Impact Extrusion

What is Impact Extrusion

Impact extrusion is a highly efficient manufacturing technique used to produce various products. Which is one of the fastest ways to get to near-net shape for many parts and components. Our process begins with a lubricated metal slug—also called a blank or a puck—that is placed in a die cavity. The metal puck is struck with a punch powered by a mechanical or hydraulic press. This forces the metal to flow into a shape or position almost instantly. In this post, we will cover its working principles, materials used, surface treatments available, advantages, disadvantages, applications, and future trends.

How impact extrusion works？

Impact extrusion is a manufacturing process used to create hollow metal parts with thin walls. Here’s a detailed look at how it works:

TYPES OF IMPACT EXTRUSIONS

Reverse Impacting

In reverse-impact extrusions, metal flows backwards—in the opposite direction in which the force is applied—and then around the punch. The resultant part has a shape similar to that of the punch.

Forward Impacting

In forward impact extrusions, the punch pushes the material through an aperture inside the die. The punch fits into the cavity to the point that the metal cannot flow backward.

Combination Impacting

Combination Impacting is the combination of two impacting processes. Making more complicated shapes for parts Combination impacting pushes metal through a hole and as well backward around the punched.

The Basics of Impact Extrusion

Impact Extrusion is a precise and efficient machining process that produces high-quality cylindrical parts by rotating a workpiece against a cutting tool. This technology is crucial in various industries, from automotive to aerospace, due to its ability to create intricate and accurate components.

1. Material Placement

The process begins with a slug or blank of metal, typically a soft, ductile material like aluminum, copper, lead, zinc, or tin. This slug is placed in a die, a tool that shapes the material.

2. Punch Movement

A punch, a solid piece of metal, then strikes the slug at high speed and pressure. The impact force is usually generated by a mechanical or hydraulic press.

3. Metal Flow

Upon impact, the metal flows around the punch and into the die cavity, taking the shape of the die. The metal’s flow is primarily in the radial direction, allowing the material to spread thinly and evenly.

4. Die Action

The die, which is precisely machined to the desired shape of the final product, confines and directs the flow of the metal. Depending on the die design, the process can create various shapes, including cylindrical, conical, or complex profiles.

5. Ejection

After the punch retracts, the newly formed part is ejected from the die. This step may involve additional mechanical systems to ensure the part is removed without damage.

The Basics of Impact Extrusion

Several factors affect the quality and efficiency of the impact extrusion process:

Temperature

Although impact extrusion is generally a cold-working process (performed at room temperature), the temperature of the material can influence its ductility and flow characteristics. Preheating the metal can sometimes be beneficial, especially for harder materials.

Pressure and Speed

The pressure exerted by the punch and the speed at which it strikes the slug are critical. Higher pressures and faster speeds typically result in better material flow and more precise shapes but require robust machinery and tooling.

Lubrication

To minimize friction and prevent damage to the die and punch, lubrication is often applied to the slug and die surfaces. This also helps in the smooth ejection of the final part.

Advantages and Disadvantages of Impact Extrusion

Vorteile

Preparation:

Fast production rates.

Material Utilization:

Minimal waste compared to other methods.

Low Cost:

Economical for large-scale production.

Precision:

High dimensional accuracy and consistency.

Disadvantages

Equipment Investment:

Requires significant initial capital.

Material Requirements:

Only certain metals are suitable.

Limited Scope:

Best for specific shapes and sizes.

MATERIALS FOR IMPACT Extrusion

Material selection is crucial for the success of the impact extrusion process. The choice of material affects the ease of extrusion, the quality of the final product, and the range of possible applications. Here, we will discuss the common materials used in impact extrusion, their characteristics, and typical grades or alloys.

Aluminium

Copper

Lead

Zinc

Titan

Aluminium

Copper

Lead

Zinc

Titan

Surface Treatment in Impact Extrusion

Surface treatment is a vital aspect of the impact extrusion process, significantly affecting the performance, durability, and appearance of the final product. Proper surface treatment can enhance properties such as wear resistance, corrosion resistance, and aesthetics. Here, we will explore the importance of surface treatment, common methods, and their impact on product performance.

Importance of Surface Treatment

Surface treatment is crucial for several reasons:

Enhances Durability: Increases resistance to wear and tear, extending the product’s lifespan.
Improves Corrosion Resistance: Protects against environmental factors, preventing rust and degradation.
Optimizes Surface Properties: Improves hardness, reduces friction, and enhances conductivity.
Aesthetic Appeal: Provides a polished, uniform appearance, improving the product’s marketability.
Functional Performance: Enhances specific properties required for the product’s application, such as electrical conductivity or reflectivity.

Common Surface Treatment Methods

Mechanical Polishing

Purpose: To smooth the surface and improve its appearance.
Process: Involves abrasive techniques to remove surface irregularities and achieve a mirror-like finish.
Applications: Used for products requiring a high-gloss finish, such as consumer goods and decorative items.

Chemical Treatment

Purpose: To clean and prepare the surface for further processing.
Process: Involves using acids, alkalis, or other chemicals to remove oxides, scale, and contaminants.
Applications: Pre-treatment for plating or coating processes, ensuring better adhesion and uniformity.

