Aluminum product

Advanced Powder Metallurgy & Extrusion Solutions

Our integrated sintering and aluminum extrusion technology combines precision powder metallurgy, controlled compaction, atmosphere-protected sintering and hot extrusion forming. It overcomes the microstructure and performance limitations of conventional casting and traditional extrusion, producing high-performance aluminum components with ultra-uniform density, refined grain structure and consistent dimensional accuracy.

This versatile technology supports the production of aluminum rods, tubes, profiles, sleeves, structural parts, wear-resistant parts and custom near-net-shape components. It is highly applicable for high-end scenarios where conventional manufacturing fails to meet strict material and geometric requirements.

Dual Manufacturing Process Routes

Standard Full Process Route

Alloy Powder → Classification → Mixing & Blending → Compaction → Green Billet → Debinding & Pre-treatment → Controlled Atmosphere Sintering → Sintered Billet → Preheating → Hot Extrusion → Cooling → Heat Treatment → Finishing → Inspection & Packaging

Simplified Direct Powder Extrusion Route

Atomized Powder → Consolidation → Degassing & Preheating → Hot Extrusion → Heat Treatment → Precision Machining

The powder extrusion process effectively eliminates casting segregation, refines microscopic grains, and manufactures high-strength fine-grained and dispersion-strengthened aluminum products. It is mature for rapidly solidified aluminum powder and PM 6061 alloy mass production.

Core Pre-Processing Technology

Aluminum Powder Preparation & Blending

We adopt gas/water atomized aluminum alloy powder (1xxx/2xxx/6xxx/7xxx/Al-Si series) with controlled particle size of 15–150 μm. Strict control of oxygen content, moisture and humidity environment avoids powder oxidation and ensures stable forming performance.

According to product performance requirements, alloy powders, master alloys and lubricants are precisely blended with controlled time, speed and temperature, achieving uniform composition, zero segregation and stable powder flowability.

Precision Compaction & Debinding

Blended powder is compacted under 200–700 MPa pressure to form green billets with 80–95% theoretical density, ensuring excellent dimensional stability and mechanical integrity for subsequent processing.

Controlled thermal debinding at 250–500°C removes organic lubricants and volatile impurities under nitrogen, argon or vacuum atmosphere, preventing cracking, oxidation and internal gas defects.

Controlled Atmosphere Sintering (Core Process)

Different from traditional steel powder metallurgy, aluminum sintering is extremely sensitive to oxide films and atmospheric conditions. We implement low-dew-point (≤−40°C) and low-ppm oxygen controlled atmosphere sintering at 590–640°C.

After 30–180 minutes of constant-temperature sintering, powder particles achieve complete metallurgical bonding, with sintered billet density reaching over 95% theoretical density, realizing pore reduction and microstructure stabilization for optimal extrusion performance.

Extrusion Process, Advantages & Applications

Hot Extrusion & Post-Processing Technology

Precision Hot Extrusion Forming

Qualified sintered billets are preheated uniformly to 350–550°C, then extruded via professional direct/indirect extrusion equipment. With an extrusion ratio of 10:1–40:1 and optimized ram speed and die temperature, the material achieves secondary high-density consolidation.

Custom-designed porthole and bridge dies balance metal flow accurately, effectively avoiding surface tearing, die lines, uneven wall thickness and internal welding defects. Real-time infrared temperature monitoring ensures the exit temperature stays within the optimal alloy process window.

Heat Treatment & Precision Finishing

For heat-treatable alloys such as 6061, 6063 and 7xxx series, standardized solution treatment, quenching and artificial aging (150–200°C) are adopted to stabilize mechanical properties and meet customized strength and toughness requirements.

Subsequent stretch straightening, fixed-length cutting, CNC machining, grinding and surface treatment ensure full precision control of product size, straightness, roundness and surface roughness.

Full-Process Quality Control System

We implement full-chain quality inspection from raw powder to finished products, covering chemical composition, particle size, sintered density, porosity, dimensional tolerance, tensile/yield strength, hardness and microstructure.

Equipped with metallographic analysis, SEM/EDS, ultrasonic testing, eddy current testing and CMM precision inspection, we ensure stable batch consistency and qualified product yield.

Process Comparison: Conventional vs Sintered Powder Extrusion