| 1. Alloy and billet selection | Aluminum billets are selected to suit the required strength, corrosion resistance, formability, and finishing needs. Common extrusion alloys include 6063 and 6061, but the appropriate choice depends on the application. | Controlled material sourcing, billet handling, and traceability systems. | Request the proposed alloy and temper, material documentation, and a method for tracing production batches. |
| 2. Die design and preparation | A heated billet is pushed through a shaped die to create a continuous profile. Die design affects wall thickness, dimensional consistency, surface quality, and how easily a shape can be extruded. | Die design and machining capability, die maintenance, and experience with the requested profile geometry. | Review the profile drawing, critical dimensions, proposed tolerances, and whether a production sample or first-article approval is available. |
| 3. Extrusion | The press forces the billet through the die. Extruded material exits as a continuous shape and is handled on a run-out system before being cut to manageable lengths. | Press capacity suited to the profile's dimensions, weight, and complexity, along with appropriate handling equipment. | Ask how the supplier confirms press suitability and controls profile dimensions and visible surface defects during production. |
| 4. Cooling and quenching | After leaving the die, the profile is cooled. The cooling method and conditions depend on the alloy, profile, and required properties. | Controlled cooling equipment and handling that limits distortion and damage. | Confirm that the cooling process is defined for the specified alloy and temper and that any required mechanical properties are verified. |
| 5. Stretching and straightening | Profiles may be stretched to reduce residual stresses and improve straightness before being cut to length. The exact process depends on the product and specification. | Stretching equipment, straightness measurement, and careful length cutting. | Agree on straightness, length, and dimensional requirements in the drawing or purchase specification. |
| 6. Heat treatment and aging | When required for the specified alloy and temper, controlled heat treatment develops the intended mechanical properties. Not every profile uses the same treatment. | Temperature-controlled furnaces, production records, and procedures appropriate to the alloy and temper. | Specify the required temper and property criteria; ask for relevant test records when these properties are part of the order requirements. |
| 7. Machining and fabrication | Profiles may be cut, drilled, milled, punched, or assembled after extrusion to meet the finished-part drawing. | Appropriate cutting and machining equipment, workholding, and process control for the part's tolerances. | Check sample parts against the drawing, including hole locations, cut lengths, fit, and any specified burr or edge requirements. |
| 8. Surface finishing | Depending on the application, profiles can be supplied unfinished or given treatments such as anodizing or powder coating. Finish requirements should be defined for the intended environment and appearance. | In-house or qualified finishing capacity, process control, and protection of finished surfaces during handling. | Specify finish type, color, appearance, and applicable performance tests. Request inspection records for the requirements that matter to the application. |
| 9. Inspection and shipment | Finished profiles are inspected, identified, packed, and prepared for transport. Inspection scope should match the agreed drawings and order specifications. | Measurement tools, inspection procedures, batch identification, and packaging appropriate to profile length and finish. | Review sample inspection reports, traceability, packaging details, and any quality-management certificates required by the buyer. |
| 10. Supplier evaluation | A suitable manufacturer is one whose demonstrated process, quality controls, technical support, and delivery capability match the product requirements—not simply the one with the lowest quotation. | Relevant extrusion and finishing capacity, engineering support, stable quality systems, and a clear process for handling nonconforming product. | Compare approved samples, written specifications, quality records, capacity and lead-time commitments, communication, and corrective-action practices. |