| Alloy Selection | 6063-T5 / 6063-T6 | Yield strength commonly about 145–214 MPa, depending on temper and wall thickness | Use for architectural, enclosure, heat-transfer, and general-purpose tubing | Offers good extrudability, surface finish, corrosion resistance, and availability | Review the mill test certificate and confirm compliance with ASTM B221 or an equivalent regional standard |
| Alloy Selection | 6061-T6 | Yield strength commonly about 240 MPa or higher for many standard product forms | Use when higher structural strength and machinability are required | Usually stronger than 6063, but generally more difficult to extrude and finish | Confirm temper, mechanical properties, chemical composition, and minimum wall capability |
| Alloy Selection | 6005A-T6 or similar structural alloy | Yield strength commonly about 225–250 MPa, subject to product form and specification | Use for structural tubes where strength-to-weight performance is important | Can provide a practical balance between strength, extrudability, and corrosion resistance | Request certified tensile-test results for the actual production lot |
| Dimensional Capability | Outside diameter and wall thickness | Common commercial tube sizes: approximately 10–150 mm outside diameter; wall thickness around 1–8 mm | Select the smallest wall that meets strength, stiffness, forming, and machining requirements | Wall thickness strongly affects weight, cost, die difficulty, and minimum-order quantity | Compare supplier tolerances with ASTM B221, EN 755, or the drawing tolerance specified in the purchase order |
| Profile Complexity | Hollow ratio, ports, ribs, and tight corners | Simple round or rectangular tubes generally have lower tooling risk than multi-void or thin-wall profiles | Use a simple cross-section unless the added geometry delivers measurable product value | Complex dies can increase tooling cost, trial iterations, scrap, and lead time | Request a die-feasibility review, extrusion-ratio assessment, and sample-section analysis |
| Raw Material Cost | Aluminum billet and conversion content | Budget using an aluminum index or billet surcharge plus conversion; finished extrusion pricing often varies by alloy, size, and quantity | Require a transparent formula separating metal price, conversion charge, finishing, packaging, and freight | Aluminum market movement can materially change quoted prices between order and shipment | Ask for the price basis, index date, surcharge mechanism, and validity period of the quotation |
| Conversion Cost | Extrusion conversion charge | Indicatively about USD 1.00–3.50 per kg for standard profiles; complex or low-volume profiles may be higher | Compare quotes only after normalizing alloy, profile weight, length, finish, quantity, and packaging | Conversion charges reflect press size, die complexity, production yield, labor, and energy | Request a line-item quotation and confirm whether die trials, cutting, inspection, and packing are included |
| Tooling Cost | Extrusion die and trial charges | Simple dies may be approximately USD 300–1,500; complex hollow or multi-port dies may exceed USD 3,000 | Obtain ownership, maintenance, storage, and replacement terms in writing | Die cost is usually a one-time expense but can be significant for low-volume projects | Confirm die life assumptions, trial quantity, revision policy, and whether the die remains dedicated to the buyer |
| Surface Finish | Mill finish, anodizing, powder coating, or mechanical finishing | Typical added lead time: 5–15 working days, depending on finish, color, batch size, and inspection requirements | Specify finish type, color reference, gloss, film thickness, and visible-surface requirements | Finishing can affect appearance, corrosion resistance, dimensional fit, and total cost | Approve a physical master sample and define acceptable color, gloss, coating thickness, and surface defects |
| Minimum Order Quantity | Commercial production quantity | Common starting quantities range from approximately 300–1,000 kg per profile; custom terms vary | Match the order size to die amortization, finish batch size, and annual demand | Small orders usually carry higher conversion, setup, finishing, and freight costs per kilogram | Request price breaks at sample, pilot, 1-ton, 5-ton, and annual-contract volumes |
| Sample Lead Time | First extrusion samples after drawing approval | Approximately 2–5 weeks for a standard profile; 4–8 weeks for complex tooling or multiple revisions | Obtain dimensional samples before approving mass production | Early sampling reduces the risk of discovering die, fit, or finish problems after production | Use a signed drawing, inspection plan, sample approval record, and change-control process |
| Mass-Production Lead Time | Extrusion only | Approximately 3–6 weeks after order, material, drawing, and die approval | Build a schedule with production, inspection, packing, and dispatch milestones | Lead time depends on press availability, billet allocation, die readiness, and order quantity | Ask for a written production schedule and a defined late-delivery escalation process |
| Finished-Goods Lead Time | Extrusion plus anodizing or powder coating | Approximately 5–9 weeks after all technical approvals; special colors or secondary operations may add time | Allow additional contingency for first production and external finishing capacity | Multiple process steps create additional scheduling and quality-control interfaces | Require process-by-process status updates and a final pre-shipment inspection date |
| Supplier Capacity | Press size, monthly capacity, and backup production capability | Small, medium, and large presses differ substantially in billet diameter, maximum profile size, and available tonnage | Select a press that can produce the profile without excessive extrusion ratio or scrap | Capacity and press suitability affect dimensional stability, productivity, and delivery reliability | Request equipment list, relevant profile references, capacity statement, and planned production location |
| Quality System | Manufacturing and inspection management | ISO 9001 certification is a useful baseline; product-specific control plans remain necessary | Supplier maintains documented incoming, in-process, final, and nonconformance controls | A certificate alone does not prove that the actual profile will meet the drawing | Audit the certificate scope, inspection records, calibration system, corrective-action process, and traceability |
| Dimensional Inspection | Outside dimensions, wall thickness, straightness, twist, length, and cut quality | Use drawing tolerances or applicable standards; critical fits may require tighter, separately agreed tolerances | 100% inspection for critical dimensions during first article; sampling after process capability is demonstrated | Extrusion dimensions can vary with temperature, die wear, cooling, stretching, and cutting | Review first-article inspection reports, calibrated instruments, CMM records, and capability data where applicable |
| Mechanical Testing | Tensile strength, yield strength, elongation, and hardness | Requirements depend on alloy, temper, wall thickness, and governing standard | Every production lot is traceable to a material certificate and, where specified, test results | Correct alloy designation does not guarantee the required temper or mechanical performance | Review certified test results and verify sampling frequency, test method, and lot traceability |
| Surface Quality | Scratches, die lines, dents, discoloration, pits, weld lines, and coating defects | Acceptance depends on viewing distance, visible surface, finish type, and agreed reference samples | Define cosmetic zones and defect limits before production | Visual acceptance can be subjective if the purchase specification is incomplete | Use approved limit samples, controlled lighting, inspection distance, and documented defect criteria |
| Traceability | Billet, heat, extrusion lot, finish batch, and packing identification | Each shipment should link finished bundles to production and material records | Maintain traceability from raw material through shipment | Traceability enables faster root-cause analysis and targeted containment if a defect occurs | Check bundle labels, heat numbers, certificates, inspection reports, and packing-list consistency |
| Logistics Cost | Packaging, inland transport, freight, insurance, and import charges | Long-length aluminum products can incur non-standard freight or dimensional surcharges | Compare total landed cost rather than ex-works or unit price alone | Freight and packaging can materially change the economics of low-density or long-length products | Request quotations under the same Incoterm, destination, length, bundle weight, and insurance assumptions |
| Commercial Risk | Payment terms, price validity, claim handling, and delivery performance | Common structures include deposit plus balance against shipment documents; terms vary by supplier and risk level | Use milestone payments linked to sample approval, production completion, and inspection | Commercial controls reduce exposure to late delivery, nonconforming goods, and unexpected surcharges | Include acceptance criteria, replacement or credit terms, response time, and documented change approval in the contract |
