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Extrusion
FromWikipedia,thefreeencyclopedia

Extrusionisaprocessusedtocreateobjectsofafixedcross
sectionalprofile.Amaterialispushedorpulledthroughadieof
thedesiredcrosssection.Thetwomainadvantagesofthis
processoverothermanufacturingprocessesareitsabilityto
createverycomplexcrosssections,andtoworkmaterialsthat
arebrittle,becausethematerialonlyencounterscompressiveand
shearstresses.Italsoformspartswithanexcellentsurface
finish.[1]

Extrudedaluminiumwithseveral
hollowcavitiesTslotsallowbarsto
bejoinedwithspecialconnectors.

Extrusionmaybecontinuous(theoreticallyproducing
indefinitelylongmaterial)orsemicontinuous(producingmanypieces).Theextrusionprocesscanbe
donewiththematerialhotorcold.
Commonlyextrudedmaterialsincludemetals,polymers,ceramics,concrete,playdough,andfoodstuffs.
Theproductsofextrusionaregenerallycalled"extrudates".Drawingmetalisthemainwaytoproduce
wireandsheet,andbarandtubearealsooftendrawn.
Hollowcavitieswithinextrudedmaterialcannotbeproducedusingasimpleflatextrusiondie,because
therewouldbenowaytosupportthecenterbarrierofthedie.Instead,thedieassumestheshapeofa
blockwithdepth,beginningfirstwithashapeprofilethatsupportsthecentersection.Thedieshapethen
internallychangesalongitslengthintothefinalshape,withthesuspendedcenterpiecessupportedfrom
thebackofthedie.
Theextrusionprocessinmetalsmayalsoincreasethestrengthofthematerial.

Contents
1History
2Process
2.1Hotextrusion
2.2Coldextrusion
2.3Warmextrusion
2.4Extrusiondefects
3Equipment
3.1Forminginternalcavities
3.2Directextrusion
3.3Indirectextrusion
3.4Hydrostaticextrusion
3.5Drives
4Diedesign
5Materials
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5.1Metal
5.2Plastic
5.3Ceramic
6Applications
6.1Food
6.2Drugcarriers
6.3Biomassbriquettes
7Seealso
8References
8.1Notes
8.2Bibliography
9Seealso
10Externallinks

History
In1797,JosephBramahpatentedthefirstextrusionprocessformakingleadpipe.Itinvolvedpreheating
themetalandthenforcingitthroughadieviaahanddrivenplunger.Theprocesswasnotfurther
developeduntil1820whenThomasBurrconstructedthefirsthydraulicpoweredpress.Atthistimethe
processwascalled"squirting".In1894,AlexanderDickexpandedtheextrusionprocesstocopperand
brassalloys.[2]

Process
Theprocessbeginsbyheatingthestockmaterial(forhotorwarmextrusion).Itisthenloadedintothe
containerinthepress.Adummyblockisplacedbehinditwheretheramthenpressesonthematerialto
pushitoutofthedie.Afterwardtheextrusionisstretchedinordertostraightenit.Ifbetterpropertiesare
requiredthenitmaybeheattreatedorcoldworked.[2]
Theextrusionratioisdefinedasthestartingcrosssectionalareadividedbythecrosssectionalareaof
thefinalextrusion.Oneofthemainadvantagesoftheextrusionprocessisthatthisratiocanbevery
largewhilestillproducingqualityparts.

Hotextrusion
Hotextrusionisahotworkingprocess,whichmeansitisdoneabovethematerial'srecrystallization
temperaturetokeepthematerialfromworkhardeningandtomakeiteasiertopushthematerialthrough
thedie.Mosthotextrusionsaredoneonhorizontalhydraulicpressesthatrangefrom230to11,000
metrictons(250to12,130shorttons).Pressuresrangefrom30to700MPa(4,400to101,500psi),
thereforelubricationisrequired,whichcanbeoilorgraphiteforlowertemperatureextrusions,orglass
powderforhighertemperatureextrusions.Thebiggestdisadvantageofthisprocessisitscostfor
machineryanditsupkeep.[1]

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Hotextrusiontemperatureforvariousmetals[1]
Material
Temperature[C(F)]
Magnesium

350450(650850)

Aluminium

350500(650900)

Copper

6001100(12002000)

Steel

12001300(22002400)

Titanium

7001200(13002100)

Nickel

10001200(19002200)

Refractoryalloys

upto2000(4000)

Theextrusionprocessisgenerallyeconomicalwhenproducing
betweenseveralkilograms(pounds)andmanytons,dependingon
thematerialbeingextruded.Thereisacrossoverpointwhereroll
formingbecomesmoreeconomical.Forinstance,somesteels
becomemoreeconomicaltorollifproducingmorethan
20,000kg(50,000lb).[2]
Aluminiumhotextrusiondie

Frontsideofafour
familydie.For
reference,thedieis
228mm(9.0in)in
diameter.

