades, in both design and manufacturing technology. But die vendors are often reticent to make the best low-pressure dies due to a perceived or real lack of confidence in customers' production systems. This often has less to do with technical limitations than with managerial ones. Further, die correctors have long known that they have tools and knowledge enough to make major positive impacts on the operations, but the managerial disincentives for taking risks often outweigh the benefits in the drive toward improvement. How do we actually implement real optimization in die correction? Selected examples from one of the leading extrusion manufacturers in North America will be discussed, with reference to other well-established methods for design improvements in the industry. A roadmap is presented to a system to develop confidence of die vendors to die corrector input, with facilitation and support of managers. 

Johnny Pangborn, MetalStar Consulting; Greg Lea, EGA America; Eskild Hoff, Hydro Aluminum Metals USA, USA; and Ulf Tundal, Hydro Aluminium Metal, Norway 

The purpose of this paper is to educate a new generation of extrusion personnel about the history behind the technology that so many of them use on a daily basis, and one of the key architects of this technology over the past decades: Oddvin Reiso. This will include such topics as the two types of metallurgical tearing, optimization of homogenization, alloy modernization, taper quenching, and the causes of metallurgical defects. The paper will be a review paper, focused on Dr. Reiso’s and co-authors’ award winning ET Papers over the years, highlighting the practical utilization of their presented technology and how it is the basis of many common practices in extrusion plants around the world. The review paper would also show links to more recent works whose bases are found in Dr. Reiso’s ET papers. 

Enrique Calvo Ordonez, Independent Aluminum Extrusion Professional, France 

In many extrusion plants, surface defects such as streaks are detected too late, leading to added cost, rework, and risk of nonconforming products. These defects are especially difficult to interpret because the visible surface mark does not always clearly indicate its actual die-related cause. Although these defects are often linked to the initial die design, they may also arise from changes in the actual geometric condition of the bearing during the die’s service life. Production wear, loss of flatness, local straightness variations, and modifications introduced during polishing, filing, or corrective work can alter metal friction and restraint conditions, disturbing flow balance in critical areas. This paper presents a practical interpretation of these mechanisms, including the effect of transitions between zones with different bearing heights, with the aim of improving defect diagnosis and the accuracy of corrective actions in an industrial extrusion environment. 

Saurabh Sedha, Jerome Fourmann and Nick Parson, Rio Tinto, USA; Jean-Francois Beland, National Research Council Canada’s (NRC) Aluminium Technology Centre (ATC) and National Research Council Canada, Canada; Lei Pan and Paul Rometsch, Rio Tinto Aluminium, Canada, and Rio Tinto, USA 

Non-recrystallized 6XXX extrusions offer an attractive combination of strength ductility and crush performance for automotive applications. Corresponding alloy compositions and homogenization practices are typically designed to inhibit recrystallization occurring during extrusion. However, the high levels of deformation produced at the profile surface can often promote a peripheral coarse grain (PCG) recrystallized layer which can be detrimental to mechanical performance. This paper examines the effect of extrusion process parameters on PCG formation. 

Tomás Beltran and Jose Fernando García, Alvarez-Schaer, SLU, Spain 

The aluminum extrusion process requires regular cleaning of dies with caustic soda baths to remove embedded aluminum. Over time, aluminum accumulates as sodium aluminate and reduces bath efficiency. This exhausted solution is classified as hazardous waste due to its highly corrosive nature. Globally, extrusion processes generate around 35T of spent solution per 1000T of aluminum extruded, impacting the environment and increasing management costs. Technological alternatives for caustic soda recovery must focus on removing dissolved aluminum, the main inhibitor of bath reactivity, while minimizing waste and operational costs. At ALSAN, a study of technical and economic factors across caustic soda recovery technologies led to an optimized system that recovers at least 80% of the caustic soda used. Aluminum is removed as a high-purity, non-hazardous by-product. This approach reduces waste and operational costs and supports circular economy principles in the aluminum extrusion industry. 

Danny Dunn and Richard Dickson, Castool Tooling Systems, Canada; and Nicholas Noecker, International Extrusions Inc., USA 

Ten years ago, a statistics and productivity discussion with an extrusion plant owner ended with the owner stating that 4000lbs/hr on an 8” press was not credible. Once he realized that some extruders were already achieving 4000lbs/hr, he embarked upon a mission to improve the productivity of his 8” press. This paper documents the successes (and occasional failures) along this path using practical examples and hard data. Ten years later it is not uncommon to see profiles running 8000lbs/hr on his press. Initially these improvements were based upon management driving team factors; such as support, motivation, skills, systems, etc. With these solid foundations in place, equipment and technical advances were added. The good systems work ensured that the benefits of this additional technology could be better harvested. This plant is now ready to take the next step and utilize the “Open Die” philosophy, allowing even greater improvements. 

