Comparing Aluminum Extrusion and Roll Forming for Aircraft Parts

When it comes to manufacturing aluminum aircraft parts, the methods used to form them significantly impact their strength and performance. Two of the most widely employed processes are extrusion and roll forming, which are each efficient in shaping aluminum but offer distinct advantages depending on a part's design and functionality. Understanding the differences between these two processes is critical for choosing the best method for an aircraft component, so read on as we explore the fundamental aspects of both and examine how each process fits into the production of aviation parts.

What Is Metal Forming for Aircraft Parts?

Metal forming plays a central role in the production of aircraft parts, as it allows manufacturers to shape metal into complex designs for the means of creating lightweight yet durable components. Precision in the metal forming process is a crucial aspect of ensuring structural integrity and aerodynamic efficiency, and aluminum is often the metal of choice given its favorable strength-to-weight ratio. Because of its importance, understanding the methods of metal extrusion and roll forming are essential for selecting the right method for specific applications.

What Is Extruded Aluminum?

Extrusion is a method where a piece of aluminum is heated to a malleable, yet still solid, temperature and then subjected to high pressure as it is forced through a die. As the metal exits, it takes on the form of the die’s opening, creating long, continuous pieces with uniform cross-sections. Extruded aluminum parts are known for their consistent quality and excellent dimensional accuracy, as the process allows for tight tolerances and ensures that parts fit together seamlessly during assembly. As such, extrusion is well-suited for creating complex shapes with hollow sections or intricate details, like landing gear components or seat tracks.

What Is Roll Form Aluminum?

Roll forming is a continuous bending operation in which a long strip of aluminum, usually in coil form, is passed through a series of rollers. Each roller progressively bends the metal until it achieves a desired shape. Unlike the complexity associated with extrusion, roll forming is typically used for parts with uniform profiles along their length, such as beams, channels, or structural reinforcements in aircraft. This process is highly efficient for producing long, straight components in large volumes. Moreover, because the material passes through rollers gradually, there is less stress placed on the aluminum, reducing the likelihood of defects like cracking or warping.

What Are the Disadvantages of Extrusion and Roll Forming?

As we previously touched on, both extrusion and roll forming offer distinct advantages depending on the design requirements of aluminum aircraft parts. However, understanding the limitations of each process is equally important when determining which method is most suitable for a specific component. For instance, roll forming is less ideal for creating complex shapes, limiting its applications to parts that do not require significant design complexity. Extrusion is perfect for more intricate detailing, but it tends to be more expensive as it requires specialized dies and more intensive processing, especially when it comes to making longer parts.

In terms of material usage, both processes can minimize waste, although roll forming is generally more efficient in this regard. Because it uses continuous strips of aluminum that are bent and shaped without the express need for trimming, material wastage is greatly reduced. This makes roll forming an attractive option for manufacturers focused on optimizing material usage and lowering costs in high-volume production runs. In contrast, extrusion may involve more waste, as parts that are extruded into intricate shapes may require trimming or additional processing to achieve precise dimensions, potentially leading to higher costs. Despite this, extrusion’s ability to craft custom shapes often outweighs the drawback of excess material usage when complexity is critical for the final design.

Conclusion

When deciding between extrusion and roll forming for aluminum aircraft components, it is important to consider both the design and production volume to optimize cost and functionality, but at the end of the day, both methods produce high-quality results. If you are seeking aluminum parts for your aircraft, we have you covered on Aerospace Unlimited. Here, you can expect to come across some of the best parts on the market, as we adhere to a strict NO CHINA SOURCING pledge and only stock products from trusted entities. Additionally, many items undergo testing and inspections by our in-house staff and third parties as necessary, helping us to further guarantee fit, form, and function. With our commitment to quality-assurance in mind, take the time to explore our offerings, and get in touch with our team to learn more about how we can serve as your reliable partner in procurement.

1. steven helmer
2. Posted on October 23, 2024
aviation