Extrusion is a process used to create objects of a fixed
cross-sectional
Cross-sectional data, or a cross section of a study population, in statistics and econometrics, is a type of data collected by observing many subjects (such as individuals, firms, countries, or regions) at the one point or period of time. The analy ...
profile by pushing material through a
die
Die, as a verb, refers to death, the cessation of life.
Die may also refer to:
Games
* Die, singular of dice, small throwable objects used for producing random numbers
Manufacturing
* Die (integrated circuit), a rectangular piece of a semicondu ...
of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work materials that are brittle, because the material encounters only
compressive
In continuum mechanics, stress is a physical quantity. It is a quantity that describes the magnitude of forces that cause deformation. Stress is defined as ''force per unit area''. When an object is pulled apart by a force it will cause elon ...
and
shear
Shear may refer to:
Textile production
*Animal shearing, the collection of wool from various species
**Sheep shearing
*The removal of nap during wool cloth production
Science and technology Engineering
*Shear strength (soil), the shear strength ...
stresses. It also creates excellent surface finish and gives considerable freedom of form in the design process.
Drawing
Drawing is a form of visual art in which an artist uses instruments to mark paper or other two-dimensional surface. Drawing instruments include graphite pencils, pen and ink, various kinds of paints, inked brushes, colored pencils, crayons, ...
is a similar process, using the tensile strength of the material to pull it through the die. It limits the amount of change that can be performed in one step, so it is limited to simpler shapes, and multiple stages are usually needed. Drawing is the main way to produce
wire
Overhead power cabling. The conductor consists of seven strands of steel (centre, high tensile strength), surrounded by four outer layers of aluminium (high conductivity). Sample diameter 40 mm
A wire is a flexible strand of metal.
Wire is c ...
. Metal
bar
Bar or BAR may refer to:
Food and drink
* Bar (establishment), selling alcoholic beverages
* Candy bar
* Chocolate bar
Science and technology
* Bar (river morphology), a deposit of sediment
* Bar (tropical cyclone), a layer of cloud
* Bar (u ...
s and
tube
Tube or tubes may refer to:
* ''Tube'' (2003 film), a 2003 Korean film
* ''The Tube'' (TV series), a music related TV series by Channel 4 in the United Kingdom
* "Tubes" (Peter Dale), performer on the Soccer AM television show
* Tube (band), a ...
s are also often drawn.
Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). It can be done with hot or cold material. Commonly extruded materials include
metal
A metal (from Greek μέταλλον ''métallon'', "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electricity and heat relatively well. Metals are typicall ...
s,
polymer
A polymer (; Greek '' poly-'', "many" + ''-mer'', "part")
is a substance or material consisting of very large molecules called macromolecules, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic a ...
s,
ceramic
A ceramic is any of the various hard, brittle, heat-resistant and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain ...
s,
concrete
Concrete is a composite material composed of fine and coarse aggregate bonded together with a fluid cement (cement paste) that hardens (cures) over time. Concrete is the second-most-used substance in the world after water, and is the most wi ...
,
modelling clay
Modelling clay or modelling compound is any of a group of malleable substances used in building and sculpting. The material compositions and production processes vary considerably.
Ceramic clay
Ceramic clays are water-based substances made f ...
, and foodstuffs. Products of extrusion are generally called ''extrudates''.
![HDPE pipe being extruded](https://upload.wikimedia.org/wikipedia/commons/b/b4/HDPE_pipe_being_extruded.jpg)
Also referred to as "hole flanging", hollow cavities within extruded material cannot be produced using a simple flat extrusion die, because there would be no way to support the centre barrier of the die. Instead, the die assumes the shape of a block with depth, beginning first with a shape profile that supports the center section. The die shape then internally changes along its length into the final shape, with the suspended center pieces supported from the back of the die. The material flows around the supports and fuses to create the desired closed shape.
The extrusion of metals can also increase their strength.
History
In 1797,
Joseph Bramah
Joseph Bramah (13 April 1748 – 9 December 1814), born Stainborough Lane Farm, Stainborough, in Barnsley, Yorkshire, was an English inventor and locksmith. He is best known for having improved the flush toilet and inventing the hydraulic pr ...
patented the first extrusion process for making pipe out of soft metals. It involved preheating the metal and then forcing it through a die via a hand-driven plunger. In 1820 Thomas Burr implemented that process for lead pipe, with a
hydraulic press
A hydraulic press is a machine press using a hydraulic cylinder to generate a compressive force. It uses the hydraulic equivalent of a mechanical lever, and was also known as a Bramah press after the inventor, Joseph Bramah, of England. He inven ...
