The content of this article explains the use, manufacture, and types of aluminum channels.
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An aluminum channel is a robust metal component created through the extrusion process, allowing for a variety of shapes, forms, and designs suitable for numerous applications. One of the primary advantages of aluminum channels is their lightweight nature, which is about one-third the weight of steel while maintaining durability and reliability. The distinctive channel shape is characterized by its internal radius corners.
Aluminum channels offer countless applications, particularly where corrosion resistance and lightweight materials are essential. They are frequently used in store mounting fixtures, edge and face protection framing, LED lighting applications, and truck bed framing. The two primary alloy grades used for aluminum channels are 6061 and 6063.
Aluminum channels come in various types and can be cut to any size to meet diverse application needs, with thicknesses ranging from 0.01 inch to 5 inches. Their versatility and adaptability make them a popular choice for construction projects.
For applications requiring both strength and corrosion resistance, aluminum channels are an excellent choice. Their ability to be configured, shaped, and customized makes them one of the most widely used materials in construction.
Angle aluminum channels form a right angle and are the simplest and most cost-effective type of aluminum channels. They are extruded from various aluminum alloys and are often used for trim and finishing. These channels can be finished in different styles to enhance their visual appeal.
You'll commonly find aluminum angle channels on roof edges, handrails, and building corners. Their corrosion resistance and ability to endure harsh weather conditions make them ideal for protecting and sealing building corners.
The right angle of angle trim can be squared for a sharp edge or rounded for a smooth curve, as illustrated in the image below. The legs of the angle can vary in length from 1/8 inch to 4 inches.
While the basic shape of C channels remains consistent, variations exist in the interior and exterior corners and flanges. The three primary types of C channels are Aluminum Association, American Standard, and Canadian. Aluminum Association C channels are thicker with rounded inner corners, whereas American Standard C channels feature flanges that taper toward the top with rounded corners.
Another variant of C channels starts with a U shape, including a web and flanges. In this design, the tops of the flanges are bent inward, creating a gap for placing a nut channel. Similar to U channels, C channels come in various web widths and flange lengths, as illustrated in the images below.
C channels are versatile and can be used to protect edges in millwork, complement wood panels, serve as store fixtures, or function as framing elements. They are also frequently used for their aesthetic value, adding a sophisticated touch to projects.
The profile of an F-shaped aluminum channel resembles the letter F. It is similar to a U channel but features an extended web without a flange. One flange of the F channel is positioned at the edge like a U channel, while the second flange is set further down from the first flange, with the web extending between them. The length of the extended web and the distance between the flanges can vary based on the channel's design.
H aluminum channels come in various styles for both decorative and structural applications. Their stability makes them ideal for railings, trim, and door frames. Available in several finishes, H channels offer versatility and an aesthetic appeal for different design needs.
In addition to their decorative uses, H aluminum channels are valued for their structural integrity. They are durable and designed to accommodate various widths, wall thicknesses, and features like battens to enhance their support and functionality.
H aluminum channels are available in both lowercase 'h' and uppercase 'H' shapes. Lowercase 'h' channels are typically used to extend ceiling systems by attaching them to the perimeter of a room.
Furring is a construction technique that involves leveling walls and ceilings using furring channels. A hat channel features a hat-shaped profile with two horizontal flanges designed for this furring process. These channels are corrosion-resistant and offer exceptional durability and resilience, making them ideal for furring out walls, masonry, or ceilings. Hat channels also provide a high strength-to-weight ratio and are an affordable structural component.
Both hat channels and Z channels are used to level uneven walls and ceilings while offering additional protection for interior and exterior framing against fire, moisture, and corrosion. Beyond their protective qualities, hat channels help maintain structural integrity by addressing unevenness in walls and ceilings.
The I-shaped aluminum channel closely resembles H channels but is designed specifically as an I beam. Known as the American Standard I beam, it features rounded edges with a wide web and shorter flanges compared to the web. The durability, strength, and resilience of I channels make them ideal for use as cross beam supports.
J aluminum channels are essential for vinyl siding projects, used to mount siding at corners where it meets the ground, roof, and openings. They create an airtight barrier against weather conditions and are easy to install with minimal tools, resulting in cost savings on labor and materials.
Since their introduction in the 1950s, the use of J aluminum channels has expanded. The distinctive J shape comes from a 90-degree bend on one side of the channel's framing profile.
T-slot aluminum channels feature one or more T-shaped slots that allow T-shaped attachments to slide up and down. This design enables the creation of complex configurations without the need for clamping or welding. By using T-slot channels, costs associated with riveting and welding are reduced, as they can be easily connected with mounting bolts.
Like all aluminum channels, T-slot channels offer excellent durability and can be removed, adjusted, and reconfigured as needed—advantages that are not possible with permanently welded metals.