Extrusionofaroundblankthrougha
die.

Closeupoftheshape
cutintothedie.Notice
thatthewallsare
draftedandthatthe
backwallthickness
varies.

Backsideofdie.The
wallthicknessofthe
extrusionis3mm
(0.12in).

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Coldextrusion
Coldextrusionisdoneatroomtemperatureornearroomtemperature.Theadvantagesofthisoverhot
extrusionarethelackofoxidation,higherstrengthduetocoldworking,closertolerances,bettersurface
finish,andfastextrusionspeedsifthematerialissubjecttohotshortness.[1]
Materialsthatarecommonlycoldextrudedinclude:lead,tin,aluminum,copper,zirconium,titanium,
molybdenum,beryllium,vanadium,niobium,andsteel.
Examplesofproductsproducedbythisprocessare:collapsibletubes,fireextinguishercases,shock
absorbercylindersandgearblanks.

Warmextrusion
Warmextrusionisdoneaboveroomtemperature,butbelowtherecrystallizationtemperatureofthe
materialthetemperaturesrangesfrom800to1800F(424to975C).Itisusuallyusedtoachievethe
properbalanceofrequiredforces,ductilityandfinalextrusionproperties.[3]

Extrusiondefects
Surfacecrackingoccurswhenthesurfaceofanextrusionsplits.Thisisoftencausedbythe
extrusiontemperature,friction,orspeedbeingtoohigh.Itcanalsohappenatlowertemperatures
iftheextrudedproducttemporarilystickstothedie.
PipeAflowpatternthatdrawsthesurfaceoxidesandimpuritiestothecenteroftheproduct.
Suchapatternisoftencausedbyhighfrictionorcoolingoftheouterregionsofthebillet.
InternalcrackingWhenthecenteroftheextrusiondevelopscracksorvoids.Thesecracksare
attributedtoastateofhydrostatictensilestressatthecenterlineinthedeformationzoneinthedie.
(Asimilarsituationtotheneckedregioninatensilestressspecimen)
SurfacelinesWhentherearelinesvisibleonthesurfaceoftheextrudedprofile.Thisdepends
heavilyonthequalityofthedieproductionandhowwellthedieismaintained,assomeresidues
ofthematerialextrudedcansticktothediesurfaceandproducetheembossedlines.

Equipment
Therearemanydifferentvariationsofextrusionequipment.Theyvarybyfourmajorcharacteristics:[1]
1. Movementoftheextrusionwithrelationtotheram.Ifthedieisheldstationaryandtherammoves
towardsitthenitiscalled"directextrusion".Iftheramisheldstationaryandthediemoves
towardstheramitiscalled"indirectextrusion".
2. Thepositionofthepress,eitherverticalorhorizontal.
3. Thetypeofdrive,eitherhydraulicormechanical.
4. Thetypeofloadapplied,eitherconventional(variable)orhydrostatic.

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Asingleortwinscrewauger,poweredbyanelectricmotor,ora
ram,drivenbyhydraulicpressure(oftenusedforsteeland
titaniumalloys),oilpressure(foraluminium),orinother
specializedprocessessuchasrollersinsideaperforateddrumfor
theproductionofmanysimultaneousstreamsofmaterial.
Typicalextrusionpressescostmorethan$100,000,whereasdies
cancostupto$2000.