Mark West, Pennex Aluminum, USA 

Increasing demand for more complex automotive and commercial profiles, along with higher strength alloys, has pushed process limits to an all-time high. Nitrogen is widely used, but application methods (gas vs liquid) and best practices are not widely understood. Nitrogen is frequently treated as a static utility rather than a dynamic process control variable. This project examines how nitrogen delivery impacts thermal management, die stability, and surface quality. The study will evaluate conditions where nitrogen can enable higher extrusion speeds without sacrificing metallurgical properties or dimensional tolerances. Through controlled trials and benchmarking, the project aims to develop practical guidelines for nitrogen utilization on 6xxx-series alloys, to support extrusion operations in making data driven decisions to maximize efficiency and competitiveness in today’s ever demanding market. 

Brandon Taysom, Brian Milligan and Scott Whalen, Pacific Northwest National Laboratory, USA 

Shear Assisted Processing and Extrusion (ShAPE) is an emerging technology that applies intense in‑situ rotational shear to refine microstructure and produce hollow extrusions, including seamless tubing and complex multi‑cell profiles, in both common and advanced aluminum alloys. Until now, ShAPE has been demonstrated primarily on lab‑scale systems in the 100–200-ton range, capable of forming extrusions 1–2 inches in diameter. To assess industrial scaling needs, physics‑based modeling was used to identify key contributors to force, torque, and power requirements. In parallel, AA6061 seamless tubes were extruded across a broad range of die sizes, extrusion ratios, speeds, and temperatures to validate model predictions. Results from modeling and experiments show that axial force and rotational power scale with the square of die diameter, torque scales with the cube of die diameter, and extrusion speed produces a non‑linear influence on required force, torque, and power. 

Bala Jayachandran, Andrew Wheeler, Aminah Williamson and Mike Tozier, Hydro Extrusions USA LLC, USA 

High-strength 6xxx-series aluminum extrusions are widely used in automotive crash-management systems to meet strength and energy absorption requirements. Bendability is commonly assessed using the VDA-238-100 test; however, instances have been observed where extrusions fail coupon-level bend criteria while meeting component-level performance requirements, indicating a disconnect between laboratory and structural evaluations. This study examines the relationship between extrusion processing, microstructure, and bendability in high strength 6xxx extrusions. The effects of extrusion temperature, speed, metal flow, and quench sensitivity on grain structure, recrystallization behavior, and weld microstructure are evaluated. Emphasis is placed on local microstructural heterogeneity and strain localization, which strongly influence VDA bend response. Results indicate that VDA-238-100 is highly sensitive to localized microstructural discontinuities that may not govern component-level behavior. A processing-based framework is proposed to improve bendability robustness and better align coupon-level testing with structural performance. 
 

Gebrekirstos Gebreamlak Berhe, Filmon Gebrehiwet Surafiel, Gebremedhn Berhe Wureata, Meresa Kindeya Gesese, Arsema Fisseha Yaye, Gebreslassie Gebremedhn Gebremariam, Tekhaf Aluminium, Ethiopia 

The relationship between extrusion speed and thermal stability of billet, die, and container remains a critical constraint in the aluminum extrusion industry. This paper explores how to achieve higher speeds for the extrusion process without loss of surface integrity or dimension tolerances. Based on production logs and real-time infrared and digital thermometers data, this study shows how the heat at tapered billet heating into optimized tooling temperatures compensates for significant heat buildup between various extrusion ratios. To address this problem, we quantify the relationship between exit temperature and speed to determine the ideal thermal window for isothermal extrusion of AA6063. Results showed that synchronized thermal management enables an increase in press speed while maintaining a stable process and eliminating surface defects. This provides a practical roadmap for plants to enhance productivity and power consumption through improved process control variables. 

Donnie Hudson and Steve James, Alfiniti Inc., USA 

Extruded aluminum tubes are drawn to achieve tighter dimensional tolerances. Drawing introduces cold work that increases hardness and reduces ductility, limiting formability. To enable forming of drawn tubes, the cold work must be removed while allowing restoration of temper. Solution heat treatment is the method used to achieve this. Traditional processing uses drop furnaces and large quench tanks. Alfiniti’s study investigates a novel continuous process using in-line induction heating followed by a forced-air quench to return drawn tubes to T4 temper. After forming, the material can then be artificially aged. This study evaluates the feasibility of a compact in-line process capable of restoring formability as an alternative to conventional furnace and quench tank systems. Evaluation of this process includes comparative analysis of the initial T8 condition, post-solution treated T4 condition, and final T6 condition. Testing will focus on mechanical properties, microstructure, corrosion resistance, and achievable bend radii of each condition. 

Todd Allison, The Oilgear Company, USA 

Integrating advanced hydraulic technology with digital monitoring to improve the performance and reliability of your industrial systems. The solution enables continuous data acquisition, remote diagnostics by experienced hydraulic specialists, and detailed analysis with clear, actionable recommendations. By combining hardware, secure connectivity, and engineering expertise, it increases system transparency and supports faster, informed decision making. It reduces unplanned downtime and supports a shift from reactive maintenance to preventive and predictive maintenance strategies. It also enables optimization of control parameters, improving efficiency and extending equipment life. As part of a comprehensive service portfolio, it delivers value across the entire lifecycle of hydraulic installations. Customers benefit from higher equipment availability, improved productivity, and reduced operating costs. Ultimately a hydraulic diagnostics reliability program supports sustainable performance, operational stability, and long-term competitiveness in demanding industrial hydraulic applications worldwide.  

