EXTRUSION
ALUMINIUM BILLET HEATING FURNACE
We design and manufactures furnaces for rapidly heating aluminum logs/billets prior to the extrusion process. These furnaces are direct gas-heated and have PLC-controlled pre-mix jet type nozzle burners. The logs/billets are heated quickly with low gas consumption (18 Nm3/ton Al.) thanks to the special arrangement of the burners.
The temperature is measured within a range defined by surface thermocouples that can be moved back and forth. Following the heating process, the desired material surface temperature remains within a +10 °C tolerance. Reusing flue gases generated in the preheating zone improves heating efficiency.
These furnaces are outfitted with low thermal mass insulation materials and easily replaceable refractory blocks for insulation. The use of insulating materials with low heat retention capacity prevents melting. The furnace transfer system, which includes a roller conveyor, is designed to work in tandem with the hot billet cutting machines. The front heaters and the last zone burners located at the furnace outlet can heat the first 200 mm above the set values (tapper heating).
LOG HOT SHEAR/SAWS
We provide hot saws and hot shears for cutting aluminum logs prior to extrusion. Hot saws with a chip collecting system are recommended for diameters greater than 9”, whereas shears are best for diameters between 4′′ and 9′′. Billets are cut with zero waste using a double cutting system in hot shears. Hot shears communicate with the furnace loading table to cut heated billets to the desired length with a 3 mm tolerance. We also manufactures loading conveyors that are installed at the exit of hot shears and saws to directly transfer cut billets to the press punch.
ALUMINIUM AGEING OVEN
We design and manufactures ageing ovens for aluminum extrusion profiles. We have double-length (16 m) aging ovens with up to 24 baskets and single-length (8 m) aging ovens with 12 baskets. We ensure that production processes after extrusion are completely automated by integrating smart loading cars into the system.
Ageing ovens are heated up to 185 °C in less than an hour using electricity or natural gas (indirectly), and the entire heat treatment process takes 6 hours, allowing the application to take place four times per day.
The use of the reversible end flow system (changeable air flow direction) maximizes temperature homogeneity inside the ovens, ensuring excellent hardness along the entire length of the profiles.
The system’s recirculation fan moves horizontally through the reversible end flow system, directing hot air generated in the thermo-blocks into the oven. Ageing ovens can achieve desired material temperature homogeneity within +3 °C tolerance based on the particular time intervals during heating.
While two transfer cars at the entrance and exit zones handle the loading and unloading, chain or roller conveyor systems can also be used.
DIE HEATING OVEN
We create heating ovens for press extrusion dies. We provide control systems to our customers and guarantee +5 °C tolerance on desired temperature in these ovens using horizontal air flow because temperature homogeneity at the die is critical for isothermal extrusion.
Heating is provided by self-recuperating gas burners with radiant tubes in gas heated ovens, whereas tube resistances are used in electric heated ovens.
The dies are easily loaded from the top or the front via pneumatic or hydraulically actuated doors. Bolsters can also be used to assist with the loading process. These ovens can also be equipped with a fully automated loading system.