Automotive Aluminum Extrusions

The most suitable aluminum for manufacturing automotive aluminum extrusions is 6061T6. This alloy is special, having been solution heat treated, quenched, cooled, and aged. The aging is done artificially to ensure that the aluminum alloy presents precipitation hardening according to specifications.

Since this alloy is in the 6xxx series, it has one of the best corrosion resistance. It also has fair machinability, cementing its candidacy for automotive aluminum extrusion applications.

For the economics of a project, aluminum 6061T6 is relatively cost-effective. Most manufacturers prefer it because it presents good properties at an affordable price. Even if an alloy such as 7075T6 aluminum is stronger, you will find most users going for 6061T6 based on cost.

It is also worth noting that even though 6061T6 may require a skilled welder, joining it is not so challenging. Surface finishing and painting the aluminum alloy is simple too.

For these main reasons, aluminum alloy extrusions manufactured from aluminum 6061T6 are the most popular in the automotive industry.

The use of aluminum extrusions in cars continues to increase worldwide. Many parts in a car are made out of aluminum extrusions, and there are several reasons for this choice. The most popular reason is that aluminum is lightweight, so it enhances fuel economy in the car.

Other reasons are the recyclability of aluminum and the simplicity of creating different geometries with the material. The parts of a car that are made using aluminum extrusions include chassis parts, body components, exterior trim components, and parts of the suspension system.

There are specific alloys that fit these applications, the most popular ones being 6xxx and 7xxx aluminum. These series feature the required strength for the different applications.

Here are specific parts of a car that are made using aluminum extrusions:

• Engine cover
• Tailgate frame
• Seat backrest
• Bumper beam
• Fuel distribution pipe
• Steering column
• Engine mount
• Dashboard beam
• Seat track
• Anti-intrusion beam

There are many more automotive extruded solutions. These extrusions are found in possibly every system in a car.

Using aluminum extrusions to build different parts of a truck presents many benefits. They include corrosion resistance, strength, and lightweight (fuel economy). Many parts of a truck are made from aluminum extrusions. A good example is the doors, which can be designed according to the customer’s specifications because aluminum allows for flexible design. Provided the doors are designed together with quality seals, dust and moisture will be kept off.

Truck roofs are also made from extruded aluminum. They work perfectly together with aluminum roof bows and wall panels to ensure that the product not only meets the customer’s size requirements but also prevents the entry of weather elements.

Truck frames are also made from aluminum extrusions. Customers have diverse requirements, and aluminum is capable of meeting most of these requirements. For instance, truck frames need to be lightweight. Alongside this is the requirement to be sturdy because the trucking industry is synonymous with extreme stress.

Other parts of the truck that use aluminum extrusions include:

• Battery Tray
• Thermal management components
• Ramp

Aluminum extrusions present numerous benefits in a vehicle because they have numerous attractive qualities.

Lightweight – this is one characteristic that makes aluminum extrusions stand out from steel and other alternatives for vehicle extrusions. Due to its high strength-to-weight ratio, the material weighs a fraction of the other metals while offering good strength.

Strength – Even before being strengthened, aluminum extrusions for vehicles are strong. Fabricators of vehicle components can capitalize on this feature by varying the thickness, length, and profiles of the material. Not even falling of temperature can affect the strength of aluminum.

Sustainability – the fact that aluminum extrusions are recyclable and do not lose a significant level of original integrity is beneficial in vehicle manufacture.  When the vehicle becomes old, the aluminum extrusions can be repurposed into a new vehicle or something else.

Corrosion resistance – The corrosion resistance of aluminum extrusions is excellent, but it can also be enhanced through anodizing and other processes.

Non-magnetic – being non-magnetic, aluminum extrusions don’t interfere with vehicle electronics

For these and other features, aluminum extrusions offer numerous benefits in vehicle design. Lightweight is the most prominent because it means that the vehicle’s fuel economy is enhanced. The vehicle engine does not have a lot of weight to carry.

It also means that transport is more cost-effective because more passengers or goods can be carried.

The quality of automotive aluminum extrusions at FONNOV ALUMINIUM is assured. Our quality standards are strict and in line with industry standards.

Our quality levels are checked and maintained from the point of aluminum billets. The raw material (the aluminum billet) determines how good the automotive aluminum extrusions turn out to be. Before the billet is sent to the process, it must be subjected to quality inspection. First, the billet must be free of physical flaws such as cracks and cavities. The chemical components must also be as per the alloy specifications.

We also know the importance of ensuring the highest performance of the extrusion process. With so many parameters involved, we are always on our toes to ensure the product aligns with the customer’s requirements. We have advanced systems for monitoring process temperature, pressure, and feed rate, among other parameters. This helps us avoid variations that can impact the profile, surface finish, and thickness of an automotive aluminum extrusion.

We further ensure the highest quality of our automotive aluminum extrusions by using the best die designs. Superior die design is the reason FONNOV ALUMINIUM extrusions are devoid of shape issues and surface finish flaws.

Strictly adherent to national standards, FONNOV ALUMINIUM takes no chances regarding the quality of extrusions. With our mantra of “ALWAYS WORTH YOUR TRUST”, you have every reason to trust our automotive aluminum extrusions.

FONNOV ALUMINIUM manufactures aluminum extrusions that meet the stringent requirements of the automotive industry and present many advantages. Using the most effective and advanced manufacturing methods, we can satisfy any custom automotive aluminum extrusion orders at very affordable prices.

With a high strength-to-weight ratio and corrosion resistance, automotive aluminum extrusions from FONNOV ALUMINIUM are the best automotive applications. The flexibility of aluminum alloys gives us numerous design options. Aluminum extrusions are also highly durable, making them suitable for tough engineering environments. The malleability of the alloys also makes intricate designs possible.

Using the high quality aluminum alloy for the extrusions is among the most important manufacturing characteristics to consider. At FONNOV ALUMINIUM, we are very careful about standard aluminum alloys we use to build automotive aluminum extrusions. By working with us, you can be sure to get access to varied but quality alloys for extrusions including aluminum 6xxx and 7xxx series.

Here is a summary of the advantages of buying automotive aluminum extrusion from FONNOV ALUMINIUM:

• Well-established extrusions manufacturing process
• High quality aluminum alloys for extrusion
• Strict quality test for each delivery

The future of aluminum extrusions for the automotive industry looks very positive. Consumer trends point towards an increasing demand for fuel efficiency. This gives aluminum a head start because it is lightweight. Using aluminum extrusions minimizes the weight of the vehicle, thereby helping use less fuel.

Many governments are keen on enhancing fuel efficiency and reducing emissions in the automotive industry. The consequent policies and regulations give a boost to aluminum extrusions because the demand for lightweight extrusions increases.

Electric vehicles (EVs) are also becoming trendier by the day, and we are certain this will increase the demand for automotive aluminum extrusions. Batteries can bring a lot of weight, so the rest of the vehicle design must be as light as possible. Aluminum extrusions are the best option. As EVs become more common around the globe, expect a related increase in the demand for aluminum profiles. Automotive factories are also increasingly incorporating aluminum extrusions in their processes.

Currently, popular alloys for automotive aluminum extrusions include 7xxx series and 6xxx series. Prominently extruded auto components include the heatsink, EV battery tray, framework, and body.