U-shaped aluminum channels are widely used and come in various wall thicknesses, ranging from 1/16 inch to 1/4 inch, depending on their application. These channels are defined by their web (the bottom part) and flanges (the sides). The dimensions of the web and flanges can vary, with configurations such as a short web with long flanges or a wide web with short flanges, as shown in the diagram below.
Z-shaped aluminum channels feature legs or flanges extending in opposite directions from the web, forming a Z profile. They are commonly used for metal roofing or in specific applications for wood roofing. Z channels serve as receivers for panels, ridge caps, and headwall flashing, and their directional installation helps prevent leaks. They are often used as an alternative to J channels due to their slightly narrower width compared to panels.
Z channels come in various types, with some known as clips and others as bars. Clips have a very narrow web, while bar Z channels maintain the traditional Z profile.
The ten basic aluminum channels discussed here represent just a small selection of the many types available. Each year, new and innovative shapes are being developed, expanding the applications and versatility of this highly durable and useful material.
As a form of aluminum extrusions, there are no lists, or information, found solely discussing the best equipment or machines used specifically for producing aluminum channels. As a result, we discuss many of the top brands of machines available in the United States and Canada to produce aluminum extrusions below.
Description: Presezzi Extrusion Group is a leading global provider of extrusion equipment. Their P7 Extrusion Press stands out with its advanced automation, high precision, and excellent control over the extrusion process. Designed for efficient energy use and durable construction, this model is capable of handling a wide range of extrusion profiles.
Description: HPM (Hamilton Plastic Molding) is a prominent manufacturer of industrial machinery, including aluminum extrusion presses. The HPM Aluminum Extrusion Press is designed for high productivity and precision, offering flexibility to handle various alloy compositions and extrusion profiles while ensuring precise control throughout the process.
Description: Inductotherm Group is a global leader in induction heating technology. The Alpha 2 Billet Heating System is designed for heating aluminum billets in the extrusion process. This system features cutting-edge induction heating technology, precise temperature control, and energy-efficient operations to ensure optimal heating and high-quality extrusions.
Description: CEC Extrusion Technology is known for its expertise in extrusion handling and downstream equipment. The CEC Dual Puller is a highly regarded model for handling and pulling extruded profiles with precision. It offers efficient material handling, controlled profile movement, and adjustable pulling speeds to accommodate various extrusion needs.
Description: RDM Industries is a well-known manufacturer of cutting and fabrication equipment for aluminum extrusions. The RDM M-Series Flying Cutoff Saw is renowned for its precise and high-speed cutting capabilities. It features programmable length control, rapid saw movement, and accurate cutting angles for high-quality profile cutting.
Note: The availability and specifications of models may change over time. For the most current information, it is recommended to contact manufacturers directly or refer to their product catalogs.
Since the advent of its mass production, aluminum has become essential in construction as well as industrial and commercial applications. Its impressive strength-to-weight ratio and aesthetic appeal make it the top choice for various projects. Additionally, aluminum aligns with 21st-century environmental concerns due to its recyclability, repurposability, and reusability.
One of the key attractions for builders and designers is aluminum's low cost, which allows for the production of complex and detailed products at affordable prices. Despite its many advantages, the variety of available finishes plays a crucial role in aluminum's versatility and appeal.
There are a couple of reasons designers and engineers decide to have aluminum finished.
Aluminum naturally forms an oxide film when exposed to air, which generally provides effective protection against corrosion and environmental damage. However, in extreme conditions, additional protection is necessary, which can be achieved through appropriate finishing techniques.
Applying a finish allows designers to select an aesthetic that complements their project. The diverse range of aluminum channels can be enhanced with finishes to serve as finishing touches or standout features. The right finish adds to the overall appeal and quality of the aluminum.
Various mechanical methods are employed to finish aluminum channels, aimed at achieving a smoother surface or specific patterns. These mechanical finishes include:
Pretreating is a preparatory process used alongside strip cleaning before the coating application. This process can be carried out chemically or electrolytically, with the chemical method being the most common due to its compliance with various federal regulations and suitability for architectural, construction, and transportation applications. The pretreatment process must be executed with precision to prevent contamination of the aluminum surface.
Pretreatment provides the following functions and benefits:
While pretreatment might appear to be a minor step in aluminum channel processing, it plays a crucial and essential role.
Bright dipping is a chemical polishing process used to enhance aluminum channels before anodizing. Conducted at high temperatures, this process requires precise control to maintain the correct chemical balance between nitric acid, phosphoric acid, aluminum suspension, gravity, and temperature.