(also invented by Joseph Bramah). At that time the process was called "squirting". In 1894, Alexander Dick expanded the extrusion process to copper and brass alloys.
Process
The process begins by heating the stock material (for hot or warm extrusion). It is then loaded into the container in the press. A dummy block is placed behind it where the ram then presses on the material to push it out of the die. Afterward the extrusion is stretched in order to straighten it. If better properties are required then it may be
heat treat
Heat treating (or heat treatment) is a group of industrial, thermal and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also ...
ed or
cold work
Cold is the presence of low temperature, especially in the atmosphere. In common usage, cold is often a subjective perception. A lower bound to temperature is absolute zero, defined as 0.00K on the Kelvin scale, an absolute thermodynamic ...
ed.
[
The extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts.
]
Hot extrusion
Hot extrusion is a hot working
In metallurgy, hot working refers to processes where metals are plastically deformed above their recrystallization temperature. Being above the recrystallization temperature allows the material to recrystallize during deformation. This is impor ...
process, which means it is done above the material's recrystallization temperature to keep the material from work hardening
In materials science, work hardening, also known as strain hardening, is the strengthening of a metal or polymer by plastic deformation. Work hardening may be desirable, undesirable, or inconsequential, depending on the context.
This strengt ...
and to make it easier to push the material through the die. Most hot extrusions are done on horizontal hydraulic press
A hydraulic press is a machine press using a hydraulic cylinder to generate a compressive force. It uses the hydraulic equivalent of a mechanical lever, and was also known as a Bramah press after the inventor, Joseph Bramah, of England. He inven ...
es that range from . Pressures range from , therefore lubrication is required, which can be oil or graphite for lower temperature extrusions, or glass powder for higher temperature extrusions. The biggest disadvantage of this process is its cost for machinery and its upkeep.[
The extrusion process is generally economical when producing between several kilograms (pounds) and many tons, depending on the material being extruded. There is a crossover point where ]roll forming
Roll forming, also spelled roll-forming or rollforming, is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into a desired cross-section. The strip passes through sets of rolls mounted o ...
becomes more economical. For instance, some steels become more economical to roll if producing more than 20,000 kg (50,000 lb).[
Image:Aluminium extrusion die front.png, Front side of a four family die. For reference, the die is in diameter.
Image:Aluminium extrusion die closeup.png, Close up of the shape cut into the die. Notice that the walls are drafted and that the back wall thickness varies.
Image:Aluminium extrusion die back.png, Back side of die. The wall thickness of the extrusion is .
]
Cold extrusion
Cold extrusion is done at room temperature or near room temperature. The advantages of this over hot extrusion are the lack of oxidation, higher strength due to cold working
In metallurgy, cold forming or cold working is any metalworking process in which metal is shaped below its recrystallization temperature, usually at the ambient temperature. Such processes are contrasted with hot working techniques like hot roll ...
, closer tolerances, better surface finish, and fast extrusion speeds if the material is subject to hot shortness.[
Materials that are commonly cold extruded include: ]lead
Lead is a chemical element with the symbol Pb (from the Latin ) and atomic number 82. It is a heavy metal that is denser than most common materials. Lead is soft and malleable, and also has a relatively low melting point. When freshly cu ...
, tin
Tin is a chemical element with the symbol Sn (from la, stannum) and atomic number 50. Tin is a silvery-coloured metal.
Tin is soft enough to be cut with little force and a bar of tin can be bent by hand with little effort. When bent, t ...
, aluminum
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It has ...
, copper
Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
, zirconium
Zirconium is a chemical element with the symbol Zr and atomic number 40. The name ''zirconium'' is taken from the name of the mineral zircon, the most important source of zirconium. The word is related to Persian '' zargun'' (zircon; ''zar-gun'', ...
, titanium
Titanium is a chemical element with the symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resistant to corrosion in ...
, molybdenum
Molybdenum is a chemical element with the symbol Mo and atomic number 42 which is located in period 5 and group 6. The name is from Neo-Latin ''molybdaenum'', which is based on Ancient Greek ', meaning lead, since its ores were confused with lea ...
, beryllium
Beryllium is a chemical element with the symbol Be and atomic number 4. It is a steel-gray, strong, lightweight and brittle alkaline earth metal. It is a divalent element that occurs naturally only in combination with other elements to form mi ...
, vanadium
Vanadium is a chemical element with the symbol V and atomic number 23. It is a hard, silvery-grey, malleable transition metal. The elemental metal is rarely found in nature, but once isolated artificially, the formation of an oxide layer ( pas ...