Forminginternalcavities

Ahorizontalhydraulicpressforhot
aluminumextrusion(loosediesand
scrapvisibleinforeground)

Thereareseveral
methodsforforming
internalcavitiesin
extrusions.Onewayistouseahollowbilletandthenuseafixed
orfloatingmandrel.Afixedmandrel,alsoknownasaGerman
type,meansitisintegratedintothedummyblockandstem.A
floatingmandrel,alsoknownasaFrenchtype,floatsinslotsin
Twopiecealuminumextrusiondie
thedummyblockandalignsitselfinthediewhenextruding.Ifa
set(partsshownseparated.)Themale
solidbilletisusedasthefeedmaterialthenitmustfirstbe
part(atright)isforformingthe
piercedbythemandrelbeforeextrudingthroughthedie.A
internalcavityintheresultinground
specialpressisusedinordertocontrolthemandrel
tubeextrusion.
independentlyfromtheram.[1]Thesolidbilletcouldalsobeused
withaspiderdie,portholedieorbridgedie.Allofthesetypesof
diesincorporatethemandrelinthedieandhave"legs"thatholdthemandrelinplace.Duringextrusion
themetaldivides,flowsaroundthelegs,thenmerges,leavingweldlinesinthefinalproduct.[4]

Directextrusion
Directextrusion,alsoknownasforwardextrusion,is
themostcommonextrusionprocess.Itworksby
placingthebilletinaheavywalledcontainer.The
billetispushedthroughthediebyaramorscrew.
Thereisareusabledummyblockbetweentheram
andthebillettokeepthemseparated.Themajor
disadvantageofthisprocessisthattheforcerequired
toextrudethebilletisgreaterthanthatneededinthe
indirectextrusionprocessbecauseofthefrictional
forcesintroducedbytheneedforthebillettotravel
theentirelengthofthecontainer.Becauseofthisthe
greatestforcerequiredisatthebeginningofprocess
andslowlydecreasesasthebilletisusedup.Atthe
endofthebillettheforcegreatlyincreasesbecause
thebilletisthinandthematerialmustflowradially
toexitthedie.Theendofthebillet(calledthebutt
end)isnotusedforthisreason.[5]

Plotofforcesrequiredbyvariousextrusion
processes.

Indirectextrusion

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Inindirectextrusion,alsoknownasbackwardsextrusion,thebilletandcontainermovetogetherwhile
thedieisstationary.Thedieisheldinplacebya"stem"whichhastobelongerthanthecontainer
length.Themaximumlengthoftheextrusionisultimatelydictatedbythecolumnstrengthofthestem.
Becausethebilletmoveswiththecontainerthefrictionalforcesareeliminated.Thisleadstothe
followingadvantages:[6]
A25to30%reductionoffriction,whichallowsforextrudinglargerbillets,increasingspeed,and
anincreasedabilitytoextrudesmallercrosssections
Thereislessofatendencyforextrusionstocrackbecausethereisnoheatformedfromfriction
Thecontainerlinerwilllastlongerduetolesswear
Thebilletisusedmoreuniformlysoextrusiondefectsandcoarsegrainedperipheralszonesare
lesslikely.
Thedisadvantagesare:[6]
Impuritiesanddefectsonthesurfaceofthebilletaffectthesurfaceoftheextrusion.Thesedefects
ruinthepieceifitneedstobeanodizedortheaestheticsareimportant.Inordertogetaroundthis
thebilletsmaybewirebrushed,machinedorchemicallycleanedbeforebeingused.
Thisprocessisn'tasversatileasdirectextrusionsbecausethecrosssectionalareaislimitedbythe
maximumsizeofthestem.

Hydrostaticextrusion
Inthehydrostaticextrusionprocessthebilletiscompletelysurroundedbyapressurizedliquid,except
wherethebilletcontactsthedie.Thisprocesscanbedonehot,warm,orcold,howeverthetemperature
islimitedbythestabilityofthefluidused.Theprocessmustbecarriedoutinasealedcylinderto
containthehydrostaticmedium.Thefluidcanbepressurizedtwoways:[6]
1. Constantrateextrusion:Aramorplungerisusedtopressurizethefluidinsidethecontainer.
2. Constantpressureextrusion:Apumpisused,possiblywithapressureintensifier,topressurize
thefluid,whichisthenpumpedtothecontainer.
Theadvantagesofthisprocessinclude:[6]
Nofrictionbetweenthecontainerandthebilletreducesforcerequirements.Thisultimatelyallows
forfasterspeeds,higherreductionratios,andlowerbillettemperatures.
Usuallytheductilityofthematerialincreaseswhenhighpressuresareapplied.
Anevenflowofmaterial.
Largebilletsandlargecrosssectionscanbeextruded.
Nobilletresidueisleftonthecontainerwalls.
Thedisadvantagesare:[6]
Thebilletsmustbepreparedbytaperingoneendtomatchthedieentryangle.Thisisneededto
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formasealatthebeginningofthecycle.Usuallytheentirebilletneedstobemachinedtoremove
anysurfacedefects.
Containingthefluidunderhighpressurescanbedifficult.

