Two of the most common methods for manufacturing processes are extrusion and roll forming, both of which are significant in manipulating metals and producing various items. This article will take you through the main differences between extrusion and roll forming, making you more familiar with the processes and their uses. This article will be helpful if you work with construction, automotive, or consumer goods industries, i.e., you will be able to understand more efficiently the complexities of different manufacturing processes. So, let us step into the world of extrusion and roll forming; we’ll highlight their strengths, limitations, and best practices for their specific applications. This section should elaborate on clear distinctions between these manufacturing processes, providing insights for your next project.
What are the Basics of Roll Forming?
Roll forming is a sheet metal forming technique that gradually bends a long metal strip. This is done by forcing the strip through a sequence of rolls that progressively shape it into the desired cross-section. Roll forming is suitable for the mass production of long linear and relatively simple cross-section components, including sheets, tubes, and profiles.
Roll forming is a technique for fabricating many parts. Metal is deformed into shape by rolling several fingers.
- Date: November 2022. Continuous Bending: Inserted Image: The Warden Roll Forming Machine. Inserted Image: The Warden Roll Forming Machine. The roll-forming system strongly enhances speed and productivity in manufacturing companies.
- Tooling Design: Roll forming is no different from using a die roll with pre-punched templates to a particular configuration (cut or shape). The order and disposition of the rolls in roll-forming establish the level of intricacy of the fence’s cross-sectional profile.
- Feed and Speed Control: To achieve the required degree of precision in the roll forming process, it is essential to ensure the feed of the metal sheet and the speed of the rolls are accurate.
- Roll Forming: Best Materials to Use: Roll forming is used on a variety of materials, including steel, aluminum, stainless steel, and even other non-ferrous metals. The structural and mechanical properties of the material, like thickness and ductility, determine whether the roll-forming process will be practical.
Some advantages of roll forming include maintaining high speed, producing consistent parts, and creating complex three-dimensional structures. On the contrary, it has its issues. For instance, special tooling is required to fulfill different profiles, and it becomes exceedingly difficult to create sharp corners.
A brief understanding of roll forming will help you gauge its appropriateness for your crucial manufacturing demands and place suitable orders for your business.
How Does the Roll Form Process Work?
Roll forming is a method of a continuous strip of metal fed through a set of rolls that gradually bends and shapes the material into a desired profile. The shape of the metal can be achieved by passing through the set rolls since each roll exerts a bending force that incrementally shapes the metal profile. The rolls are thus designed carefully to result in the desired shape and dimensions of the end product. This metal forming method enables high-speed production and fabrication of highly complicated geometry with good consistency in shape. Rotary piercing has its drawbacks. For instance, it is challenging to produce pieces with sharp corners, and several dies are required to produce other shapes. With a better understanding of roll-forming principles, you can correctly judge which method can be the best given the context of your manufacturing requirements for the project at hand.
What Materials are Best for Roll Forming?
Roll forming is an adaptable method that finds its application in various materials that can be crafted into different products. While it can work with different materials, specific materials are more commonly used and lend themselves well to the roll-forming process. Below are a few materials that are more suited for roll forming:
- Steel: Steel is one of the most common materials used in roll forming because of its strength and durability. Additionally, it can be formed into varied shapes and is thus widely used in automotive, construction, and even storage systems.
- Aluminum is also a relatively popular material in roll forming. It is resistant to corrosion and relatively light, which makes it ideal for use in industries like aerospace and transportation, where weight is a major consideration.
- Stainless Steel: Due to its corrosion resistance and appealing appearance, stainless steel is quite a popular metal. It is widely used in the food and pharmaceutical industries such as food processing machines and even medical equipment.
- Copper: This metal has excellent electrical and thermal conductivity. It is frequently used in electrical and plumbing work alongside decoration purposes.
- Coatings for Galvanized or Painted Substrates: Roll Forming enhances the ISO Coating’s mechanical properties, paint after rolling, and protects the materials from rusting.
It is worth mentioning that the choice of material should be focused on the objectives, project features e.g. price, properties, application. Working with a specialized roll forming manufacturer can also help you determine which material may be the best suited for your roll forming needs.
What are the Advantages and Disadvantages of Roll Forming?
Roll forming has proved to be useful but offers some advantages along with a few disadvantages for metal forming applications. These include:
Roll Forming Advantages:Â
- Cost-effective: Roll forming is cost-effective and highly productive, making it suitable for large-scale production runs.