, niobium
Niobium is a chemical element with chemical symbol Nb (formerly columbium, Cb) and atomic number 41. It is a light grey, crystalline, and ductile transition metal. Pure niobium has a Mohs hardness rating similar to pure titanium, and it has sim ...
, and steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
.
Examples of products produced by this process are: collapsible tubes, fire extinguisher
A fire extinguisher is a handheld active fire protection device usually filled with a dry or wet chemical used to extinguish or control small fires, often in emergencies. It is not intended for use on an out-of-control fire, such as one which ha ...
cases, shock absorber
A shock absorber or damper is a mechanical or hydraulic device designed to absorb and damp shock impulses. It does this by converting the kinetic energy of the shock into another form of energy (typically heat) which is then dissipated. Most sh ...
cylinders and gear
A gear is a rotating circular machine part having cut teeth or, in the case of a cogwheel or gearwheel, inserted teeth (called ''cogs''), which mesh with another (compatible) toothed part to transmit (convert) torque and speed. The basic pr ...
blanks.
Warm extrusion
In March 1956, a US Patent was filed for "process for warm extrusion of metal". Patent US3156043 A outlines that a number of important advantages can be achieved with warm extrusion of both ferrous and non-ferrous metals and alloys if a billet to be extruded is changed in its physical properties in response to physical forces by being heated to a temperature below the critical melting point. Warm extrusion is done above room temperature, but below the recrystallization temperature of the material the temperatures ranges from 800 to 1800 °F (424 to 975 °C). It is usually used to achieve the proper balance of required forces, ductility and final extrusion properties.[
]
Friction extrusion
Friction extrusion was invented at The Welding Institute in the UK and patented in 1991. It was originally intended primarily as a method for production of homogeneous microstructures and particle distributions in metal matrix composite materials. Friction extrusion differs from conventional extrusion in that the charge (billet or other precursor) rotates relative to the extrusion die. An extrusion force is applied so as to push the charge against the die. In practice either the die or the charge may rotate or they may be counter-rotating. The relative rotary motion between the charge and the die has several significant effects on the process. First, the relative motion in the plane of rotation leads to large shear stresses, hence, plastic deformation in the layer of charge in contact with and near the die. This plastic deformation is dissipated by recovery and recrystallization processes leading to substantial heating of the deforming charge. Because of the deformation heating, friction extrusion does not generally require preheating of the charge by auxiliary means potentially resulting in a more energy efficient process. Second, the substantial level of plastic deformation in the region of relative rotary motion can promote solid state welding of powders or other finely divided precursors, such as flakes and chips, effectively consolidating the charge (friction consolidation) prior to extrusion.
Micro-extrusion
Microextrusion is a microforming extrusion process performed at the submillimeter range. Like extrusion, metal is pushed through a die orifice, but the resulting product's cross section can fit through a 1mm square. Several microextrusion processes have been developed since microforming was envisioned in 1990. Forward (ram and billet
A billet is a living-quarters to which a soldier is assigned to sleep. Historically, a billet was a private dwelling that was required to accept the soldier.
Soldiers are generally billeted in barracks or garrisons when not on combat duty, alth ...
move in the same direction) and backward (ram and billet move in the opposite direction) microextrusion were first introduced, with forward rod-backward cup and double cup extrusion methods developing later. Regardless of method, one of the greatest challenges of creating a successful microextrusion machine is the manufacture of the die and ram. "The small size of the die and ram, along with the stringent accuracy requirement, needs suitable manufacturing processes." Additionally, as Fu and Chan pointed out in a 2013 state-of-the-art technology review, several issues must still be resolved before microextrusion and other microforming technologies can be implemented more widely, including deformation load and defects, forming system stability, mechanical properties, and other size-related effects on the crystallite
A crystallite is a small or even microscopic crystal which forms, for example, during the cooling of many materials. Crystallites are also referred to as grains.
Bacillite is a type of crystallite. It is rodlike with parallel longulites.
Stru ...
(grain) structure and boundaries.
Equipment
A horizontal hydraulic press for hot aluminum extrusion (loose dies and scrap visible in foreground)
There are many different variations of extrusion equipment. They vary by four major characteristics:[
# Movement of the extrusion with relation to the ram. If the die is held stationary and the ram moves towards it then it is called "direct extrusion". If the ram is held stationary and the die moves towards the ram it is called "indirect extrusion".