Eystein Vada, Ole Runar Myhr and Helen Weykamp, Hydro Aluminium Metal; Nick Noecker, Charles Wright, Don Campbell, International Extrusions Inc., USA 

Consistently meeting tight upper and lower strength limits in aluminum extrusions require a controlled and precise production process. Narrowing the process window to achieve such requirements is resource‑intensive and often involves extensive trials spanning the entire route from billet to finished product. The main drivers for strength variation include billet chemistry, exit temperature, aging practice, intermediate storage time, stretching, and quench rate. For a specific product, the impact of these variables was evaluated using the precipitation strengthening simulation tool NaMo. Two edge cases, representing high and low strength conditions, were assessed across all process steps to estimate their influence on strength. The expected tensile strength variation was estimated to ±17% for a 6063 alloy. The most influential variables were targeted for process improvements, resulting in a substantial reduction in strength variability. This work demonstrates that a holistic process simulation approach can enable reduced variability where it matters most. 

Gebrekirstos Gebreamlak Berhe, Gebremedhn Berhe Wureata, Filmon Gebrehiwet Surafiel, Meresa Kindeya Gesese, and Gebreslassie Gebremedhn Gebremariam, Tekhaf Aluminium, Ethiopia 

Material loss in aluminum extrusion, particularly from butt-end discard and saw-cut waste, significantly impacts production cost and efficiency. The research aimed to ascertain a minimum functionally equivalent butt thickness that can lead to increased effective utilization of billets reduction in scrap. Optimal discard limits that did not compromise product quality were also identified using a data-driven approach. The research was conducted through a detailed analysis of metal flow characteristics and the sequestration of the billet’s peripheral skin. Extremely thin butts would allow surface contaminants to enter the profile, and extremely fat butts cause excessive yield loss. By implementing controlled testing on high-volume dies and monitoring recovery rates, specific parameters were identified to reduce the safety margins. The results show that the metal yield and wastage can be improved with controlled reduction in butt-end and run-out lengths. The study can positively underscore production estimation and costs optimization in aluminum extrusion. 

Jack Kalucki, Nitrex Metal, Canada 

In an aluminum extrusion plant, dies undergo a series of operations in between extrusions. They involve caustic soda cleaning, blasting, inspection and nitriding. It is necessary because at the temperatures and pressures at which aluminum is extruded, the nitrided case softens. This leads to washouts, quality issues and premature die failure – and increased tooling expenditures. Nitriding is a case hardening process which involves the enrichment of the steel surface with nitrogen. The process is usually performed at 932ºF -1076ºF. During nitriding, atomic nitrogen is diffused, improving or restoring hardness. While positive outcomes are expected of the re-nitriding cycles, at times nitriding may contribute, with other factors, to increased probabilities of die failure – or die correction. This paper delves into the factors that affect the outcome of nitriding processes, and factors that contribute to successful nitriding of aluminum extrusion dies, as opposed to factors that are detrimental and increase tooling costs. 

Enrique Calvo, Independent Aluminum Extrusion Professional, France 

Before committing to tooling or validating a quotation, it is essential to compare possible technical solutions in a structured way for any new extrusion project. The combination of press capacity, die type, number of cavities, expected productivity, scrap level, and process constraints can strongly influence technical feasibility, industrial cost, and overall project risk. This paper presents a practical pre-evaluation framework for analyzing alternative scenarios before technical or economic commitments are made. The objective is to improve the consistency of the initial decision, anticipate process limitations, and support a more robust selection of the proposed extrusion solution. The approach is based on criteria applicable to industrial practice and on the reasoned comparison of technical options in order to reduce uncertainty, strengthen the technical quality of project quotations, and improve alignment between profile design, tooling concept, and production capability. 

Md Hanif Hamzah, Press Metal Aluminium Holdings, Malaysia 

There has been much consideration and measurements on the life of a new die in the extrusion industry. What should be the best way to measure the life of a die? This paper discusses the method to measure by weight of the extrusion or the meters in extruded length. As the weight per meter of the die increases over a period of time, the die life is shortened. However, this practice is improved through a better method of nitriding and process control. The paper will guide the optimum number of nitriding and the number of billets to be extruded. A laboratory examination of the micro hardness of the white layer is examined to predetermine the life of a die. New technology of using carbide steel proves die life improves higher than the normal H13 steel with nitriding coating. The conclusions will compare the carbide steel versus the H13 steel die life. 

Yahya Mahmoodkhani, Steve Coates, Seif Badawy, Signature Aluminum Canada Ltd., Canada 

In aluminum extrusion, it is unclear how much profile geometry and bundle packing affect heat flow during aging. These factors can cause temperature differences between the bundle surface and center, which may influence the final mechanical properties. In this study, simulations are used to assess how packing and geometry change the bundle’s thermal cycle. Temperature measurements taken at different locations in the bundle during aging will be used to validate the simulation results. Mechanical testing will also be performed on samples from these locations to compare properties resulting from different temperature histories.