Aluminum is a lightweight and easily formable element that we encounter in many areas of everyday life. However, transforming a standard aluminum sheet or billet into a slim curtain profile, a durable solar energy support component, or a custom-sized industrial profile involves a very different process. Aluminum extrusion is one of the manufacturing methods that makes this transformation possible.
During the process, heated aluminum is forced through a specially designed die under high pressure, taking the shape of the die and forming a long profile. In other words, the shape of the resulting aluminum profile is determined by the die being used.
Thanks to this method, manufacturers can go far beyond simple straight aluminum bars and produce profiles with channels, hollow sections, angular geometries, or various connection points. Extruded aluminum profiles are used in a wide range of applications, from shutter and curtain systems to insect screen profiles, solar energy systems, and industrial profiles. The extrusion process combines design flexibility with the advantages of mass production.
With 25 years of industry experience, ÖZAK Aluminum Extrusion is one of the manufacturers specializing in custom die design and profile production, developing solutions for a variety of applications. The company’s 12,000 m² indoor production facility in Ankara has an annual extrusion capacity of 7,200 tons.
In this comprehensive guide prepared for you, you can discover, through ÖZAK’s experience, why aluminum is processed using the extrusion method, the stages involved in aluminum extrusion, and why temperature plays such a critical role in the manufacturing process.
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What Is Extrusion Used For?
The main advantage of extrusion is its ability to produce complex cross-sectional geometries as continuous profiles in a single manufacturing operation.
For example, a simple straight aluminum bar may not be sufficient for a curtain system. The profile may need to include connection points, channels, rails, or specially designed cavities for mounting components. Producing each of these features later through machining would increase both manufacturing costs and processing time.
When an extrusion die is designed correctly, a significant portion of these geometries can be created directly during the profile manufacturing stage.
For this reason, extrusion is used in:
- The production of long profiles with constant cross-sections,
- The manufacturing of aluminum components with custom geometries,
- Curtain and shutter systems,
- Insect screen systems,
- Solar energy applications,
- Machinery and industrial equipment,
- Construction and architectural profile applications.
The manufacturing flexibility provided by extrusion allows profiles to be shaped according to the requirements of different applications. Various cross-sections and geometries can be designed based on the intended use of the profile, the loads it will carry, and the connection details it requires.
As a result, the production process takes into account not only appearance but also the durability and performance of the profile. This advantage is particularly important in applications where long-term and reliable use is expected.
Profiles used in curtain systems are one of the most prominent examples. At ÖZAK, the curtain profiles we manufacture using high-quality aluminum extrusion technology offer resistance to corrosion and deformation, allowing them to safely support even heavy curtains for many years. With 25 years of experience, our curtain profiles are used in a significant number of homes throughout Türkiye.
What Are the Stages of Aluminum Extrusion?
Producing high-quality aluminum profiles with accurate dimensions involves much more than simply shaping the material in an extrusion press. The process consists of several stages.
Here are the stages of aluminum extrusion step by step:
1. Alloy and Billet Selection
The extrusion process begins with selecting an aluminum alloy that is suitable for the intended application of the profile.
Cylindrical aluminum blocks made from the selected alloy, known as billets, are then selected for extrusion. The dimensions and material properties of the billet directly affect the profile’s durability, surface quality, and ability to pass smoothly through the die during production.
For this reason, choosing the correct alloy and suitable billet is the foundation of producing a high-quality extruded profile.
2. Heating the Billet
In the second stage, the billet is heated in a controlled manner until it reaches a temperature suitable for extrusion.
The purpose is not to melt the aluminum but to achieve the plastic behavior required to reduce the necessary press force during deformation and allow the material to flow through the die in a controlled manner.
However, excessively high temperatures are also undesirable. Excessive heat can cause surface defects, material flow problems, and process instability.
3. Die and Pressing Process
At this stage, the heated billet is placed inside the extrusion press container.
When the hydraulic ram applies high pressure, the aluminum passes through the opening in the die and takes on the die’s cross-sectional geometry.
ÖZAK Aluminum’s production infrastructure includes 5-inch and 6-inch extrusion presses, with profiles being shaped using custom-designed dies.
During this stage, not only the pressing force but also factors such as the extrusion ratio, billet temperature, die temperature, press speed, and alloy composition must be evaluated together.
Changes in any of these parameters may affect both the surface appearance of the profile and the stability of the manufacturing process.
4. Cooling and Straightening
This is a particularly critical stage.