# The position of the press, either vertical or horizontal.
# The type of drive, either hydraulic or mechanical.
# The type of load applied, either conventional (variable) or ]hydrostatic
Fluid statics or hydrostatics is the branch of fluid mechanics that studies the condition of the equilibrium of a floating body and submerged body "fluids at hydrostatic equilibrium and the pressure in a fluid, or exerted by a fluid, on an imme ...
.
A single or twin screw auger, powered by an electric motor, or a ram, driven by hydraulic pressure (often used for steel and titanium alloys), oil pressure (for aluminium), or in other specialized processes such as rollers inside a perforated drum for the production of many simultaneous streams of material.
Typical extrusion presses cost more than $100,000, whereas dies can cost up to $2000.
Forming internal cavities
There are several methods for forming internal cavities in extrusions. One way is to use a hollow billet and then use a fixed or floating mandrel
A mandrel, mandril, or arbor is a gently tapered cylinder against which material can be forged or shaped (e.g., a ring mandrel - also called a triblet - used by jewelers to increase the diameter of a wedding ring), or a flanged or tapered or ...
. A fixed mandrel, also known as a German type, means it is integrated into the dummy block and stem. A floating mandrel, also known as a French type, floats in slots in the dummy block and aligns itself in the die when extruding. If a solid billet is used as the feed material then it must first be pierced by the mandrel before extruding through the die. A special press is used in order to control the mandrel independently from the ram.[ The solid billet could also be used with a spider die, porthole die or bridge die. All of these types of dies incorporate the mandrel in the die and have "legs" that hold the mandrel in place. During extrusion the metal divides, flows around the legs, then merges, leaving weld lines in the final product.
]
Direct extrusion
Direct extrusion, also known as forward extrusion, is the most common extrusion process. It works by placing the billet in a heavy walled container. The billet is pushed through the die by a ram or screw. There is a reusable dummy block between the ram and the billet to keep them separated. The major disadvantage of this process is that the force required to extrude the billet is greater than that needed in the indirect extrusion process because of the friction
Friction is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. There are several types of friction:
*Dry friction is a force that opposes the relative lateral motion of t ...
al forces introduced by the need for the billet to travel the entire length of the container. Because of this the greatest force required is at the beginning of process and slowly decreases as the billet is used up. At the end of the billet the force greatly increases because the billet is thin and the material must flow radially to exit the die. The end of the billet (called the butt end) is not used for this reason.
Indirect extrusion
In indirect extrusion, also known as backwards extrusion, the billet and container move together while the die is stationary. The die is held in place by a "stem" which has to be longer than the container length. The maximum length of the extrusion is ultimately dictated by the column
A column or pillar in architecture and structural engineering is a structural element that transmits, through compression, the weight of the structure above to other structural elements below. In other words, a column is a compression member. ...
strength of the stem. Because the billet moves with the container the frictional forces are eliminated. This leads to the following advantages:
*A 25 to 30% reduction of friction, which allows for extruding larger billets, increasing speed, and an increased ability to extrude smaller cross-sections
*There is less of a tendency for extrusions to crack because there is no heat formed from friction
*The container liner will last longer due to less wear
*The billet is used more uniformly so extrusion defects and coarse grained peripherals zones are less likely.
The disadvantages are:[
*Impurities and defects on the surface of the billet affect the surface of the extrusion. These defects ruin the piece if it needs to be ]anodize
Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts.
The process is called ''anodizing'' because the part to be treated forms the anode electrode of an elect ...
d or the aesthetics are important. In order to get around this the billets may be wire brushed, machined or chemically cleaned before being used.
*This process isn't as versatile as direct extrusions because the cross-sectional area is limited by the maximum size of the stem.
Hydrostatic extrusion
In the hydrostatic extrusion process the billet is completely surrounded by a pressurized liquid, except where the billet contacts the die. This process can be done hot, warm, or cold, however the temperature is limited by the stability of the fluid used. The process must be carried out in a sealed cylinder to contain the hydrostatic medium. The fluid can be pressurized two ways:[
#''Constant-rate extrusion'': A ram or plunger is used to pressurize the fluid inside the container.
#''Constant-pressure extrusion'': A pump is used, possibly with a pressure intensifier, to pressurize the fluid, which is then pumped to the container.
The advantages of this process include:][
*No friction between the container and the billet reduces force requirements. This ultimately allows for faster speeds, higher reduction ratios, and lower billet temperatures.
*Usually the ductility of the material increases when high pressures are applied.
*An even flow of material.
*Large billets and large cross-sections can be extruded.
*No billet residue is left on the container walls.
The disadvantages are:][
*The billets must be prepared by tapering one end to match the die entry angle. This is needed to form a seal at the beginning of the cycle. Usually the entire billet needs to be machined to remove any surface defects.