- Versatility: Roll forming can produce complex cross-sectional shapes and profiles of consistently the same dimensions. It allows you to create new forms with different cross sections perpetually as per project specifications.
- Material Saving: Roll forming optimizes the use of material and waste, which is only crude, making it cost-efficient.
- Strength and Durability: The process increases the substance’s performing strength and durability by working hardening it during the forming stage.
- Efficient Material Handling: Roll forming eliminates the second integrative assembly step and the later assemblage for different cuts, thus saving time.
Roll Forming Disadvantages:
- High Initial Tooling Costs: The tooling costs of roll forming are comparatively higher than those of certain other metal forming processes, particularly for special, nonstandard, or several sophisticated long specially made tool forms. However, these costs can be recovered through savings from mass production.
- Limited Customization Abilities: Roll forming offers multiple design options; however, extreme complexity or odd shapes may not be possible to manufacture. This operation is best for long longitudinal shapes with uniform profile rotation about the axis.
Materials and Thicker Profile limits in roll forming compared to extrusion methods: Roll forming is usually applied to sheet metal with a maximum gauge of about 6mm. It also mainly applies to metals, including steel, aluminum, and stainless steel.
By comprehending the pros and cons of roll forming, one can consider other metal forming operations and select the one most suitable for the project’s requirements.
How Does Extrusion Differ from Roll Forming?
What is the Extrusion Process?
Metal extrusion refers to a metal-forming process that starts with a metal slug or blank. It involves heating to a certain temperature under extreme pressure and passing it through a die along the designated axis to create a continuous cross-section profile of the given shape. This progression permits the fabrication of elaborate sections with stable proportions and equal characteristics throughout the extrusion. Because of its better formability and thermal conductivity, extrusion is commonly employed for several metals, notably aluminum.
In the case of the extrusion process, the metal workpiece in the form of a slug and an aluminum alloy is employed again. Given the physical and geometrical characteristics of the extruded cross-section, the slug or the amount of metal to be extruded is cut. The process commences by pre-heating the slug to a temperature suitable for plastic deformation or slight heating around the room temperature. During the process, a hydraulic piston or an extrusion machine pushes the metal slug inside an extrusion chamber and through the die having the desired cross-section.
Other advantages cited include better dimensional accuracy, elimination of weldments, better throughput, consolidated and complex cross sections, and customization of features in the manufactured profiles. Due to the increasing demand for components with advanced design and lightweight features, the scope of the process is increasing in all sectors, including construction, automotive components, aerospace, and consumer goods.
Using the extrusion procedure, companies can produce continuous and consistent profiles with good strength, thus satisfying the requirements of their numerous projects.
How Does Extrusion Work for Aluminum and Other Metals?
The process of extrusion in forging metals can be considered one of the culprits responsible for constructing complex cross sections while maintaining a large amount of strength within the volume of the said cross-section. This technique’s application is vast and penetrates a multitude of domains, such as construction, automotive, aerospace, and consumer goods.
The process can be summarized simply. The heat is applied to a metal billet (aluminum in this case), and the slug is placed in the hollow section of a hydraulic press, which forces metal through a die with the required shape. Under a high temperature, the slug is pushed through a hydraulic-shaped die, and as the die pushes out one side of the slug, it takes the shape of the die. The metal forced through the die is then cut per the requirements and allowed to cool off.
Metal extrusion can be used to manufacture cost-effective and efficient designs. Each extruded component will have the same dimensions and a smooth surface, which is nice. Also, cooling time, speed, and pressure can extensively change the mechanical properties of the end result, which helps make a customized product.
It allows a single step to create intricate designs instead of multiple processes which is great and efficient. Reduced amount of time spent during the fabrication process and savings in expenses will not go amiss. And of course due to the extrusion process, it becomes easy to obtain and produce strong profiles that will have extensive amounts of durability.
I’ll be able to give you an in-depth explanation of roll forming and extrusion, describe the uses of extruded aluminum in buildings, automotive, and consumer product manufacturing, and place it in relation to the other operations or metal forming processes, particularly rolling. Let’s go on with our fascinating journey to understanding various techniques of metal forming.
