Challenges and Solutions in Working with Structural Aluminum Extrusions

Structural aluminum extrusions are versatile and lightweight materials used in various industries. However, working with these extrusions presents unique challenges that require innovative solutions.


Corrosion: Aluminum is prone to corrosion, especially in humid environments. This can weaken the structure and compromise its integrity.

Welding: Aluminum alloys have a low melting point and high thermal conductivity, making welding difficult. Weld joints can be weakened or distorted if not done correctly.

Precision: Extrusions must be manufactured with high precision to ensure proper fit and function. Deviations in dimensions can affect structural stability and assembly.

Cost: Structural aluminum extrusions can be expensive, especially for complex shapes. Finding cost-effective solutions is crucial for large-scale projects.


Anodizing: Anodizing creates a protective oxide layer on the aluminum surface, enhancing its corrosion resistance. Anodized extrusions can withstand harsh environments without compromising their structural integrity.

Friction Welding: Friction welding uses friction to generate heat and fuse two aluminum pieces. This technique avoids melting, minimizing distortion and maintaining weld strength.

CNC Machining: CNC machining allows for precise cutting, drilling, and shaping of extrusions. This ensures accurate dimensions and eliminates the risk of human error.

Value Engineering: By optimizing designs and exploring alternative materials, engineers can reduce the cost of structural aluminum extrusions without compromising performance.

Additionally, understanding the characteristics of different aluminum alloys and employing proper handling techniques can further mitigate challenges. Proper storage, handling, and assembly are crucial to prevent damage or contamination.

Working with structural aluminum extrusions requires a combination of expertise, innovation, and attention to detail. By addressing the challenges and implementing effective solutions, engineers can harness the benefits of these lightweight and versatile materials to create robust and durable structures.

Online Service