*Containing the fluid under high pressures can be difficult.
*A billet remnant or a plug of a tougher material must be left at the end of the extrusion to prevent a sudden release of the extrusion fluid.
]
Drives
Most modern direct or indirect extrusion presses are hydraulically driven, but there are some small mechanical presses still used. Of the hydraulic presses there are two types: direct-drive oil presses and accumulator water drives.
Direct-drive oil presses are the most common because they are reliable and robust. They can deliver over 35 MPa (5000 psi). They supply a constant pressure throughout the whole billet. The disadvantage is that they are slow, between 50 and 200 mm/s (2–8 ips).
Accumulator water drives are more expensive and larger than direct-drive oil presses, and they lose about 10% of their pressure over the stroke, but they are much faster, up to 380 mm/s (15 ips). Because of this they are used when extruding steel. They are also used on materials that must be heated to very hot temperatures for safety reasons.[
Hydrostatic extrusion presses usually use ]castor oil
Castor oil is a vegetable oil pressed from castor beans.
It is a colourless or pale yellow liquid with a distinct taste and odor. Its boiling point is and its density is 0.961 g/cm3. It includes a mixture of triglycerides in which about ...
at pressure up to 1400 MPa (200 ksi). Castor oil is used because it has good lubricity and high pressure properties.
Die design
The design of an extrusion profile has a large impact on how readily it can be extruded. The maximum size for an extrusion is determined by finding the smallest circle that will fit around the cross-section, this is called the ''circumscribing circle''. This diameter, in turn, controls the size of the die required, which ultimately determines if the part will fit in a given press. For example, a larger press can handle diameter circumscribing circles for aluminium and 55 cm (22 in) diameter circles for steel and titanium.[
The complexity of an extruded profile can be roughly quantified by calculating the ''shape factor'', which is the amount of surface area generated per unit mass of extrusion. This affects the cost of tooling as well as the rate of production.
Thicker sections generally need an increased section size. In order for the material to flow properly legs should not be more than ten times longer than their thickness. If the cross-section is asymmetrical, adjacent sections should be as close to the same size as possible. Sharp corners should be avoided; for aluminium and magnesium the minimum radius should be 0.4 mm (1/64 in) and for steel corners should be and ]fillet
Fillet may refer to:
*Annulet (architecture), part of a column capital, also called a fillet
*Fillet (aircraft), a fairing smoothing the airflow at a joint between two components
*Fillet (clothing), a headband
*Fillet (cut), a piece of meat
*Fille ...
s should be . The following table lists the minimum cross-section and thickness for various materials.[
]
Materials
Metal
Metals that are commonly extruded include:
* Aluminium
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. I ...
is the most commonly extruded material. Aluminium can be hot or cold extruded. If it is hot extruded it is heated to 575 to 1100 °F (300 to 600 °C). Examples of products include profile
Profile or profiles may refer to:
Art, entertainment and media Music
* ''Profile'' (Jan Akkerman album), 1973
* ''Profile'' (Githead album), 2005
* ''Profile'' (Pat Donohue album), 2005
* ''Profile'' (Duke Pearson album), 1959
* '' ''Profi ...
s for tracks, frames, rails, mullions
A mullion is a vertical element that forms a division between units of a window or screen, or is used decoratively. It is also often used as a division between double doors. When dividing adjacent window units its primary purpose is a rigid supp ...
, and heat sink
A heat sink (also commonly spelled heatsink) is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant, where it is dissipated away from the device, th ...
s.
* Brass
Brass is an alloy of copper (Cu) and zinc (Zn), in proportions which can be varied to achieve different mechanical, electrical, and chemical properties. It is a substitutional alloy: atoms of the two constituents may replace each other with ...
is used to extrude corrosion free rods, automobile parts, pipe fittings, engineering parts.
* Copper
Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
(1100 to 1825 °F (600 to 1000 °C)) pipe, wire, rods, bars, tubes, and welding electrodes. Often more than 100 ksi (690 MPa) is required to extrude copper.
* Lead
Lead is a chemical element with the symbol Pb (from the Latin ) and atomic number 82. It is a heavy metal that is denser than most common materials. Lead is soft and malleable, and also has a relatively low melting point. When freshly cu ...
and tin
Tin is a chemical element with the symbol Sn (from la, stannum) and atomic number 50. Tin is a silvery-coloured metal.
Tin is soft enough to be cut with little force and a bar of tin can be bent by hand with little effort. When bent, t ...
