What is the Extrusion Process? Types & Advantages Explained

A billet is a cylindrical metal that is processed in the extruding process.

A die is a manufacturing medium that shapes or cuts materials. In the extruding process, the die is the machine a billet is pushed through and comes out with a new shape.

The extrusion ramp is the foundation that the billet slides along when going through the extrusion machine.

A hollow is a final extrusion shape that has one or more openings. Examples of hollows are square, rectangular, or circular tubes.

The puller is the mechanical arm that pulls the extruded shape out of the die.

Quench is the cooling process of shooting the extruded part with cold air or cold water after heating in the extruding process.

A ram is a machine that adds pressure to the billet to move through the die.

A semi-hollow is a final extrusion shape with a partially enclosed opening—for example, a C channel.

A solid is a type of final extrusion shape with no enclosed openings—for instance, a rod, beam, or angle.

Before extrusion occurs, die and billet preparation are required for optimal results. Preparation in hot extrusion includes heating the die oven between 400 and 500 degrees Celsius (approximately 750 to 930 degrees Fahrenheit) and placing the billet inside.

In the case of another extruding process, like cold or friction extruding, this involves lubricating the extrusion ramp or metal for easier entry into the die.

In step two, a ram adds 100 to 15,000 tons of pressure to the billet and pushes it through the die. The method in which the ram adds pressure depends on whether the extruding process is hot, cold, or frictional.

As the billet comes out of the die, a puller attached to the extrusion machine will slowly start pulling the billet along the extrusion ramp to make room for more to come out.

After the billet comes out of the die, the extrusion machine quenches the new part. The quenching solidifies the shape and prevents deformities.

Since the billet comes out of the die passage still attached to the original form, it needs to be cut by a hot saw to remove it from the die. After removal, the newly formed material cools to room temperature.

Last in the extruding process is finishing on the formed part. Finishing may be cutting the extruded shape into smaller pieces, removing oxidation, or shining.

In addition to the three main forms of extrusion, there are several specialized variants that meet specific production requirements. Impact extrusion forces material around a punch to produce hollow objects. Hydrostatic techniques lower friction during material flow by applying fluid pressure.

Every version has special advantages for various uses. Certain materials or shape requirements make certain processes more effective. Manufacturers can select the best strategy for their projects by being aware of these possibilities.

Hot extrusion uses a heated die oven for the extruding process. The heat makes the billet malleable, which is particularly effective for helping shape hard metals.

Examples of metals used for hot extrusion:

• Magnesium
• Copper
• Steel

Advantages

The malleability from heat is a massive advantage to heat extrusion over other methods. Since the metal is more malleable, the hot extruding process produces more metal in less time, and can make more complex shapes than alternative methods.

Disadvantages

Although the heat is an advantage in some terms, it can also be a disadvantage. The heat from the die creates an oxide layer that requires different finishing processes on the extruded part. These additional finishing steps take up time, energy, and costs.

Cold extrusion isn’t necessarily cold; it just doesn’t use heat for the extrusion process. Because of this, cold extrusion is used on softer metals and uses more lubrication.

Examples of metals used for cold extrusion:

• Aluminum (and alloys)
• Lead
• Tin

Advantages

An obvious advantage to cold extrusion is the absence of heat surfacing issues like oxidation layers. That’s not the only advantage, though. The cold extrusion also doesn’t use as much energy or time as the hot extrusion because it doesn’t require heating the die.

Disadvantages

Although cold extrusion avoids the detrimental effects of heat, it is a limiting extruding process. Because of the lack of heat, the metal isn’t as malleable. In turn, there is a higher cost for lubrication and limited shapes that cold extrusion can achieve.

Friction extrusion uses frictional heating to move the material through the die and into an extruded part. The metal is forcibly and quickly rotated against the die hole to create heat for increasing malleability. Once the metal generates enough heat to be malleable, it moves through the die.

Advantages

Friction extrusion is the best of both worlds of cold and hot extrusion. Similarly to hot extrusion, it uses heat to make metals malleable for complex shapes and a seamless process. However, it doesn’t use the heating-up energy that hot extrusion requires.

Disadvantages

Although friction extrusion avoids using machine energy for heat, it still uses a lot of energy to make friction between the billet and the die. Also, friction extrusion requires extra finishing because of the formation of heat oxidation.

Due to their adaptability, manufacturing extrusion techniques are essential in various industries. Automotive manufacturers employ extruded parts for interior components, bumpers, and frames. These components provide outstanding strength while reducing the vehicle's weight.

For structural beams and architectural components, extruded materials are used extensively in construction. The aerospace industry demands precise tolerances that extrusion can deliver consistently. Medical device manufacturers appreciate the smooth surfaces and biocompatible materials possible through careful process control.

Consumer electronics benefit from extruded housings and heat sinks that manage thermal loads effectively. Food processing equipment uses extruded components that resist corrosion and maintain sanitary conditions. Each industry adapts the basic extrusion process to meet specific performance requirements.

Extruded aluminum profiles are used in marine applications for corrosion-resistant boat hulls and deck structures. For strength and weight economy, railway systems rely on aluminum car bodies and extruded steel rails. Extruded pipes and fittings that can tolerate high temperatures and pressures are necessary for oil and gas operations.

In the fields of renewable energy, extruded parts are used in wind turbine and solar panel frames. Furniture producers use aluminum extrusion technologies to build frames that are both lightweight and sturdy. Sports goods manufacturers use specific extrusion methods to create equipment handles, ski poles, and bicycle frames.

For weather protection, telecommunications infrastructure depends on extruded cable conduits and antenna housings. Extruded ducting and ventilation components are used in HVAC systems to ensure effective airflow.

A number of considerations come into play when contrasting hot vs cold extrusion with other manufacturing techniques. Although forging produces stronger parts, it greatly reduces shape complexity. Although casting enables complex designs, it necessitates a lot of secondary machining.

Rolling techniques are effective for sheets but ineffective for producing hollow portions. Solid stock machining results in significant waste and increased material expenses. By fusing material efficiency with design freedom, extrusion fills these voids.

3D scanning technology enables precise comparison between extruded parts and other manufacturing methods. This analysis helps engineers select the most appropriate technique for each application. The data supports informed decisions about cost, quality, and production volume requirements.