Extrusion Tolerances Standard extrusion cross-sectional dimensional tolerances

have been established and are published by the Aluminum Association.

They are given in Table 3.4. For other tolerances (such as length,
straightness, twist, flatness of flat surfaces, surface roughness, contour of
curved surfaces, squareness of cut ends, corner and fillet radii, and angularity)
consult Aluminum Standards and Data (11). Determining extrusion tolerances
can be more complicated than you�d think, so you may want to consult your
extruder. Closer tolerances can be held at increased cost; most extrusions can
be ordered to tolerances that are one-half the Aluminum Standards and Data
values. The 5xxx series alloys have larger tolerances than other extruded
alloys.
Fabrication For many applications, extrusions require little additional fabrication
once they�ve been shipped from the mill. Typical processes involve
cutting to length and fabricating holes. Extrusions may also be rolled to take
on curvature for camber or other purposes. However, if strains required by
the rolling process are great enough, they may produce cracking. This situation
can sometimes be avoided by rolling before the material is artificially
aged. For example, 6061 extrusions can be rolled in the -T4 temper and then
artificially aged at the mill to the -T6 temper, which is usually needed for
strength in the finished member. The -T4 temper has a minimum elongation
of 16% versus 8% for the -T6 temper, so cracking is more readily avoided
this way.
Extrusion Quality Assurance Extrusion mills will generally supply certification
meeting Aluminum Association requirements at no additional charge
if this is requested when the material is ordered. The number of samples for
mechanical tests is determined as follows: for extrusions weighing less than
1 lb/ ft [1.7 kg/m], one sample is taken for each 1,000 lb. [500 kg], or fraction
thereof, in a lot; for extrusions weighing 1 lb/ ft [1.7 kg/m] or more, one
sample is taken for each 1,000 ft [300 m], or part thereof, in a lot. Tension
tests are made for the longitudinal direction only, unless other prior agreement
is made with the supplier. The tensile yield strength, tensile ultimate strength,
and elongation are reported and must meet or exceed the minimum values
for these properties established in Aluminum Standards and Data.
Purchasers of extrusions ordered in mill quantities for building structures
often do not require identification marking. (Indexing, or identification, marks
[see above] extruded into the shape are, therefore, particularly useful to keep
track of producer and alloy.) Extruded structural shapes purchased from a
warehouse usually have identification marking consisting of the producer and
the alloy and temper. Suppliers may provide either continuous (at intervals
no greater than 40 in. [1,000 mm] along the length) or spot (once per piece)
marking.