1. Extrusion workshop
Currently, KIMSEN is operating 3 modern technology aluminum extrusion lines with wattage of 920 UST, 1100 UST & 1880 UST, which are able to produce approximately 1.000 tons/month.
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Aluminum extrusion lines with wattage of 920 UST, 1100 UST & 1880 UST
Aging furnace
2. Anodizing workshop
KIMSEN has installed modern anode coating line with the capacity of around 500 tons/month. Our anode products includes 3 product lines: Natural, sandblasting, and ED coating line with various colors (white, yellow, grey, brown, black, etc.) are gradually gaining reputation.
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Surface treatment process
3. Powder coating workshop
KIMSEN is equipped with the automatic electrostatic spray coating system, which produces the highest quality products. The total capacity of our independent horizontal paint lines system is 450 tons/month (equivalent to 250,000 square meters/month). Modern painting technology helps colors last longer, less affected by environmental factors and varied in colors.
Powder coating lines
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Two independent horizontal paint lines
4. Precision machining workshop
With the purpose of providing customers with high precision mechanical details and finished products, KIMSEN is equipped with modern machining system allows the production of parts with high accuracy that meets the diverse requirements of customers.
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Production process of extruded aluminum
Extrusion Log
The starting material for making aluminum extrusions is the aluminum billet. Aluminum billet is alloyed with aluminum and many other elements such as copper, tin, manganese, silicon, magnesium ... In particular, the aluminum alloy widely used in the extrusion process are aluminum alloy 6063 and 6061. In order to ensure product quality, KIMSEN always import high quality billets well-known international corporation.
Pre-heating
In most extrusion plants today the first operation is to cut the long extrusion log into suitable lengths for extrusion based on press capacity and the final extruded length. (Typically 400 mm to 1000 mm) The cut log or billet is fed into the billet heater where it is heated typically to 400 – 500 deg.C. The exact temperature will depend on the alloy, shape complexity and other process parameters.
Extrusion
Extrusion involves pressing a preheated aluminum ingot (450-500°C) under high pressure (1600-6500 tons depending on the size of the press) through a die the opening of which corresponds to the cross-section of the extrusion. The extrusion press speed (normally 5-80 m/min) depends on the alloy and the complexity of the die’s opening.
There are two basic types of extrusion process – direct and indirect. In the traditional direct method, the die is stationary.
The pre-heated billet is loaded into the container and squeezed through the die opening, (which corresponds to the cross-section of the extrusion). Typical press sizes range 1,600 tonnes to 6,500 tonnes – sufficient force to cause the aluminum to flow plastically and exit the die at extrusion speeds in the range of 5-80 m/min. At the exit of the die the temperature of the extrusion will be in excess of 500 deg. C. The extruded length may be as long as 50 metres and may consist of one strand or multiple strands of the same section. With most commercial alloys the extrusion will be cooled or quenched as it exits the press.
Cooling
Cooling is carried out for two main reasons:
To enable the subsequent stretching and handling of the extruded lengths.
As the first part of the heat treatment of age-hardening alloys – these form the bulk of commercial alloys. This “solution cooling” operation may be achieved with air, water or a mixture of the two depending on the alloy and the final mechanical property requirements. (The use of solution in this context is a metallurgical term referring to what is happening in the aluminum alloy and does not describe the medium used for cooling).
Stretching and Cutting to Length
The long lengths are transferred across the press table into the stretcher. Here, stretcher jaws at either end grip the metal and give it a controlled stretch. This straightens the long lengths and can also have a minor effect on subsequent mechanical properties.
The up to 50 metre long extrusions are then fed to the saw conveyor where they are cut to the customer’s required length. Typical customer cut lengths range 2-6 meters, but other lengths can be accommodated. The ability to supply longer lengths will depend on the logistics of the individual plants and shorter lengths are often achieved by an additional re-cut operation off-line.
Ageing
This is a specific form of heat treatment and typically involves heating the extrusions in ovens to a temperature in the range of 170-190 deg. C for 4 to 8 hours. This develops the mechanical properties of the extrusions, particularly their strength. The minimum mechanical properties that must be achieved after ageing are specified in the relevant EN/British Standards for different alloys and tempers.
Surface treatment
To increase the durability of the product and improve the aesthetics, depending on the intended use, extruded aluminum bar may undergo some surface treatment process: Anodizing, powder coating or wood grain coloring.
