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Differences Between Regular Aluminum and Extruded Aluminum

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Aluminum is used for a wide range of applications. For instance, it`s used in the construction industry, in making appliances, consumer goods, and so much more! 

Aluminum is a versatile metal that can be formed into many shapes, including flat sheets, sheets, foil, extruded, and extruded. This makes it ideal for use in industrial applications where it's often used.

Today we take a look at the differences between regular aluminum and extruded aluminum:

What is Extruded Aluminum 


Extruded aluminum is a type of aluminum processed through a series of die-cast machines. This process results in a wire shape, which is then heated and formed into a cooled sheet. Extruded aluminum sheets have less weight and can be formed into shapes that regular aluminum cannot.

What is Regular Aluminum 


Regular aluminum is also called "pitched" or "flat" grade, while extruded aluminum is often referred to as "round" grade, although there can be some overlap between both grades.

Major Differences 




The first difference between regular aluminum and extruded aluminum is in their composition. Regular aluminum is made from elemental aluminum, which contains no other elements in its structure. The primary ingredient in extruded aluminum is carbon. Carbon makes up approximately 50% of the weight of extruded aluminum, while elemental aluminum makes up only about 5% of the weight of extruded aluminum.

Production Process 


The other difference between regular and extruded aluminum is in the production process. Regular aluminum is produced using a casting process where molten metal is poured into molds and allowed to solidify. 

Extrusion occurs when molten metal is forced through a die (the same die used to make molds) at high pressure to create an object with a specific shape. This method allows for more precise shapes but requires higher temperatures than casting, so it can be done only under certain conditions (such as in a furnace).



The third difference between regular and extruded aluminum is that extruded products are generally more robust than those produced by casting methods because they have fewer internal stresses caused by imperfections in their design or manufacturing process.

Cross-section shape


A major difference between regular aluminum and extruded aluminum is the shape of their cross-sections. Regular aluminum is cylindrical, while extruded aluminum can be flat or round depending on the manufacturer's specifications.

Melting point


Regular aluminum has a lower melting point than extruded aluminum. This means that if you use regular aluminum, your items will retain their shape better than if they were made of extruded aluminum.



Regular aluminum can be machined easily, whereas extruded aluminum is much harder to machine because it has a higher density than regular metal.


Uses of Extruded Aluminum 


Extruded aluminum is used to manufacture household appliances, such as refrigerators, freezers, and air conditioners.

Extruded aluminum is an excellent heat conductor, making it ideal for use in cooktops and grills.

Extruded aluminum has a high strength-to-weight ratio, which makes it an excellent material for building boats, cars, and other vehicles.

Extruded aluminum is also used in industrial applications, mainly when there are high requirements for corrosion resistance or when chemical processes are involved in manufacturing. 

Uses of Regular Aluminum


Radiator panels: If you have an older car with a steel radiator, you can replace it with aluminum for a more modern look. The only downside is that the radiator will be more prone to warping in the winter.

Pipes and tubes: Aluminum is used in various piping and tubing applications, including food processing equipment, water systems, and hoses.

Cookware: Aluminum cookware is lightweight, durable, and easy to clean - all things you want in a kitchen utensil!

Light fixtures: While plenty of other metals could be used for light fixtures like steel or brass, aluminum is one of the most popular choices because it's lightweight and easy to install (no need for extra hardware).

In Conclusion


Any time you see extruded aluminum in any application, there is no substitute. Aluminum extrusions are made to exact tolerances and strength/ thickness/ weight ratios that allow for the only stronger and cheaper option compared to steel and other materials.

The most compelling advantage is that they can be formed into other shapes, some with curves that steel must be bent (which creates weak spots) to accomplish.

Overall, aluminum extrusions are more cost-effective and easier to fabricate than aluminum sheets and plates. Extrusion allows for a better design than a plate or sheet, but it also makes it cheaper to create something using aluminum extrusion than from a plate.