Troubleshooting Common Issues with Aluminium Extruded Sections

In the realm of extruded aluminium sections, perfection is a relentless pursuit. However, even the most meticulously engineered products can encounter hiccups that hinder their performance. Tackling these issues requires a discerning eye, a proactive approach, and an understanding of the underlying causes.

Surface Defects: A Blemish on Aesthetics

Extrusion lines, scratches, and dents can mar the pristine surface of aluminium sections. These imperfections arise from various sources, such as imperfections in the die, tool marks, or mishandling during production. Fortunately, these blemishes can be mitigated by meticulous die maintenance, optimized process parameters, and careful handling.

Dimensional Deviations: A Metric of Precision

Discrepancies between the intended and actual dimensions of extruded sections can compromise their functionality. This problem stems from improper die design, inaccurate extrusion speed, or incorrect temperature settings. By refining the design, calibrating the extrusion process, and implementing precise temperature control, manufacturers can ensure dimensional precision.

Cracking: A Sign of Internal Stress

Cracks in extruded sections signal the presence of excessive internal stresses. These stresses may result from improper tempering, rapid cooling, or insufficient material quality. To prevent cracking, manufacturers must optimize the tempering process, control the cooling rate, and ensure the use of high-grade aluminium alloys.

Twisting and Warping: A Dance of Forces

Uneven cooling, inconsistent extrusion pressure, or inherent stresses can cause extruded sections to twist or warp. These distortions can be minimized by applying uniform cooling, maintaining consistent extrusion parameters, and optimizing the stress-relieving process.

Corrosion: A Silent Enemy

Corrosion arises from the reaction between aluminium and the surrounding environment. It manifests as pitting, discoloration, or weakening of the material. Protective measures, such as anodizing, powder coating, or painting, are crucial to combat corrosion and preserve the integrity of extruded sections.


Troubleshooting common issues with aluminium extruded sections is a critical aspect of ensuring their optimal performance. By understanding the root causes of these problems and implementing proactive measures, manufacturers can produce high-quality sections that meet the demanding requirements of various industries. From blemish-free surfaces to precise dimensions and resilient structures, continuous improvement and problem-solving drive the evolution of aluminium extrusion technology.

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