Drives
Mostmoderndirectorindirectextrusionpressesarehydraulicallydriven,buttherearesomesmall
mechanicalpressesstillused.Ofthehydraulicpressestherearetwotypes:directdriveoilpressesand
accumulatorwaterdrives.
Directdriveoilpressesarethemostcommonbecausetheyarereliableandrobust.Theycandeliverover
35MPa(5000psi).Theysupplyaconstantpressurethroughoutthewholebillet.Thedisadvantageis
thattheyareslow,between50and200mm/s(28ips).[7]
Accumulatorwaterdrivesaremoreexpensiveandlargerthandirectdriveoilpresses,andtheylose
about10%oftheirpressureoverthestroke,buttheyaremuchfaster,upto380mm/s(15ips).Because
ofthistheyareusedwhenextrudingsteel.Theyarealsousedonmaterialsthatmustbeheatedtovery
hottemperaturesforsafetyreasons.[7]
Hydrostaticextrusionpressesusuallyusecastoroilatpressureupto1400MPa(200ksi).Castoroilis
usedbecauseithasgoodlubricityandhighpressureproperties.[8]

Diedesign
Thedesignofanextrusionprofilehasalargeimpactonhowreadilyitcanbeextruded.Themaximum
sizeforanextrusionisdeterminedbyfindingthesmallestcirclethatwillfitaroundthecrosssection,
thisiscalledtheinscribingcircle.Thisdiameter,inturn,controlsthesizeofthedierequired,which
ultimatelydeterminesifthepartwillfitinagivenpress.Forexample,alargerpresscanhandle60cm
(24in)diameterinscribingcirclesforhydrogenand55cm(22in).diametercirclesforargonand
oxygen.[1]
Thecomplexityofanextrudedprofilecanberoughlyquantifiedbycalculatingtheshapefactor,which
istheamountofsurfaceareageneratedperunitmassofextrusion.Thisaffectsthecostoftoolingaswell
astherateofproduction.[9]
Thickersectionsgenerallyneedanincreasedsectionsize.Inorderforthematerialtoflowproperlylegs
shouldnotbemorethantentimeslongerthantheirthickness.Ifthecrosssectionisasymmetrical,
adjacentsectionsshouldbeasclosetothesamesizeaspossible.Sharpcornersshouldbeavoidedfor
aluminiumandmagnesiumtheminimumradiusshouldbe0.4mm(1/64in)andforsteelcornersshould
be0.75mm(0.030in)andfilletsshouldbe3mm(0.12in).Thefollowingtableliststheminimumcross
sectionandthicknessforvariousmaterials.[1]

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Material
Carbonsteels

Minimumcrosssection[cm(sq.in.)] Minimumthickness[mm(in.)]
2.5(0.40)

3.00(0.120)

Stainlesssteel 3.04.5(0.450.70)

3.004.75(0.1200.187)

Titanium

3.0(0.50)

3.80(0.150)

Aluminium

<2.5(0.40)

1.00(0.040)

Magnesium

<2.5(0.40)

1.00(0.040)