(maximum 575 °F (300 °C)) pipes, wire, tubes, and cable sheathing. Molten lead may also be used in place of billets on vertical extrusion presses.
* Magnesium
Magnesium is a chemical element with the symbol Mg and atomic number 12. It is a shiny gray metal having a low density, low melting point and high chemical reactivity. Like the other alkaline earth metals (group 2 of the periodic ta ...
(575 to 1100 °F (300 to 600 °C)) aircraft parts and nuclear industry parts. Magnesium is about as extrudable as aluminum.
* Zinc
Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi ...
(400 to 650 °F (200 to 350 °C)) rods, bar, tubes, hardware components, fitting, and handrails.
* Steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
(1825 to 2375 °F (1000 to 1300 °C)) rods and tracks. Usually plain carbon steel
Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states:
* no minimum content is specified or required for chromium, cobalt ...
is extruded, but alloy steel and stainless steel
Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
can also be extruded.
* Titanium
Titanium is a chemical element with the symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resistant to corrosion in ...
(1100 to 1825 °F (600 to 1000 °C)) aircraft components including seat tracks, engine rings, and other structural parts.
Magnesium and aluminium alloys usually have a RMS or better surface finish. Titanium and steel can achieve a RMS.[
In 1950, Ugine Séjournet, of ]France
France (), officially the French Republic ( ), is a country primarily located in Western Europe. It also comprises of Overseas France, overseas regions and territories in the Americas and the Atlantic Ocean, Atlantic, Pacific Ocean, Pac ...
, invented a process which uses glass as a lubricant for extruding steel. The Ugine-Sejournet, or Sejournet, process is now used for other materials that have melting temperatures higher than steel or that require a narrow range of temperatures to extrude, such as the platinum-iridium alloy used to make kilogram
The kilogram (also kilogramme) is the unit of mass in the International System of Units (SI), having the unit symbol kg. It is a widely used measure in science, engineering and commerce worldwide, and is often simply called a kilo colloquially ...
mass standards. The process starts by heating the materials to the extruding temperature and then rolling it in glass powder. The glass melts and forms a thin film, 20 to 30 mils (0.5 to 0.75 mm), in order to separate it from chamber walls and allow it to act as a lubricant. A thick solid glass ring that is 0.25 to 0.75 in (6 to 18 mm) thick is placed in the chamber on the die to lubricate the extrusion as it is forced through the die. A second advantage of this glass ring is its ability to insulate the heat of the billet from the die. The extrusion will have a 1 mil thick layer of glass, which can be easily removed once it cools.
Another breakthrough in lubrication is the use of phosphate coatings. With this process, in conjunction with glass lubrication, steel can be cold extruded. The phosphate coat absorbs the liquid glass to offer even better lubricating properties.[
]
Plastic
Plastics extrusion
Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic film ...
commonly uses plastic chips or pellets, which are usually dried, to drive out moisture, in a hopper before going to the feed screw. The polymer resin is heated to molten state by a combination of heating elements and shear heating from the extrusion screw. The screw, or screws as the case with twin screw extrusion, forces the resin through a die, forming the resin into the desired shape. The extrudate is cooled and solidified as it is pulled through the die or water tank. A "caterpillar haul-off" (called a "puller" in the US) is used to provide tension on the extrusion line which is essential for overall quality of the extrudate. Pelletizers can also create this tension while pulling extruded strands in to be cut. The caterpillar haul-off must provide a consistent pull; otherwise, variation in cut lengths or distorted product will result. In some cases (such as fibre-reinforced tubes) the extrudate is pulled through a very long die, in a process called "pultrusion". The configuration of the interior screws are a driving force dependent on the application. Mixing elements or convey elements are used in various formations. Extrusion is common in the application of adding colorant to molten plastic thus creating specific custom color.
A multitude of polymers are used in the production of plastic tubing, pipes, rods, rails, seals, and sheets or films.
Ceramic
Ceramic can also be formed into shapes via extrusion. Terracotta
Terracotta, terra cotta, or terra-cotta (; ; ), in its material sense as an earthenware substrate, is a clay-based ceramic glaze, unglazed or glazed ceramic where the pottery firing, fired body is porous.
In applied art, craft, construction, a ...
extrusion is used to produce pipes. Many modern bricks are also manufactured using a brick extrusion process.