Comparing the Metal Forming Capabilities
It’s worthwhile to note the specific advantages and applications of these two methods before comparing the metal shaping capabilities of extrusion and roll forming. There are cases in the extrusion method where a lot more is accomplished than through roll forming. I think three main aspects separate the two – i.e., the complexity of shapes achieved, the strength of the final product, and last but not least, the cost of production. However, what can be achieved in extrusion limits rolling because rolling makes long continuous sections with constant cross sections? By rolling aluminum, we can expand its usage into construction, automotive, consumer electronics, and many other markets, owing to its strength, lightweight, and adaptability. In the coming sections, while looking into the application of extruded aluminum in the sectors above, we will be looking deeper into the specifics of the extrusion process in contrast to fogging. Be with us for a far more in-depth understanding of these metal-forming methods.
Why Choose Extrusion Over Roll Forming?
What are the Key Differences?
As someone versed in metal shaping methods, I want to highlight the significant differences between extrusion and roll forming. The main difference can be observed in the shaping of the workpiece: when extruding, one pushes the piece through a die, while in roll-forming, one passes the sheet metal through several rolls to perform an incremental forming process. Thanks to extrusion, however, a lot of complicated designs with various cross-sectional shapes can be manufactured. Still, roll forming is optimal only where long shapes with constant cross-sections are required. Also, implying that they can produce a more aesthetically pleasing surface finish and better fitting items, extrusions can maintain closer tolerances than roll forming. Now that these distinctions have been described, you are better positioned to choose among different metal-forming processes for your unique application.
When is Extrusion More Beneficial?
Extrusion is shown to be advantageous in a variety of cases for some applications. Let’s take a look at some of the areas where extrusion is preferred, especially in single-component extrusion of complex shapes:
- Complex Geometries: The extrusion process is particularly useful for manufacturing components with more geometrically complex shapes, such as custom profiles or hollow sections. Because of its capabilities, components with complex cross sections can be manufactured, which might otherwise be difficult with other methods.
- Highly Customized Designs: Customers can achieve designs suited to their requirements after extrusion. This wide range of design capabilities permits the addition of different characteristics, such as grooves, holes, or flanges, allowing flexibility and adjustability for diverse project specifications.
- Uniform Material Properties: Since the extrusion process is performed in one shot, the material characteristics will be the same throughout the length of the profile, which leads to uniformity with regard to the structural cross-section. This uniformity is critical in applications where there are tighter tolerances for the dimensions, strength, and integrity of the materials.
- Cost-effective for High-Volume Production: Extrusion is low-cost for high-production quantities due to its ability to produce profiles continuously. The speed of the process and reduced material wastage make it more economical for production on a large scale.
Utilizing the advantages of extrusion in these cases allows the manufacturers to have exact, tailored, and economical answers for their concerned applications.
What are the Applications of Extruded Aluminum?
How is Extruded Aluminum Used in Construction?
Extruded aluminum is also widely used across the construction industry for many reasons. Being a vital component, it has a wide variety of applications. Here are some significant uses of extruded aluminum in construction, focusing on why it’s so popular for tensile strength, lightweight, and many more:
- Structural Components: Aluminum extrusion profiles are commonly utilized for structural elements in buildings, such as beams, columns, and trusses. Aluminum is a common choice, especially in extrusion, which stands for load-bearing structures, because of its high strength-to-weight ratio and light weight.
- Window and Door Frames: Aluminum is frequently extruded to manufacture door and window frames and curtain walls in commercial and residential buildings. Because of its corrosion resistance, durability, and design flexibility, aluminum allows for the creation of modern and energy-efficient fenestration systems.
- Architectural Finishes: Architectural details that include handrails, sunshades, and other features of the façade are decorative elements that can be created in various shapes and sizes by extruding aluminum profiles. These features accent the beauty of a building while helping to provide shade and safety, which is functional.
- Roofing and Cladding: Aluminum panels are easy to use for roofing and cladding due to their lightweight and strength. The addition of aluminum panels also enhances the structure’s strength and ability to remain intact from strong winds, water, and the environment around it.
- The following relates to HVAC construction components: HVAC ductwork would utilize aluminum extrusions due to aluminum’s structural and thermal conductivity properties. HVAC systems would consist of extruded aluminum profiles for ductwork, heat exchangers, and other components, as they possess good thermal properties and are coated with environmentally safe materials.
Placing aluminum extrusions into HVAC ducting systems would be a good practice. Aluminum extrusions are easy to fabricate, strong, look nice, and are highly durable. Architects, engineers, and builders love using aluminum extrusions, which can be fabricated into virtually any shape.
What Role Does Extruded Aluminum Play in Automotive Manufacturing?
