Aluminum profile processing is a branch of aluminum processing, specifically deformation processing. Core technologies revolve around four areas: forming, precision machining, surface treatment, and process optimization. The following is a summary of key technologies:
Core Forming Technologies
Forming is the foundation for transforming aluminum rods into profiles with specific cross-sections. The main types are:
Extrusion Forming: This is the most mainstream forming process for aluminum profiles. It involves applying force to a heated aluminum rod and extruding it through a die.
Process Parameters: Aluminum billets are typically heated to 400-500℃, while 6000 series alloys are controlled at 415-445℃. Product precision can reach a wall thickness of ±0.05mm.
Development Direction: Isothermal extrusion technology (controlling exit temperature fluctuations within ±10℃) can reduce uneven deformation defects. Currently, combining finite element simulation and digital twins has enabled digital monitoring of the production process. In 2025, Taiyuan Heavy Industry delivered the world's largest tonnage 235 MNT aluminum extrusion press, capable of producing ultra-large cross-section special industrial profiles.
Die Casting: Suitable for complex components, molten aluminum is injected into a mold under high pressure to form a single part. It enables integrated machining of complex mounting holes and reinforcing ribs, achieving high dimensional accuracy. It is widely used in power supply boxes, automotive parts, and other applications.
Post-Processing Precision Machining Technology: The blanks after extrusion/die casting require secondary machining to meet assembly requirements. Core technologies include:
CNC Machining:Capable of milling, drilling, boring, and tapping, with tolerances controlled within ±0.05mm. It removes extrusion burrs and refines interface precision to meet precision assembly needs.
Tapping Technology (DIY/Small Batch Scenarios): Refers to machining threads on through holes on the end face of profiles for easy bolt fixing. M6 taps are generally used for 20mm profiles, and M8 taps for 30/40mm profiles. It is recommended to choose cobalt-tipped taps and use them with a long-arm wrench for easier operation. For small-scale home machining, edible oil can be used instead of professional lubricants. Cutting and Milling: Industrial-grade cutting requires high end-face perpendicularity and length tolerance control within ±0.1mm; end-face milling machines can complete end-face/groove machining at any angle from 30° to 90°, processing multiple profiles at once with high efficiency.
Surface Treatment Technology Used to improve corrosion resistance and aesthetics, mainstream processes include:
Anodizing: Forms a dense alumina film on the aluminum surface, with salt spray resistance exceeding 500 hours. It can also be dyed. It is divided into ordinary anodizing and hard anodizing (the latter has higher hardness and wear resistance, suitable for military/mechanical applications).
Powder Coating: Thick coating, rich colors, strong UV resistance, more suitable for outdoor equipment.
Latest Industry Development Trends
In 2026, the industry experienced robust production and sales, with technological iteration focusing on three directions:
High-end: Improving the precision of high-end products such as 7-series aerospace-grade aluminum alloys through process innovation to meet the needs of the aerospace and new energy vehicle sectors;
Green: Building a dual supply pattern of "primary aluminum guarantee + recycled aluminum supplement," relying on direct aluminum molten metal supply to achieve cost reduction through supply chain synergy;
Intelligent: Improving casting speed and product precision through digital control and parameter optimization, with many companies initiating high-end capacity expansion to meet the growing demand from new energy sources.