The result of bright dipping is a highly reflective and bright finish on aluminum channels. The finish becomes brighter with the harder temper of the aluminum alloy. While the process smooths the aluminum surface at a microscopic level, it does not eliminate scratches or other blemishes. Typically, this process is applied to aluminum alloy 6063 T6 for channels.
As with some of the other processes, anodizing is an electrochemical process but is more passive than the more aggressive chemical methods. The outcome of anodizing is the conversion of the substrate of the aluminum channel to a layer of aluminum oxide. Aluminum has a natural oxide layer that forms when it is exposed to the air. The natural layer of oxide is uneven and thin, offering inconsistent protection.
Applying a controlled electrical charge in an acidic electrolytic bath forms a consistent and uniform layer of oxide on the aluminum, enhancing protection against corrosion and wear. This anodic layer also enables aluminum channels to undergo additional processing, including the application of colorants and lubricants.
Despite its limitations, liquid paint is still a viable option for finishing aluminum channels. To ensure proper adhesion, the aluminum surface must be pretreated with sprays before painting. Liquid paints offer a broader and more vibrant color range, including shades that are richer and more distinctive. Available paint types include acrylics, polyesters, silicone polyesters, and polyvinylidene fluoride (PVDF).
The choice of a liquid paint for aluminum channels is dependent on the amount of corrosion resistance required and the needs of the application. In the case of aluminum angles for building construction, liquid paints can include paints that match the colors of the sides of the structure.
Powder coatings are an excellent choice for protecting aluminum channels from environmental damage and corrosion. This type of coating, which consists of phosphates and metal particles, provides robust protection against rust and the effects of harsh weather. While the specific materials used can vary between manufacturers, the overall protective effect remains consistent.
Powder coatings do not preclude the application of paint, and they are available in a wide range of colors. Additionally, a well-applied powder coating can last up to twenty years without needing replacement or refinishing.
Aluminum is the second most commonly used metal in construction, following steel. Channels shaped as C, J, and U are frequently used in construction projects due to their tensile strength, reliability, and durability. Aluminum is alloyed with other metals to improve its performance and longevity, with each alloy being designated by a specific number and intended for particular applications.
Aluminum grades are numbered from 1 to 8, with grade 1 representing unalloyed aluminum and the remaining grades alloyed with metals such as copper, magnesium, silicon, zinc, and nickel. These alloying elements enhance the properties of raw aluminum, resulting in varied characteristics suited to different purposes.
Grade 6063 is known for its medium strength and is frequently used in the extrusion of aluminum channels. It is capable of being extruded into shapes with very thin walls and small dimensions. Its lustrous finish makes 6063 a popular choice for architectural applications.
Grade 6063 is often referred to as the architectural alloy due to its high tensile strength, excellent finishability, and exceptional corrosion resistance.
The silicon content in 6063 refines the alloy's grain structure, enhancing its fluidity, while the magnesium content contributes to its strength and durability.
Key properties of grade 6063 include:
Similar to grade 6063, grade 6061 is alloyed with silicon and magnesium, with magnesium at approximately 1% and silicon at around 0.6%. This alloy combination enhances 6061's resistance to corrosion, stress, and cracking, while also providing good formability and weldability. Due to its superior strength, aluminum grade 6061 is commonly used in structural applications.
Grade 6061 shares many of the same attributes as grade 6063, including weldability, corrosion resistance, and suitability for coating and polishing. However, unlike 6063, grade 6061 is less malleable and requires substantial force for bending or cold working. Cold forming of grade 6061 demands careful handling and precision to maintain quality and performance.
Grade 7075 is a high-strength aluminum alloy with excellent resistance to stress corrosion cracking. It is widely used in the aerospace industry due to its impressive strength-to-weight ratio. At sub-zero temperatures, the strength of grade 7075 increases. Its primary alloying elements include zinc and copper, complemented by smaller amounts of magnesium, iron, silicon, manganese, chromium, and titanium.
Grade 7075 can be anodized just like other aluminum alloys and boasts a high machinability rating, allowing it to be shaped, cut, and processed with ease. It is noted for its exceptional durability, corrosion resistance, and resistance to cracking. However, unlike grades 6063 and 6061, grade 7075 is not easily welded and requires specialized welding techniques.
Grades 6063 and 6061 are among the most commonly used aluminum alloy grades, with grade 7075 being chosen for its exceptional strength and durability. However, these three alloys are not the only ones used in aluminum channel production. Other notable grades include 2024, 5083, 7050, 5086, 5456, and 6082. The selection of the appropriate alloy is crucial for ensuring that the aluminum channels meet the specific requirements of various applications.
Aluminum temper classifications are categorized into five types: F, O, H, W, and T, each indicating a specific treatment class. Each letter designation is followed by a number that signifies the strength or degree of the treatment. This temper designation is appended to the alloy number to inform producers and users about the specific mechanical properties imparted to the alloy.
