Aluminum Extrusion Industry

Squeezing tooth paste from a tube, we are all familiar with it, isn't it? Well, the extrusion process of aluminum is just similar to that process. The aluminium metal, initially in the form of extrusion billet is made to take the shape of a die. It is through the die only where the metal gets pressed. Both pure aluminum along with the alloys it forms with other materials like magnesium and silicon are used in extrusion applications. Aluminum extrusions are typically used for making doors and windows, gates etc. Industries that find application for extruded products include automotive, aviation etc. Other popular examples include furniture, electrical equipment to athletic goods.

 

Global Aluminium Extrusion industry
Globally it is expected that from the year 2005 to 2010, the annual growth for aluminium extrusions would be somewhere around 4.9 percent.

Talking of the Chinese Aluminium Extrusion it has seen a phenomenal growth in the last 15 years. The following diagram traces the formidable growth of the chinese aluminium industry during the last 15 years. As is seen the whole period from 1990 to 2004 is divided into four phases with the growth showing tremendous upsurge from 1999 onwards.

The United States Aluminium extrusion industry has shown strong growth in the 1990's. In the year 2000 the total value of industry shipments was pegged at $6.05 billion. In USA The primary consumer of extruded aluminum products is the construction industry. However this trend is changing with automotive industry taking to extruded aluminum products big way from the year 2000. The importance of extrusion industry can be gauged from the fact that out of the total number of firms engaged in aluminum production nearly 36% are dealing in extrusion.

The US is also the leading country when it comes to per head consumption of Extruded Aluminium products. As this image shows but China's per head consumption is also showing an upsurge.

Let's take a comparative look at extrusion capacity of US and Canada Vis-a-vis Asian countries of China and Japan in the year 2003

 

	USA & CANADA	JAPAN	CHINA
Extrusion Capacity	1.65million tonnes	1.02 million tonnes	1.5 million tonnes

 

Coming to the scenario of Indian Aluminium extrusion industry, in the organized sector of aluminium extrusion business, two major players have been estimated to contribute together about 150,000 MT of aluminum extrusions. Another 5000 MT is the estimated contribution of small firms numbering 100. The following chart gives the fragmentation of the major usage of aluminium extrusion products.

Features of Aluminium Extrusion Technology

• An Aluminium Extrusion Technology should ideally include the following things.
• Selection of extruded product and further development for specific applications.
• Development of the extrusion process.
• Improvement of the extrusion billet cast house and doing constant quality assessment.
• Strict quality control that includes Micro structural evaluation and testing of texture, fatigue etc.

Strategies for Success in Aluminium Extrusion Industries
To succeed in the increasingly competitive world market for Aluminium extrusion there is requirement to understand Market Drivers in the Aluminium Extrusion Industry. Other than that, there is also a need for some well thought out strategies for garnering market share and beat competitors. Following are some of the strategies:

• Shorter lead time
• Look out for niche market
• Lower the production cost
• Value added services
• Expand production capacity
• Upgrade extrusion equipment
• Pooled research approach
• Export oriented approach

Market Drivers in the Aluminium Extrusion Industry
To understand what are the market drivers in the Aluminium extrusion industry there is need to consider three vital areas. These three areas are:

Value Added Processes
Value-Added Processes are basically downstream steps. It include steps like finishing along with fabrication. The idea behind this steps is to add to the value of the basic extruded profiles, through enhancing. Let look at few of such steps.

Friction Stir Welding

It is not very easy to implement the idea that aluminum can also be welded. As there was a concern regarding a welded aluminium's visual surface characteristics. The apprehension stemmed from the fact using brazing wire of an alloy may not be exactly like the parts being welded.

With the advent of Friction stir welding as shown above such doubts or concerns is effectively addressed. This is particularly true for automotive applications. Methods like this can surely boost a more wider application of extruded aluminium.

Curved Extrusions
Curved profile extrusion is now proving to be a very effective option for achieving curved sections. This process is without any of the disadvantages of springback or cross-sectional deformation. This type of curved profiles can be further passed through hydroforming operations for fabrication.

Product Applications
Newer and more innovative use of the extruded profiles are now ruling the market. Let's see what are these:

Extruded Aluminium bottles
A wide variety of beverages have hit the market in impact-extruded aluminum bottles. This distinctive extruded aluminium bottle's have become very popular in quick time.

Architectural Elements
On The commercial buildings items made of extruded aluminium like louvers and sunscreens are growing in popularity. More and more of extruded aluminum architectural elements are getting installed on modern construction projects. Even in applications like windows the aluminium extruded profiles give a tremendous opportunity for growth.

Strategies
Coming to the last section of strategies, the following points are important factors in guiding the aluminium extrusion industry.

Competitive Excellence
Aluminium extruders are now learning a new lesson. The lesson is, for competing with offshore imports, only price is not enough. What is needed is:

• Superior quality
• Value-added services
• Customization
• Exemplary customer service

Process Integraton
There is need to have a total system approach in the aluminum extrusion industry. Things like, thermal alignment during the extrusion process gives rise to performance improvements for getting increased productivity and reduce the level of scrap. Conducting of profitability analysis throughout a business unit also gives rise to operational efficiencies. To conclude the need of the hour is to have a holistic approach toward the aluminium extrusion industry. Attempts that are directed to isolate individual functions as discreet units unperturbed by related activities, would invariably result in failures and loss.

 

U.K. Vs Italy : Comparative status in Aluminium Extrusions Italy has been able to sustain extrusion industry which is four times that of UK’s but population of the two countries are of almost similar size. Italy's export of aluminium extrusions was net 140,000 tonnes per year whereas during the same period UK has seen a net import of 70,000 tonnes per year. Italy typically uses around 7 kg per capita of total aluminium extrusions in comparison, U.K.'s per capita usage is under 4kg the lowest among the developed countries.