Aluminum is a metal that has come of age: it is diverse, it is lightweight and it is cost-effective. In a society in which all three are constantly in demand, aluminum processing technologies are quickly gaining in importance.
The Aluminum Extruders Council (AEC) consists of 152 member companies involved in the aluminum extrusion industry. Collectively, AEC members comprise approximately 80 percent of the production of extruded aluminum profiles in the U.S and Canada.
The council’s mission is to:
- provide opportunities to network with peers and suppliers, address common internal and external issues, share data, train and sponsor research;
- work together to enable members to function more efficiently, cost effectively, and knowledgeably;
- enhance the growth of the aluminum extrusion industry by promoting the advantages of the processes and product applications.
Demand for aluminum in construction, transportation and other industries, is strong and growing. Worldwide, the aluminum extrusion industry is expanding. Demand is particularly strong in newly industrialized economies such as China and India.
A versatile mineral
Aluminum is the most abundant mineral in the earth's crust. In nature, however, it typically does not appear in its pure form. There is evidence of its use from as early as 300 B.C., but it was not until 1888 that an economically feasible process was developed for modern, commercial production of aluminum.
Aluminum is derived from bauxite, a mineral mined from the earth. The bauxite is crushed and sprayed with water; clay and silica are removed as waste by-products. The remaining bauxite is kiln-dried, then mixed with soda ash and crushed lime. The mixture is processed in a digester, then reduced under pressure and sent to a settling tank where additional impurities are removed.
After filtering, cooling, and further processing in a precipitator, the mixture is thickened and filtered once more before being heated in a calcinating kiln. The resultant material is alumina, a powdery chemical combination of oxygen and aluminum.
Aluminum in general (and extruded aluminum profiles in particular) offers a number of advantages over other materials (and other forming processes). Other materials may offer some of the beneficial characteristics of aluminum profiles, but aluminum can offer a complete range of benefits at once. Aluminum extrusion is a versatile metal-forming process that enables designers, engineers, and manufacturers to take full advantage of a wide array of physical characteristics.
Historically, aluminum has proven to be one of the most important materials in successful recycling programs. Aluminum offers high scrap value, widespread consumer acceptance, and aluminum recycling enjoys significant industry support.
All forms of aluminum can be recycled, from aluminum foil to automobile hoods and, of course, aluminum extrusions. Storm doors, window frames, and aluminum ladders are among the more common household extrusions that can be recycled, but large items such as rail cars and trailers can yield an especially impressive financial return when harvested for scrap. As a case in point: The chief executive of a prominent primary metals producer recently cited the fact that, when hundreds of all-aluminum railcars had been returned to the company in 1993 at the end of their 25-year lease, the value of the recycled metal was equal to 90 percent of the original manufacturing cost.
The industry connection
Material substitution (e.g., light-weighting of automobiles) has led to aluminum replacing iron and steel, which is a positive for the industry. On the other hand, there is strong competition from other non-ferrous metals and from non-metals that can have opposite effects. Internationalization of this industry is taking place, leading to shifts where production takes place (from high labor cost to low labor cost regions, for example).
AEC is at the forefront of helping members identify and communicate industry “best practices.” This is the theory behind the world-famous “ET” (Extrusion Technology) seminars, which spotlight the best and brightest technological ideas. Automation, recycling (of aluminum), new applications – these are all areas of change and ongoing interest to AEC members and their customers.
Product quality, manufacturing tolerances, strength-to-weight considerations are also extremely important to extruders and their customers. Many of these are subject to standards (ISO, ANSI, ASTM) and even legislative/regulatory focus. AEC maintains an active presence in these matters. An example is AEC’s five-year campaign to “Keep Aluminum Windows” (KAW). The mission of this campaign is simple: to keep aluminum windows as a viable and preferred component within the residential and commercial construction markets. As a battle whose front is continuously challenged, a lot of time, money, and energy have been invested into this aggressive advocacy program fueled with proactive initiatives and constant vigilance.
Aluminum is a “Future Source” for many other manufacturing processes worldwide. Extruders of aluminum – and their many customers – will expand and grow as knowledge of aluminum increases with its increasing demand. The future is bright for aluminum extruders worldwide.
Rand A. Baldwin, CAE, is president of the Aluminum Extruders Council in Wauconda, Ill., the international trade association dedicated to advancing the role of aluminum extrusion worldwide. For information contact 847-526-2010 or visit : www.aec.org.
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