Extruded aluminum is indispensable to the automotive industry as it helps to improve the performance, efficiency, and safety of vehicles in many ways. For instance, car frames, structural components, and body panels are constructed using aluminum extrusions because of their lightweight and high strength-to-weight ratio properties. As a consequence, the overall weight of the vehicle is decreased, which not only leads to better fuel efficiency but also better handling and reduced emissions. Besides, extruded aluminum has very good corrosion resistance, increasing the life span of automobile parts. Also, its excellent thermal conductivity can be effectively used in multiple automotive systems for heat dissipation. All in all, the use of extruded aluminum in the production of automobiles translates to the production of lightweight, fuel-economical, and eco-friendly vehicles.
Why is Extruded Aluminum Popular in Consumer Goods?
The ability to extrude aluminum has found uses across a variety of industries. Let us delve into this: why choose extruded aluminum?
- Strength-to-Weight Ratio: Consumer goods are always looking for durability coupled with lightweight structures. Extruded aluminum provides a very good strength-to-weight ratio, which makes it an excellent fit for the said use cases. In fact, due to its low weight, products are easy to carry and transport, improving the overall user experience.
- Cost reduction: The extrusion technique allows designers and manufacturers to design complex geometric shapes and cross sections, making it easier. This also opens the door to mass-produced bespoke products due to the cost-effective production of intricate consumer goods.
- Stimulation inhibition: Aluminium automatically forms an oxide layer that helps thwart corrosion. Coupled with the properties of extruded aluminum, this aids in the increased life span of a product and allows it to withstand different environmental conditions and moisture.
- Thermal Protection: Products made of extruded aluminum have very high thermal conductivity. This aids products that emit heat during use, allowing them to be cooled effectively. Additionally, this is beneficial when the consumer goods are electronics or appliances with heat-generating components.
- Recyclability: Aluminum is a metal that is virtually 100 percent recyclable without losing any of its characteristics or functionality. The fact that extruded aluminum can be recycled encourages the use of this metal in consumer products and responds to the growing trend for environmentally friendly goods.
- Cost-Effective Production: The extrusion process contributes to the efficient and economical production of components made of aluminum. This low cost contributes to the growing interest of manufacturers in extruded aluminum to minimize production costs while still guaranteeing quality.
These factors have made extruded aluminum an increasingly exotic material in the manufacture of consumer products in such sectors as the automotive, electrical, appliances, and furniture industries. Thanks to its exceptionally lightweight structure, strength, versatile applications, resistance to corrosion, thermal conduction, conductivity, ability to be recycled, and cost of the materials, a range of robust, reliable, and eco-friendly consumer products can be produced.
How Does the Rolling Process Compare to Extrusion?
Understanding the Rolling Process
Often used in industry to modify metal sheets, strips, and plates into desired thicknesses or shapes, the rolling process entails introducing a metal sheet between a series of rollers and passing it through them. This process results in the reduction of the sheet’s depth or modification of its dimensions. Rolling differs from extrusion in the fact that it applies force to make the metal more elongated without the necessity of a die. Extrusion requires a die to push the metal through, and in this case, a particular shape can be obtained only in the cross-section of the die. Due to the mechanical deformation of materials, greater strength, more excellent surface finishing, and greater accuracy of dimensions can be achieved.
The rolling process has many benefits when looking at roll forming vs extrusion.
- Modification Of Mechanical Properties: Metal rolling reduces the metal’s microstructure, enhancing its mechanical properties, such as strength, hardness, and toughness.
- Improved Surface Quality: Rollings surface preparation adds to material quality by refining and cutting excessive roughness, bringing more beauty to both the appearance and usage of the metal.
- Greater Dimensional Control: Adjusting the parameters for rolling allows the manufacturer to achieve the requisite thickness and dimension for each layer of metal, guaranteeing that the required specifications are met for all the layers in the final product.
- Cost-Effective: Rolling greatly enhances the manufacturing process of large metals, requires little material to waste, and is highly efficient in production.
- Wide Range of Applications for Extruded vs. Roll-formed Products: The rolling process uses a variety of metals, such as steel, aluminum, copper, and alloys of these metals. It is used in several industries, such as automobiles, construction, space, and production.
It is vital for any manufacturer wanting to enhance his manufacturing processes and take maximum advantage of this rolling process to look into the details of it. This means using the advantages of the rolling process to produce very suitable metal products to meet the needs of the different industries, which are very strict.
What are the Strengths of Cold Rolling?
