It prevents the overheating of the bearing surface of a mold during the extrusion process and maintains a constant temperature through precise extrusion temperature control.
Depending on the product, the extrusion speed is improved by 75%, even up to ≥ 300%, by improving productivity and preventing oxidation through the blocking of air with gaseous nitrogen.
The replacement cycle of extrusion mold can be extended by more than 100%, and product loss can be reduced through constant temperature control. Drawbacks and Improvements of the Existing Aluminum Extrusion Process
Drawback in the Existing Process
Improvements Acquired by CVS LN Cooling
Storage Tank for CVS Gas-Liquid Separator
Double Cooling Unit
Outdoor LN Storage Tank and Insulating Piping Lines
LN Flow Control Valve
1. Heat an aluminum billet (a lump of aluminum) at high temperature.
2. Put the heated aluminum billet into the extruder.
3. Push the heated aluminum billet out of the extruder with excessive force.
4. Check the temperature of the extruded product with an infrared thermometer.
5. Cool the bearing surface of the mold with liquid nitrogen via the installed LN inlet depending on the temperature of the extruded product.
6. Aluminum is extruded in the form of a mold.
7. Cool the extruded product with water or wind and cut it to an appropriate size.
8. Depending on the type of extruded product, color it by anodizing or cut it to an appropriate size.
Liquid nitrogen is supplied to the bearing surface of the mold during aluminum extrusion.
Liquid nitrogen cools the bearing surface of the mold to control the temperature of the aluminum extruded product to the set temperature.
Even if the extrusion speed is increased by 2 to 4 times, frictional heat is cooled with liquid nitrogen; thus producing the products at the set extrusion temperature.
Consequently, it is possible to increase production significantly compared to the existing process.
If the aluminum billet is heated to the extrusion temperature and then extruded, product loss in the accelerated process can be drastically decreased due to the liquid nitrogen cooling.
Extruding heated billets allow the extrusion temperature set by liquid nitrogen cooling to be maintained, reducing losses in the accelerated process.
The reduced product loss in the accelerated process leads to decreased total product loss and improved production.
It is possible to keep the extrusion temperature constant with liquid nitrogen cooling, no scale occurs, and none of the extrusion defects such as pick-up are formed.
By completely preventing the occurrence of scale, the surface roughness becomes significantly higher.
Since gaseous nitrogen is vaporized after using liquid nitrogen cooling, it serves to block the air.
This air barrier prevents the oxidation of the extruded products.
In the bending strength test, the bending strength is kept constant at 500 mm and 1000 mm.
Since uniform products can be produced in the post-processing, the defect rate is reduced, and the product quality is increased.
Since it completely suppresses the occurrence of scale, the shelf life of the mold can be raised remarkably.
Existing extrusion molds require reheating and finishing after producing about 30 billets, but extrusion molds using liquid nitrogen cooling increase the number of extrusions by more than 10 times compared to the conventional molds.
In the bending strength test, the bending strength is kept constant at 500 mm and 1000 mm in the products extruded and cooled by liquid nitrogen even with the higher extrusion speed.
Because the extrusion temperature is constant, the extruded products have uniform quality, leading to the uniform quality of finished products.
|Category||3-point Flexural Strength (with LN Cooling)||3-point Flexural Strength (Conventional)|
* Source: Demo Test Report by G.S.ACE
Even if the frictional heat increases by raising the extrusion speed, there is no change in the dimensions of the extruded product because it is cooled with liquid nitrogen and adjusted to the set extrusion temperature.
The table below summarizes the dimensional changes for each section according to the increase in extrusion speed when the liquid nitrogen cooling system is adopted.
With the liquid nitrogen cooling system, the product dimension can be kept constant.
|Category||Cavity||Point||Ram Moving Speed (m/min)|
|3.8 <Mass Production Speed>||4.7||5.5|
* Source: Demo Test Report by G.S.ACE
Rough surface; deteriorated gloss; significant defect rate; slow extrusion speed
Excellent anodized color; reduced loss of extruded products; decreased defect rate