Limit the irregularities of shape as much as the function of the part allows. Metal flows less readily into narrow and irregular die sections, making distortion and other quality problems more likely to occur.

Many extrusion shops and metals suppliers provide standard shapes that might serve the designer. A good rule of thumb is to always use standard cross sections when possible.

Tolerances are advised to be liberal enough to avoid secondary drawing operations, if possible.

With all metals, and particularly with steel and less easily extruded metals, it is recommended to avoid extreme changes in section thickness.

Radius corners on a product reduces die stress and extends the life of the die. Use metal-to-metal dimensions whenever possible in dimensioning a profile as it allows for more accurate inspection. Keep profiles as uniform as possible when designing an extrusion Minimize areas that will weaken the die or impede metal flow, including transition areas from heavy to thin sections.

 

 

IF THE PRODUCT Requires Superior Strength Is Non-Structural (Most Common) Is Used As A Heat sink Is Buffed/Polished/Bright Dip Anodized

THEN CONSIDER 6061 or 6005A 6063 or 6060 6063 6463

The most popular all purpose extrusion alloy. Recommended when surface finish is critical or when material is to be anodized. More intricate shapes are available in this alloy. It machines and forms well.

6061 Alloy

Useful when additional strength or better machining is a consideration. there are configuration limitations. 6061 is not recommended for critical finishes

6463 Alloy

Basically the same as 6063 with some chemistry changes to improve response to chemical polishing processes.

6063 Alloy