A primary method of metal fabricating is cold rolling, and several advantages can be pointed out to simplify its selection as a working method:
- Bitter followers of sporting events and masses of people engaged in athletic activity. Cold rolling increases the material’s hardness, strength, and durability, making it wear-resistant, fatigue-resistant, and resistant to deformation.
- Improved Surface Finish: Cold rolling results in a better surface finish of metal products with better and uniform surfaces. This is critical for situations where design and surface quality are important, like in the car and consumer electronics industry.
- Through the application of cold rolling, the manufacturer can achieve accurate dimensions and the required finite tolerances for metal products. This brings about uniformity and accuracy of the finished components intended for use in applications where precise measurements are critical.
- Cold Working Strengthening: The low-temperature deformation called cold rolling undergone by the metal during cold rolling increases its strength through work hardening. So, it is possible to make stronger but lighter and performance-oriented parts.
- This method applies to most other metals and alloys, including copper, aluminum, and steel, and it is useful for manufacturers for fabricating components in different industries, ranging from automotive and aircraft to construction and smithery.
Producers can obtain precise dimensions, enhanced mechanical properties, and a better surface finish on their metallic products through cold rolling. This gives a reasonably cheap and adaptable approach to fabricating quality components that can withstand the tough requirements of different sectors.
What Makes Extrusion a Preferred Choice for Metal Parts?
Metal parts can be manufactured through casting, stamping, or cutting, but manufacture through extrusion molding seems to be the most highly favored method. The process can achieve great control regarding the different shapes that can be made and the great details that can be incorporated into the final product. As a result, the finished products have the same properties and uniform composition, bringing about outstanding component performance. Furthermore, extrusion is a relatively cheaper since it preserves material and decreases post-production costs. As a result, it is optimal for mass production. The ease of operation, accuracy, and low cost offered by the extrusion process is why manufacturing metal parts is the most widely used method in various industries.
Frequently Asked Questions (FAQs)
Q: Do you have any distinguishing traits, or do roll forming and extrusion seem broadly similar?
A: Roll forming and extrusion may both be recognized as two distinct metal-appropriate processes. Roll forming necessitates feeding a flat sheet of metal through a succession of rollers to shape it to the desired form, while extrusion is a process in which heated metals are pushed through a die to obtain the required shape. Roll forming is usually sent through a long profile and strip, while extrusion can be sent through a small, compact die.
Q: Is the roll form aluminum process different from aluminum extrusion?
A: Roll-form aluminum comprises a flat sheet of aluminum fed through a series of rollers to yield an aluminum sheet of an identical cross-section. Aluminum extrusion, however, is a process that includes pushing a heated material through a die to acquire a specific shape in the aluminum inlet. For more complex shapes, extrusion is very useful and works for shorter lengths; on the other hand, roll forming is suitable for longer and continuous profiles that are not complex-shaped cross sections.
Q: What are the benefits of using extrusion instead of a roll-forming process?
A: Extrusion has several benefits over roll forming. To begin with, more complex and intricate profiles can be created. Furthermore, material properties are improved due to the heating during the process. Also, hollow sections can be manufactured by extrusion. The extrusion process also accommodates changes in design much more readily and is probably more economical regarding shorter runs. Moreover, due to their production procedures method, extruded parts tend to have smoother surfaces than roll-formed parts.
Q: What does sheet metal fabrication mean considering roll forming and extrusion?
A: In the general sense, sheet metal fabrication is an encompassing term that includes roll forming, amongst others. While roll forming specifically makes sheets into long, continuous sections, extrusions form the shape from a starting material that is a billet or ingot. Roll forming and extrusion are important forming of metal processes that lie in the wider discipline of sheet metal fabrication. However, they apply more for specific manufacturing purposes because they have different strengths.
Q: In defining technology, what parameters are key in choosing between roll forming and extrusion?
A: In light of the factors listed previously, one needs to consider the intricacy of cross-section shape, volume of output, material type, final cross-section length, surface quality, desired tensile strength, and economics of roll forming and extrusion. Normally, roll forming has been found applicable for mass manufacturing of long and simplex cross-sectional shaped products, while extrusion has had more application for short and cross-sectional shaped products that may have intricate detailing features or material requirements. The other considerations that ought to be taken into consideration include the machines to be used, cost of tools and the estimated scrap to be generated.
Q: What is the role of an extrusion press in the extruded aluminum process?
