Development of Low-Weight and High-Strength AA6005A Extrudates Intended for Modern Architecture and Design of Innovative Die for Extrusion Process

In the realm of modern architecture, the demand for materials that combine strength, durability, and aesthetic flexibility is ever-growing. Addressing this need, this paper presents a study on the innovative use of aluminum extrudates in construction. Focusing on the AA6005 alloy, which is known for its excellent balance of strength, corrosion resistance, and weldability, this research delves into the development of an extrusion process that yields thin-walled, lightweight, yet high-strength structural components. Using FEM simulations, a new extrudate of the AA6005A was developed. It is compatible with standard façade systems, with high-strength properties and a weight reduced by 20% compared to that of conventional extrudates made of the AA6063 alloy. Using CAD engineering and FEM simulations of aluminum extrusion process, an innovative die was designed for the extrusion process, ensuring uniform flow of metal from the bearing and minimizing the elastic deflection of the die. This resulted in an increase in the extrusion velocity of thin-walled extrudate from AA6005A by 24% compared to conventional profiles extruded from AA6063. As part of the research, a trial test was carried out in production conditions and the quality of the extrudates was tested by 3D optical scanning, mechanical and structural properties tests, and microstructure observation.