The aluminum profile emerging from the extrusion die is still at a high temperature and has not yet reached its final dimensions and shape.
Therefore, the profile is cooled in a controlled manner to preserve the desired material properties. It is then subjected to a straightening process to eliminate bending and deformation that may have occurred during production.
The profile is then ready for the next stage.
5. Cutting, Aging, and Surface Treatments
At this stage, the straightened profiles are cut to the required lengths.
Depending on the alloy and the targeted temper condition, the profiles are then subjected to an aging process. Afterward, they may undergo anodizing, painting, or other surface treatments.
In addition to surface treatments, TSE-controlled quality assurance processes should also be implemented throughout production.
An error occurring at any stage of this production chain may become visible in the final product. For example, a profile that appears perfectly straight when leaving the die may fall outside dimensional tolerances after straightening.
For this reason, quality control in extrusion production is not limited to inspecting the finished product; it is performed at different stages throughout the manufacturing process.
What Are the Aluminum Extrusion Techniques?
The techniques used in aluminum extrusion vary depending on the geometry of the profile to be manufactured and the properties of the material.
The most fundamental distinction in the industry is between direct extrusion and indirect extrusion.
In direct extrusion, the billet is pushed directly toward the die by the press ram. This is the method most commonly used in industrial aluminum profile production.
In indirect extrusion, the die moves toward and into the billet. This configuration can reduce friction caused by the relative movement between the billet and the container, although it requires a different equipment and process design.
The table below summarizes the main differences between direct and indirect extrusion:
What Are Aluminum Extrusion Products?
One of the greatest strengths of extrusion is that manufacturers are not limited to producing a single type of product. By changing the die, a wide variety of cross-sectional geometries can be produced.
At ÖZAK Aluminum, our product range includes profiles for roller blinds, zebra blinds, mini zebra blinds, rustic curtain systems, silhouette blinds, vertical blinds, and pleated blinds, as well as curtain rails.
We also manufacture standard tube, box-section, and solid bar profiles; café rods; hospital curtain rails; insect screen profiles; screed, plaster, and joint profiles; and solar energy profiles.
However, it is important to distinguish between a standard profile and a custom profile.
Standard profiles are suitable for regular production based on predetermined dimensions and geometries.
For custom extrusion profiles, on the other hand, a new die can be designed according to the customer’s technical drawing, mounting system, or intended application.
At ÖZAK Aluminum Extrusion, we can also provide custom die solutions with the support of our fast and experienced technical drafting team.
What Should the Aluminum Extrusion Temperature Be?
One of the most frequently asked questions among those interested in the subject is:
“What should the aluminum extrusion temperature be?”
However, from a technical standpoint, there is no single numerical answer to this question.
The appropriate billet temperature varies depending on factors such as the alloy, profile cross-section, extrusion ratio, press speed, and die conditions.
In general, billet temperatures of approximately 375–500°C may be encountered in aluminum extrusion.
However, there can be significant differences depending on the alloy.
For example, according to ASTM B807/B807M data, the upper billet temperature limit for alloys such as 6060, 6063, and 6101 is specified as 570°C, while lower upper limits are defined for certain other 6xxx-series alloys.
These figures should not be interpreted as the target temperature for every production process. Instead, they represent the upper limits specified by the relevant process standard.
An important point to remember is that increasing the temperature does not automatically improve the extrusion process.
Although the material may flow more easily at higher temperatures, surface quality or process stability may be negatively affected. Therefore, manufacturers optimize billet and die temperatures together with the press speed.
ÖZAK Aluminum Extrusion: An Expert Approach to Profile Manufacturing
Producing a high-quality aluminum extrusion profile requires much more than simply having a powerful extrusion press.
Every stage—from die design and production process control to surface treatments and inventory management—must operate in harmony.
ÖZAK applies this integrated approach at its 12,000 m² modern production facility in Ankara, manufacturing aluminum profiles for the needs of different industries with an annual production capacity of 7,200 tons.
Its manufacturing capabilities can be adapted to a wide range of profile requirements, from curtain systems and solar energy applications to glass balcony solutions and industrial designs.
Managing processes ranging from die design to electrostatic powder coating under one roof allows every stage of production to proceed in a more controlled manner.
A 300-ton ready-stock capacity also supports faster access to the profiles required for different projects.
Conducting its production processes in accordance with ISO standards, ÖZAK allocates a significant portion of its production capacity to global markets.
As a result, aluminum extrusion production that begins in Ankara is transformed into profiles used in projects across different countries.