Aluminum is a key material in modern manufacturing, especially in the transportation industry, because it's lightweight, strong and recyclable. As vehicles and other systems become more advanced, manufacturers need strong, lightweight aluminum parts in multifaceted shapes. This demand calls for new approaches to aluminum component production.
One of the most common shaping methods is extrusion, which shapes heated aluminum by forcing it through a shaped opening called a die to produce a continuous piece with a specific cross-sectional profile. Extrusion can produce everything from rods and tubes to complex structural parts used in vehicles, buildings and machinery.
However, making stronger and more complex aluminum profiles can slow production and increase costs. To address this, the National Research Council of Canada's (NRC) METALTec Industrial R&D group led a 4-year initiative to help manufacturers produce parts with variable shapes and better mechanical properties. The resulting advanced extrusion technologies create high-performance parts more efficiently and at lower cost.
Innovating the extrusion process
To achieve these advancements, a team of NRC researchers led by Jean-François Béland, Research Officer and subject matter expert, and supported by Julie Menier, Project Manager, developed a virtual tool that digitally models the extrusion process. This work was done in collaboration with a team from École de technologie supérieure, Université de Sherbrooke and Rio Tinto, a member of the METALTec Industrial R&D group.
Such digital tools allow researchers to test designs before building physical prototypes, saving time and money. The team also created a new additive manufacturing technique for tool steel by adding complex cooling channels to improve productivity. Together, these innovations enhance the efficiency and performance of the extrusion processes, particularly for transportation applications, while meeting industry standards.
Creating stronger, smarter aluminum components
The team developed new algorithms for simulation tools to test extrusion manufacturing processes where the profile cross-section change during extrusion. For example, adding or removing material can thicken or change the profile as it is extruded. These new algorithms are as accurate as standard methods while being 50 times faster. This virtual tool can model complex extrusion processes involving varying cross-sections, enabling the design of lighter and stronger components with less trial and error. The researchers also developed models that predict how aluminum's internal structure (its crystal orientation) changes during extrusion. By adjusting the die design to reorient crystals during extrusion and balance the metal flow, they improved formability up to 30% for certain extruded alloys. This approach allows experts to make consistent, stable profiles with superior mechanical properties for cold forming applications such as bending and hydroforming.
Boosting productivity and efficiency
If an alloy overheats during extrusion, the process must slow down to maintain part quality. To overcome this limitation, the team explored ways to extract heat during extrusion.
Using a wire-arc additive manufacturing (WAAM) method, they added complex cooling channels into an extrusion die to remove the heat as the aluminum profile exits the die, allowing for faster extrusion. While similar techniques exist for steel, the WAAM method is faster and uses more cost-effective materials. When tested on a high-strength alloy (AA6011), the die with cooling channels extruded 30% faster—a major step toward improved efficiency.
Collaboration and impact
This initiative succeeded thanks to collaboration with École de technologie supérieure de Montréal, Université de Sherbrooke and Rio Tinto's Arvida Research and Development Centre in Saguenay–Lac-Saint-Jean. The project was funded through the NRC's Collaborative Science, Technology and Innovation Program (CSTIP) under the Advanced Manufacturing program, with additional support from METALTec industrial partners, the Centre québécois de recherche et développement de l'aluminium, and the Natural Sciences and Engineering Research Council of Canada.
The research has already led to 7 peer-reviewed publications and helped train 10 highly qualified personnel, strengthening Canada's expertise in advanced manufacturing and materials engineering.
Shaping the future of manufacturing
Through this work, NRC researchers are helping manufacturers produce aluminum components that are stronger, lighter and more complex—while keeping production efficient and cost-effective. These advances will benefit industries across Canada and beyond, driving innovation in transportation and supporting the shift toward more sustainable, high-performance products.