Electroplating

Purpose: To deposit a thin layer of metal onto the surface.
Process: Involves using an electrolytic solution to deposit metals such as chromium, nickel, or gold onto the product.
Applications: Used in electronics, automotive, and jewelry for enhanced corrosion resistance, electrical conductivity, and aesthetics.

Shot Peening

Purpose: To improve fatigue strength and resistance to stress-corrosion cracking.
Process: Involves bombarding the surface with small spherical media to induce compressive residual stresses.
Applications: Used in aerospace, automotive, and heavy machinery components to enhance durability.

Anodizing

Purpose: To increase the thickness of the natural oxide layer on the surface.
Process: An electrochemical process that enhances corrosion resistance and allows for dyeing the surface in various colors.
Applications: Commonly used for aluminum products in the aerospace, automotive, and consumer electronics industries.

Powder Coating

Purpose: To apply a protective and decorative coating.
Process: Involves applying a dry powder to the surface and curing it under heat to form a durable finish.
Applications: Widely used in the automotive, appliance, and furniture industries for a high-quality, long-lasting finish.

Passivation

Purpose: To enhance corrosion resistance.
Process: Involves treating the surface with a nitric or citric acid solution to remove free iron and form a passive oxide layer.
Applications: Used for stainless steel and other corrosion-resistant alloys in medical and food processing equipment.

Surface Treatment Impact on Product Performance

Wear Resistance

Surface treatments like electroplating and anodizing can increase the wear resistance of products used in harsh environments, making them more resilient in such conditions as corrosion.

Corrosion Resistance

Corrosion-resistant treatments such as anodizing, passivation, and powder coating provide crucial corrosion protection to products subjected to extreme environments.

Aesthetics

Aesthetics Mechanical polishing, anodizing, and powder coating enhance the aesthetic value of products to make them more desirable to consumers.

Functional Properties

Electroplating with metals like gold or silver enhances electrical conductivity, essential for electronic components.

Anodizing can improve thermal conductivity and emissivity, beneficial for heat dissipation applications.

Choosing the appropriate surface treatment depends on several factors:

Material Type: Different materials respond differently to surface treatments. For example, aluminum is commonly anodized, while steel might be electroplated or powder coated.
Application Requirements: Consider the specific performance needs such as corrosion resistance, wear resistance, electrical conductivity, and aesthetic requirements.
Cost and Production Volume: Some surface treatments are more cost-effective for large production volumes, while others may be better suited for smaller, high-value items.
Environmental Considerations: Eco-friendly processes and materials are increasingly important in modern manufacturing.

Applications of Impact Extrusion

Impact extrusion is a versatile manufacturing process used across various industries due to its ability to produce high-quality, lightweight, and complex metal parts. Here, we explore the specific applications of impact extrusion in different sectors:

Automotive Industry

Aerospace Industry

Electronics Industry

Packaging Industry

Medical
and Pharma-ceutical Industry

Consumer Goods

Energy Industry

Automotive Industry
Aerospace Industry
Electronics Industry
Packaging Industry

Components:

Engine Parts: Cylinders, pistons, and valve lifters are often produced using impact extrusion due to the need for high strength and precise tolerances.
Heat Exchangers: The process is ideal for creating thin-walled tubes and fins used in radiators and intercoolers.
Brackets and Supports: Lightweight yet strong components that support various systems within the vehicle.

Benefits:

Weight Reduction
Strength and Durability
Precision

Components:

Structural Parts: Frames, ribs, and stiffeners used in aircraft fuselage and wings.
Landing Gear Components: Strong and lightweight parts that need to withstand high-impact forces.
Heat Shields and Panels: Thin-walled components used in thermal protection systems.

Benefits:

High Strength-to-Weight Ratio
Corrosion Resistance
Precision Manufacturing

Components:

Enclosures and Housings: Cases for electronic devices such as smartphones, laptops, and tablets.
Connectors and Contacts: Precision parts used in electrical connectors and interconnects.
Heat Sinks: Efficiently dissipate heat from electronic components.

Benefits:

Thermal Management
Miniaturization
Aesthetic and Functional Finishes

Components:

Metal Cans and Containers: Beverage cans, aerosol cans, and food containers.
Tubes: Collapsible tubes for products such as toothpaste, creams, and gels.

Benefits:

Seamless Construction
High-Speed Production
Recyclability

Medical and Pharmaceutical Industry
Consumer Goods
Energy Industry

Components:

Medical Devices: Housings and components for devices such as inhalers, insulin pens, and surgical instruments.
Implants: Structural components for orthopedic implants and dental implants.

Benefits:

Biocompatibility
Precision and Cleanliness
Customizability

Components:

Sporting Goods: Components for items like golf clubs, fishing reels, and bicycle frames.
Appliances: Structural and functional parts for household appliances.
Tools: Durable and lightweight hand tools and power tool components.

Benefits:

Enhanced Performance
Durability
Aesthetic Appeal

Components:

Battery Housings: Casings for lithium-ion and other batteries used in electric vehicles and portable electronics.
Heat Exchangers: Components for systems in power plants and renewable energy installations.
Fuel Cells: Parts used in hydrogen fuel cells and other energy generation devices.

Benefits: