Thunderbird Metals impact extrusions are superior to other metal-forming processes


Benefits of using impact extrusion

The near-net shape of aluminum and steel impact extrusions delivers many benefits that other metal-forming technologies simply can't match. Frequently a single-stroke process, impact extrusion can lower the cost while improving the quality of metal parts.


Metal impacting creates parts faster

Depending on the size and complexity of the part as well as the equipment producing parts, production rates can reach up to 4,000 pieces per hour. Impacted parts also are instantly ready for application because there is no flash to be machined away and no sand, scale, or parting lines to be removed.


Metal impacting reduces costs in several ways

The metal impact extrusion process produces components at a cost lower than other metal-forming technologies. Impacting produces near-net-shape components with less waste than other metal-fabrication processes. Compared to casting and machining, metal savings alone justify the adoption of impact extrusion. In addition, a one-time tooling investment and longer tool life lower overall cost.


Metal impacting increases component strength

Impact extrusion parts are dense, porous-free, and stronger than other metal-forming techniques thanks to the resulting highly uniform metal grain alignment that produces superior quality and durability. The impact process naturally hardens non-heat-treatable alloys; other alloys can be heat-treated after processing. There are no fire cracks, pores, or parting lines to weaken the part.

Illustration of metal impacting with benefits chart

More precise

Impact extrusions can achieve superb tolerance integrity and parts of near-net shape. Part walls made from alloy 6061 can be precision manufactured to within .02 inch even when the walls are less than 0.205 inch thick. These measurements are difficult for other metal-forming processes to reach.

More versatile

There is nearly no limit to the variety of sizes and part types that impacting can quickly create. After impacting, secondary operations such as machining, grinding, welding, bending, plating, or anodizing can be performed on an extruded part in the same way as any other piece manufactured through a more conventional process.

More efficient

In many designs, impacts can directly replace machined components or welded or riveted assemblies. The impacting process results in near-net-shape components that often reduce product costs for secondary machining operations and increase the strength of a product that was previously an assembly.

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