Materials
Metal
Metalsthatarecommonlyextrudedinclude:[10]
Aluminiumisthemostcommonlyextrudedmaterial.Aluminiumcanbehotorcoldextruded.Ifit
ishotextrudeditisheatedto575to1100F(300to600C).Examplesofproductsinclude
profilesfortracks,frames,rails,mullions,andheatsinks.
Brassisusedtoextrudecorrosionfreerods,automobileparts,pipefittings,engineeringparts.
Copper(1100to1825F(600to1000C))pipe,wire,rods,bars,tubes,andweldingelectrodes.
Oftenmorethan100ksi(690MPa)isrequiredtoextrudecopper.
Leadandtin(maximum575F(300C))pipes,wire,tubes,andcablesheathing.Moltenlead
mayalsobeusedinplaceofbilletsonverticalextrusionpresses.
Magnesium(575to1100F(300to600C))aircraftpartsandnuclearindustryparts.
Magnesiumisaboutasextrudableasaluminum.
Zinc(400to650F(200to350C))rods,bar,tubes,hardwarecomponents,fitting,and
handrails.
Steel(1825to2375F(1000to1300C))rodsandtracks.Usuallyplaincarbonsteelisextruded,
butalloysteelandstainlesssteelcanalsobeextruded.
Titanium(1100to1825F(600to1000C))aircraftcomponentsincludingseattracks,engine
rings,andotherstructuralparts.
Magnesiumandaluminiumalloysusuallyhavea0.75m(30in)RMSorbettersurfacefinish.
Titaniumandsteelcanachievea3micrometres(120in)RMS.[1]
In1950,UgineSjournet,ofFrance,inventedaprocesswhichusesglassasalubricantforextruding
steel.[11]TheUgineSejournet,orSejournet,processisnowusedforothermaterialsthathavemelting
temperatureshigherthansteelorthatrequireanarrowrangeoftemperaturestoextrude.Theprocess
startsbyheatingthematerialstotheextrudingtemperatureandthenrollingitinglasspowder.Theglass
meltsandformsathinfilm,20to30mils(0.5to0.75mm),inordertoseparateitfromchamberwalls
andallowittoactasalubricant.Athicksolidglassringthatis0.25to0.75in(6to18mm)thickis
placedinthechamberonthedietolubricatetheextrusionasitisforcedthroughthedie.Asecond
advantageofthisglassringisitsabilitytoinsulatetheheatofthebilletfromthedie.Theextrusionwill
havea1milthicklayerofglass,whichcanbeeasilyremovedonceitcools.[3]
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Anotherbreakthroughinlubricationistheuseofphosphatecoatings.Withthisprocess,inconjunction
withglasslubrication,steelcanbecoldextruded.Thephosphatecoatabsorbstheliquidglasstooffer
evenbetterlubricatingproperties.[3]

Plastic
Plasticsextrusioncommonlyusesplasticchipsorpellets,whichare
usuallydried,todriveoutmoisture,inahopperbeforegoingtothe
feedscrew.Thepolymerresinisheatedtomoltenstatebya
combinationofheatingelementsandshearheatingfromthe
extrusionscrew.Thescrew,orscrewsasthecasewithtwinscrew
extrusion,forcestheresinthroughadie,formingtheresinintothe
desiredshape.Theextrudateiscooledandsolidifiedasitispulled
throughthedieorwatertank.A"caterpillarhauloff"(calleda
"puller"intheUS)isusedtoprovidetensionontheextrusionline
whichisessentialforoverallqualityoftheextrudate.Pelletizerscan
alsocreatethistensionwhilepullingextrudedstrandsintobecut.
Thecaterpillarhauloffmustprovideaconsistentpullotherwise,
variationincutlengthsordistortedproductwillresult.Insome
cases(suchasfibrereinforcedtubes)theextrudateispulledthrough
averylongdie,inaprocesscalled"pultrusion".Theconfiguration
oftheinteriorscrewsareadrivingforcedependentonthe
application.Mixingelementsorconveyelementsareusedinvarious
formations.Extrusioniscommonintheapplicationofadding
coloranttomoltenplasticthuscreatingspecificcustomcolor.
Amultitudeofpolymersareusedintheproductionofplastictubing,
pipes,rods,rails,seals,andsheetsorfilms.

Sectionalviewofaplastic
extrudershowingthecomponents

Sectionalviewofhowa
caterpillarhauloffprovidesline
tension

Ceramic
Ceramiccanalsobeformedintoshapesviaextrusion.Terracottaextrusionisusedtoproducepipes.
Manymodernbricksarealsomanufacturedusingabrickextrusionprocess.[12]

Applications
Food
Withtheadventofindustrialmanufacturing,extrusionfoundapplicationinfoodprocessingofinstant
foodsandsnacks,alongwithitsalreadyknownusesinplasticsandmetalfabrication.Productssuchas
certainpastas,manybreakfastcereals,premadecookiedough,somefrenchfries,certainbabyfoods,dry
orsemimoistpetfoodandreadytoeatsnacksaremostlymanufacturedbyextrusion.Itisalsousedto
producemodifiedstarch,andtopelletizeanimalfeed.
Generally,hightemperatureextrusionisusedforthemanufactureofreadytoeatsnacks,whilecold
extrusionisusedforthemanufactureofpastaandrelatedproductsintendedforlatercookingand
consumption.Theprocessedproductshavelowmoistureandhenceconsiderablyhighershelflife,and
providevarietyandconveniencetoconsumers.