Applications
Food
With the advent of industrial manufacturing, extrusion found application in food processing
Food processing is the transformation of agricultural products into food, or of one form of food into other forms. Food processing includes many forms of processing foods, from grinding grain to make raw flour to home cooking to complex industr ...
of instant foods and snacks, along with its already known uses in plastics and metal fabrication. The main role of extrusion was originally developed for conveying and shaping fluid forms of processed raw materials. Present day, extrusion cooking technologies and capabilities have developed into sophisticated processing functions including: mixing, conveying, shearing, separation, heating, cooling, shaping, co-extrusion, venting volatiles and moisture, encapsulation, flavor generation and sterilization. Products such as certain pasta
Pasta (, ; ) is a type of food typically made from an unleavened dough of wheat flour mixed with water or eggs, and formed into sheets or other shapes, then cooked by boiling or baking. Rice flour, or legumes such as beans or lentils, are som ...
s, many breakfast cereal
Cereal, formally termed breakfast cereal (and further categorized as cold cereal or warm cereal), is a traditional breakfast food made from processed cereal grains. It is traditionally eaten as part of breakfast, or a snack food, primarily in ...
s, premade cookie dough
Cookie dough is an un-cooked blend of cookie ingredients. Cookie dough is normally intended to be baked into individual cookies before eating, however edible cookie dough is made to be eaten as is, and usually is made without eggs to make it safer ...
, some french fries
French fries (North American English), chips (British English), finger chips ( Indian English), french-fried potatoes, or simply fries, are '' batonnet'' or ''allumette''-cut deep-fried potatoes of disputed origin from Belgium and France. Th ...
, certain baby food
Baby food is any soft easily consumed food other than breastmilk or infant formula that is made specifically for human babies between four and six months and two years old. The food comes in many varieties and flavors that are purchased ready-mad ...
s, dry or semi-moist pet food
Pet food is animal feed intended for consumption by pets. Typically sold in pet stores and supermarkets, it is usually specific to the type of animal, such as dog food or cat food. Most meat used for animals is a byproduct of the human food indu ...
and ready-to-eat snacks are mostly manufactured by extrusion. It is also used to produce modified starch
Modified starch, also called starch derivatives, are prepared by physically, enzymatically, or chemically treating native starch to change its properties. Modified starches are used in practically all starch applications, such as in food produ ...
, and to pelletize animal feed
Animal feed is food given to domestic animals, especially livestock, in the course of animal husbandry. There are two basic types: fodder and forage. Used alone, the word ''feed'' more often refers to fodder. Animal feed is an important input to ...
.
Generally, high-temperature extrusion is used for the manufacture of ready-to-eat snacks, while cold extrusion is used for the manufacture of pasta and related products intended for later cooking and consumption. The processed products have low moisture and hence considerably higher shelf life, and provide variety and convenience to consumers.
In the extrusion process, raw materials are first ground to the correct particle size. The dry mix is passed through a pre-conditioner, in which other ingredients may be added, and steam
Steam is a substance containing water in the gas phase, and sometimes also an aerosol of liquid water droplets, or air. This may occur due to evaporation or due to boiling, where heat is applied until water reaches the enthalpy of vaporization ...
is injected to start the cooking process. The preconditioned mix is then passed through an extruder, where it is forced through a die and cut to the desired length. The cooking process takes place within the extruder where the product produces its own friction and heat due to the pressure generated (10–20 bar). The main independent parameters during extrusion cooking are feed rate, particle size of the raw material, barrel temperature, screw speed and moisture content. The extruding process can induce both protein denaturation
In biochemistry, denaturation is a process in which proteins or nucleic acids lose the quaternary structure, tertiary structure, and secondary structure which is present in their native state, by application of some external stress or compound ...
and starch gelatinization
Starch gelatinization is a process of breaking down the intermolecular bonds of starch molecules in the presence of water and heat, allowing the hydrogen bonding sites (the hydroxyl hydrogen and oxygen) to engage more water. This irreversibly d ...
, depending on inputs and parameters. Sometimes, a catalyst is used, for example, when producing texturised vegetable proteins (TVP).
Drug carriers
For use in pharmaceutical products, extrusion through nano-porous, polymeric filters is being used to produce suspensions of lipid vesicles liposome
A liposome is a small artificial vesicle, spherical in shape, having at least one lipid bilayer. Due to their hydrophobicity and/or hydrophilicity, biocompatibility, particle size and many other properties, liposomes can be used as drug deliver ...
s or transfersome Transfersome is a proprietary drug delivery technology, an artificial vesicle
Vesicle may refer to:
; In cellular biology or chemistry
* Vesicle (biology and chemistry), a supramolecular assembly of lipid molecules, like a cell membrane
* Synapti ...