For aluminum grades 6063 and 6061, the tempering designation will typically be T-5 or T-6, which indicates the level of thermal treatment the alloy has undergone.
The primary method for forming and producing aluminum channels is extrusion. This process involves forcing an aluminum alloy through a die with the cross-sectional profile of the desired channel. Extrusion is straightforward and involves applying pressure to the raw alloy, pushing it through a die to shape the aluminum channel.
Aluminum channel extrusions are categorized into two types: solid and semi-hollow. Solid extrusions, like angle channels, have no internal voids or openings. Semi-hollow extrusions, such as C channels, feature partially enclosed voids.
The extrusion process starts with a round die crafted from high-grade steel. For many standard aluminum channels, pre-existing dies are used, which are retrieved from storage. The die is preheated to temperatures ranging from 400°C up to 500°C to enhance its durability and ensure consistent metal flow. Once the die reaches the desired temperature, it is installed in the extrusion press.
Aluminum used for manufacturing channels is provided in the form of solid cylindrical blocks, or billets. These billets are heated to temperatures ranging from 750°C up to 930°C to make them malleable for the extrusion process. The heating raises the billet to a temperature just below its melting point, making it pliable enough to be forced through the die.
The malleable, heated billet is mechanically transferred to the extrusion press, where it is treated with a release agent or lubricant to prevent it from sticking to the ram or die.
The loading process of the billet is illustrated in the diagram below. The billet is placed into the extrusion press chamber and pushed through the die. In this example, the flow direction is from left to right, with the extruded aluminum channel emerging on the right.
Hydraulic pressure, up to 15,000 tons, is applied by the ram to push the billet through the die. As the pressure increases, the billet material expands to fill the walls of the extrusion chamber and is compressed against the die. This force causes the billet to become smaller and wider until it completely fills the chamber, forcing the softened aluminum to exit solely through the die. The aluminum takes on the desired shape as it is squeezed through, forming the final aluminum channel profile.
After the extruded channel exits the die, it is captured by a puller that guides it along the runout table. The channel is then cooled through quenching methods, which may involve a water bath, spray mist, air, or fans. Once the channel has traversed the length of the table, it is cut by a hot saw to make space for the next extrusion.
After the extrusions are removed from the runout table, they are transferred to a cooling table where they remain until they reach room temperature. During the extrusion process, twisting may occur, causing imperfections in the profiles. These issues are addressed through a stretching and straightening process.
Stretching and straightening involve a mechanism that grips the aluminum channel at both ends. The channel is then pulled and stressed until it is fully straightened and meets the required tolerances and specifications.
Once the extrusions have cooled to room temperature, they are cut to the required lengths using a finishing saw, typically a circular saw.
After the aluminum channels are cut to length, they may undergo additional processes such as anodizing, powder coating, or aging. The choice of these final treatments depends on the intended application of the channels and the specific protective features required.
Since its introduction in the early twentieth century, aluminum has become integral to various facets of modern life, ranging from aluminum cans to structural I-beams in buildings. Its unique combination of lightness and strength allows it to be adapted for numerous applications.
One essential use of aluminum is in channels, which serve as the framework for display cases, building corners, and decorative elements in architecture. The versatility and durability of aluminum channels have cemented their role in engineering plans and design schematics.
The diverse properties of aluminum channels make them a vital and versatile solution for a wide range of processes and applications.
Aluminum offers twice the conductivity of copper by weight, making it an optimal choice for large capacity overhead power lines.
While aluminum's malleability might suggest a lack of strength, this property actually enhances its versatility. Unlike other metals, aluminum retains its strength across various conditions, whereas other metals may become brittle in cold weather or susceptible to corrosion. With one-third the weight of steel but a superior strength-to-weight ratio, aluminum channels are perfect for applications requiring lightweight load-bearing capabilities.
Aluminum channels are particularly beneficial in applications where weight and rigidity are crucial for protection. They offer significant advantages over copper in such scenarios.
The selection of aluminum channels for construction is often based on their high resistance to rust and corrosion. Unlike other metals that may deteriorate under harsh conditions, aluminum channels maintain their strength and durability.
Aluminum channels are utilized in modern electronics due to their non-magnetic properties, which prevent interference in applications sensitive to magnetic fields.
Aluminum channels are safe for use in environments that are highly flammable or potentially explosive, as they do not produce sparks.
In today’s world, the ability to recycle raw materials is a key focus across social, commercial, and industrial sectors. Aluminum’s recyclability is a major factor in its widespread use, as aluminum components, parts, and channels can be returned to manufacturers for repurposing, reprocessing, and remanufacturing into new raw materials.
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