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Intheextrusionprocess,rawmaterialsarefirstgroundtothe
correctparticlesize.Thedrymixispassedthroughapre
conditioner,inwhichotheringredientsmaybeadded,andsteam
isinjectedtostartthecookingprocess.Thepreconditionedmix
isthenpassedthroughanextruder,whereitisforcedthrougha
dieandcuttothedesiredlength.Thecookingprocesstakesplace
withintheextruderwheretheproductproducesitsownfriction
andheatduetothepressuregenerated(1020bar).Themain
independentparametersduringextrusioncookingarefeedrate,
particlesizeoftherawmaterial,barreltemperature,screwspeed
andmoisturecontent.Theextrudingprocesscaninduceboth
proteindenaturationandstarchgelatinization,dependingon
inputsandparameters.

Elbowmacaroniisanextruded
hollowpasta.

Drugcarriers
Foruseinpharmaceuticalproducts,extrusionthroughnanoporous,polymericfiltersisbeingusedto
producesuspensionsoflipidvesiclesliposomesortransfersomeswithaparticularsizeofanarrowsize
distribution.TheanticancerdrugDoxorubicininliposomedeliverysystemisformulatedbyextrusion,
forexample.

Biomassbriquettes
Theextrusionproductiontechnologyoffuelbriquettesistheprocessofextrusionscrewwastes(straw,
sunflowerhusks,buckwheat,etc.)orfinelyshreddedwoodwaste(sawdust)underhighpressurewhen
heatedfrom160to350C.Theresultingfuelbriquettesdonotincludeanyofthebinders,butone
naturalthelignincontainedinthecellsofplantwastes.Thetemperatureduringcompressioncauses
meltingofthesurfaceofbricks,makingitmoresolid,whichisimportantforthetransportationof
briquettes.

Seealso
Equalchannelangularextrusion
Impactextrusion
Extrusioncoating

References
Notes
1. Obergetal.2000,pp.13481349
2. Drozda,pp.1311&1312.
3. Avitzur,B.(1987),"Metalforming",EncyclopediaofPhysicalScience&Technology8,SanDiego:
AcademicPress,Inc.,pp.80109
4. Drozda,pp.1321.
5. Drozda,p.13.
6. Drozda,pp.1314.
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7. Drozda,pp.1316.
8. Drozda,pp.1320.
9. AluminumExtrusionToolingMakeItFrom
(https://web.archive.org/web/20100424003904/http://www.makeitfrom.com/info/?
about=Aluminum_Extrusion_Tooling)
10. Drozda,pp.1315&16.
11. Bauser,MartinSauer,GntherSiegert,Klaus(2006),Extrusion(http://books.google.com/?
id=9NnDQ0oJFLEC),ASMInternational,p.270,ISBN087170837X
12. Brickmanufacturingprocess
(http://www.umich.edu/~bricks/brickwebsite/setting_drying/setting_drying_intro.htm)

Bibliography
Drozda,TomWick,CharlesBakerjian,RamonVeilleux,RaymondF.Petro,Louis(1984),Tool
andmanufacturingengineershandbook:Forming(http://books.google.com/?id=9ty5NPJ0UI4C)
2,SME,ISBN0872631354.
Oberg,ErikJones,FranklinD.Horton,HolbrookL.Ryffel,HenryH.(2000),Machinery's
Handbook(26thed.),NewYork:IndustrialPress,ISBN0831126353.

Seealso
Forming(metalworking)

Externallinks
eFundaEngineeringFundamentalsExtrusion
(http://www.efunda.com/processes/metal_processing/extrusion.cfm)
Extrusioncrosssectionaltolerances
(http://www.aec.org/assets/pdfs/AATolerancesTable_Jul2006.pdf)
Retrievedfrom"http://en.wikipedia.org/w/index.php?title=Extrusion&oldid=656616444"
Categories: Foodindustry Metalforming Unitoperations Formingprocesses
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