s with a particular size of a narrow size distribution. The anti-cancer drug Doxorubicin
Doxorubicin, sold under the brand name Adriamycin among others, is a chemotherapy medication used to treat cancer. This includes breast cancer, bladder cancer, Kaposi's sarcoma, lymphoma, and acute lymphocytic leukemia. It is often used togeth ...
in liposome delivery system is formulated by extrusion, for example. Hot melt extrusion is also utilized in pharmaceutical solid oral dose processing to enable delivery of drugs with poor solubility and bioavailability. Hot melt extrusion has been shown to molecularly disperse poorly soluble drugs in a polymer carrier increasing dissolution rates and bioavailability. The process involves the application of heat, pressure and agitation to mix materials together and ‘extrude’ them through a die. Twin-screw high shear extruders blend materials and simultaneously break up particles. The resulting particle can be blended with compression aids and compressed into tablets or filled into unit dose capsules.
Biomass briquettes
The extrusion production technology of fuel briquettes is the process of extrusion screw wastes (straw, sunflower husks, buckwheat, etc.) or finely shredded wood waste (sawdust) under high pressure when heated from 160 to 350 °C. The resulting fuel briquette
A briquette (; also spelled briquet) is a compressed block of coal dust or other combustible biomass material (e.g. charcoal, sawdust, wood chips, peat, or paper) used for fuel and kindling to start a fire. The term derives from the French word '' ...
s do not include any of the binders, but one natural – the lignin contained in the cells of plant wastes. The temperature during compression causes melting of the surface of bricks, making it more solid, which is important for the transportation of briquettes.
Textiles
The majority of synthetic materials Synthetic things are composed of multiple parts, often with the implication that they are artificial. In particular, 'synthetic' may refer to:
Science
* Synthetic chemical or compound, produced by the process of chemical synthesis
* Synthetic o ...
in textile
Textile is an umbrella term that includes various fiber-based materials, including fibers, yarns, filaments, threads, different fabric types, etc. At first, the word "textiles" only referred to woven fabrics. However, weaving is not the ...
s are manufactured with extrusion only. Fiber
Fiber or fibre (from la, fibra, links=no) is a natural or artificial substance that is significantly longer than it is wide. Fibers are often used in the manufacture of other materials. The strongest engineering materials often incorporate ...
forming substances are used in extrusion to form various synthetic filaments. The molten materials are passed through a spinneret that helps in forming fibers.
See also
*Equal channel angular extrusion
Equal channel angular extrusion (ECAE) called also equal channel angular pressing (ECAP) is one technique from the Severe Plastic Deformation (SPD) group, aimed at producing Ultra Fine Grained (UFG) material. Developed in the Soviet Union in 1973 ...
*Impact extrusion Impact extrusion is a manufacturing process similar to extrusion and drawing by which products are made with a metal slug. The slug is pressed at a high velocity with extreme force into a die or mold by a punch.
Process
The punch is attached to ...
*Extrusion coating
Extrusion coating is the coating of a molten web of synthetic resin onto a substrate material. It is a versatile coating technique used for the economic application of various plastics, notably polyethylene, onto paperboard, corrugated fiberboa ...
*Fused deposition modeling
Fused filament fabrication (FFF), also known as fused deposition modeling (with the trademarked acronym FDM), or called ''filament freeform fabrication'', is a 3D printing process that uses a continuous filament of a thermoplastic material. Filam ...
*HDPE Pipe
HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer and is often used to replace ageing concrete or steel mains pipelines. Made from the thermoplastic HDPE (high-density polyethylene), its high level of impermeability and ...
*Heated hose
Heated hoses are hoses used for transporting liquids or molten materials where integral heat is needed for temperature control. Heated hoses are used in bonding technology, filling and dosing systems, medical technology, chemical, pharmaceutical ...
*3D printer extruder
A 3D printer extruder is a filament feeding mechanism used in many fused filament fabrication (FFF) 3D printers. There are several types of 3D printer extruders. A Bowden extruder is a type of extruder that pushes filament though a long and flex ...
*Curtain coating Curtain coating is a process that creates an uninterrupted curtain of fluid that falls onto a substrate. The substrate is transported on a conveyor belt or calender rolls at a regulated speed through the curtain to ensure an even coat of the die. ...
*Forming (metalworking)
Forming, metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. Forming operates on the mater ...
*Film blowing machine
A film blowing machine involves one process used to make plastic film. Extruded tubular processing is most often used with polyethylene films but can be used with other polymers.
The film may be Laminate, laminating film, shrink film, Agriculture ...
References
Notes
Bibliography
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{{Authority control
Food industry
Metal forming
Unit operations
Forming processes