The best aluminum extruders take the time to develop a true understanding of their client’s needs and offer personalized service. At PSI Industries, Inc., we combine high-quality, certified aluminum materials with automated extrusion presses and handling systems to provide superior custom aluminum extrusions with fast lead times.

Whether you need a prototype or a high-volume production run, our ISO 9001:2015-certified facilities are equipped to meet your needs. All of our manufacturing is performed in one of our four Texas locations, supported by expert guidance from our team.

Benefits of Aluminum Extrusions

As a leader in aluminum extrusions, we produce profiles with a cross-section that is very close to its final shape. This not only reduces costs but also the amount of machining needed to achieve the product’s finished size. Our aluminum extrusion processes deliver benefits that include:

  • Fast manufacturing with reduced material waste
  • Consistent product quality
  • Lower per part cost
  • Optimal control over your design
  • Operation flexibility
  • High production volume capabilities
  • Continuous operation for faster lead times
  • Quality surface finishes

The Extrusion Process

Producing a custom extrusion involves six basic steps:

  • Selecting the right extrusion log: The process begins with an extrusion log, which is an alloy cylinder of raw material that ranges in size. PSI only uses high-quality, certified aluminum sourced in North America.
  • Preheating the extrusion log: After obtaining the raw material needed, extrusion logs are loaded into a furnace and heated to approximately 900 °F. At this temperature, the aluminum is softened but will not lose its cylindrical shape.
  • Extrusion: The softened log is then loaded into an extrusion press where a hydraulic ram forces it through a custom-shaped die.
  • Quenching: The material is immediately cooled at a precise rate using air or water.
  • Further processing: The extrusions are stretched before they are cut to the desired length and then aged in an oven to achieve the required hardness.
  • Surface finishing: Finally, the extruded aluminum components are deburred and prepared for surface coating.

Aluminum Extrusion Alloy Types

The aluminum extrusion process is compatible with a wide variety of aluminum alloys, including the following:

  • 1000 series: This series is best for applications that require good weldability, formability, and corrosion resistance. However, it does not respond well to heat treatments and offers low strength. The 1000 series is commonly used for general fabrication purposes.
  • 2000 series: Offering high strength and high machinability, the 2000 series is often used to produce parts with complex geometries. Its strength-to-weight ratio makes it ideal for aerospace applications, however, it offers low corrosion resistance and low weldability.
  • 3000 series: This series is the most widely used of all aluminum alloy series. These alloys include manganese, creating an aluminum that is much stronger than the 1000 series while remaining commercially pure. It is commonly used in the food and beverage and chemical industries, as well as in general fabrication applications.
  • 5000 series: These alloys provide extremely high corrosion resistance, making them the ideal choice for marine applications. They do not respond well to heat treatments but are fairly easy to weld and form and provide fairly high strength.
  • 6000 series: The 6000 series is easily welded and can also be anodized to create different finishes. It is commonly used in architectural and structural settings, as well as in hardware applications.

At PSI Industries, we produce aluminum extrusions specifically using 6061 and 6063 alloys from the 6000 series.

  • Alloy 6061. This alloy is commonly referred to as structural aluminum. It offers good tensile strength, weldability, machinability, workability, and corrosion resistance. These properties make it a popular alloy for extruding everything from sports and recreational equipment to more complex aerospace components.
  • Alloy 6063. Also known as architectural aluminum, alloy 6063 has been specifically optimized for extrudability. This alloy can be easily anodized and offers good workability, weldability, and tensile strength. It’s also more corrosion-resistant than alloy 6061. Common applications include furniture, recreational equipment, and architectural elements that will be exposed to moisture.

Aluminum Extrusion Manufacturing from PSI Industries, Inc.

PSI Industries is your source for Texas-made, precision-extruded aluminum components. We can help you get your products to market faster, with low minimum order quantities and as little as a two to three-week turnaround time to create your first dies. Whether your product requires highly precise tolerances, large quantities, or prototype development, we offer unrivaled quality and expertise.

If you have any questions, give us a call at (972) 712-7900 or request a quote through our website today.