A: The extruded aluminum process involves employing an extrusion press with an aluminum billet heated and forced through a die under high pressure. The aluminum takes on the created cross-section when shaped through the die and ejected. Depending on the die used, the extrusion press can produce solid and hollow profiles of different sizes. Because the aluminum went through the process, it became re-crystallized, normalized the newly formed substance, and modified its hardness, among other characteristics.
Q: What are some shortcomings of roll forming in comparison to extrusion?
A: Roll forming cannot extrude hollow sections, has some limitations in producing various shapes, and may experience issues with springback for some materials. Also, roll forming is used with sheet metals chiles extrusion can adopt any form of raw material. Further, roll forming may require many threading machine set-ups for different profiles while extrusion may just change the die if a design change is necessary.
Q: Between roll forming and extrusion, how does the overall selection of material differ for each?
A: The process of selecting materials for roll forming and extrusion can be quite different depending on the technique. Roll forming involves processing sheet metals such as steel, aluminum, and other alloys, which provides better formability. On the other hand, extrusion, especially aluminum extrusion processes, may use many more types of alloys and may be able to combine different materials in certain cases. The metal is selected based on the sought end state, possible deformation, and the needs of the processes.
Reference Sources
1. Overview of extensive deformation processes, enabling techniques, and their associated problems
- Authors: K. Santosh, K. Rakesh
- Publication Year: 2022
- Journal: i-manager’s Journal on Future Engineering and Technology
- Citation: (Santosh & Rakesh, 2022)
- Summary: The paper reviews several large deformation operations like extrusion and rolling, explaining their benefits and challenges. The main outcomes were:
- Cost-Effectiveness: Extrusion’s manufacturing costs have been found to be low, considering the expense of rolling or the additional material and energy demand when working on complex shapes.
- Material Utilization: Nearly all extrusion processes can utilize most materials because close-shaped components are formed, thus reducing excessive machining processes.
- Flexibility in Design: The manual further explains that extrusion is potent because it opens up a wider scope of design, including numerous complex geometries that may not be easily produced via rolling.
- Production Speed: The rolling and extrusion process can achieve shorter manufacturing lead times, especially when there are many products to be manufactured, as long segments of the material can be produced.
2. Aluminum matrix nanocomposite fabrication has been successfully done using a twin screw rheometer and also using the hot rolling technique.Â
- Authors: S. Behnamfard et al.
- Year of Publication: 2019
- Journal: Materials Science and Engineering: A.
- Citation: Behnamfard et al, 2019.Â
- This work aimed to analyze the hot-rolling and the twin-screw rheo-extrusion processes as means for working with nanocomposites Al matrix. The main conclusions reached include:
- Microstructural Evidence: The rheo-extrusion process produced a finer microstructure with better mechanical properties than hot rolling.
- Improved Fabrication Methods: The research findings show that the mechanical properties of composites fabricated using extrusion were enhanced due to better nanoparticle dispersion throughout the synthesized matrix.
- Economics: The authors discovered their extrusion technique required less energy than rolling, especially for producing intricate shapes and designs.
3. Some Methods of Channel Production are Compared
- Authors Kind: A. Vorontsov
- Publication Year: 2021
- Journal Name: Russian Engineering Research
- Citation: Vorontsov, 2021
- Summary: This particular paper compares quite a few methods of channel production, such as extrusion, rolling, and the use of conventional die and dolly processes. The main conclusions that the authors have reached include:
- Notes on Efficiency in Production: The practice shows that in some instances, it is easier to mold channels of different thicknesses via extrusion, as it is more efficient while minimizing material wastage during the production process.
Main Benefits of Extrusion about Rolling
- Material Utilization: Extrusion technologies usually consume less material than rolling processes, which produce near-.net shapes that require considerably smaller machining operations (Behnamfard et al., 2019; Santosh & Rakesh, 2022).
- Design Flexibility: With extrusion different complicated sections or profiles which might not be achievable by rolling processes can be made (Santosh & Rakesh, 2022).
- Time: Extrusion processes may be relatively more rapid especially when large volumes are produced as long continuous sections of the same material can be produced continuously (Santosh & Rakesh, 2022).
- Microstructure: The quality and mechanical properties of rolled materials are poor due to the uncontrolled microstructure of the material while microstructure of materials extruded is more controlled and hence enhanced mechanical properties are expected (Behnamfard et al., 2019).
- Cost: In certain processes like recoiling, more energy is required as more temperature is needed than used in extrusion where heating is naturally more expensive (Behnamfard et al., 2019).
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