Introduction
Extruded aluminum tubes offer numerous advantages, including lightweight, high strength, and excellent corrosion resistance. However, working with and fabricating these tubes requires specific techniques to ensure optimal results. This article presents a comprehensive guide to the techniques involved in working with and fabricating extruded aluminum tubes, providing insights into best practices and common pitfalls.
Preparation
Selecting the Right Tube: Choosing the appropriate tube size, alloy, and temper is crucial. Consider factors such as the application, load requirements, and desired finish.
Cleaning and Degreasing: Remove any surface impurities, oils, or lubricants using solvents or detergents to ensure proper adhesion during fabrication.
Measuring and Marking: Accurately measure and mark the tubes to ensure precise cuts and connections. Use appropriate tools and techniques to minimize errors.
Cutting
Sawing: Use a fine-toothed saw blade specifically designed for aluminum. Clamp the tube securely to prevent vibration and maintain accuracy.
Shearing: Utilize a sharp shear to cut the tubes perpendicularly. Ensure that the blades are sharp and properly aligned to avoid tearing or rough edges.
Notching: Use a specialized notching tool to create notches or slots in the tubes. Choose the appropriate notch size and radius to avoid weakening the material.
Bending
Tube Bending Machine: For complex bends, use a dedicated tube bending machine equipped with the appropriate dies or mandrels. Follow the manufacturer’s guidelines for setting up and operating the machine.
Hand Bending: Manual bending is suitable for smaller tubes or simple bends. Use a bending tool or vice to carefully apply pressure and form the tube to the desired shape.
Joining
Welding: Use specialized welding techniques, such as TIG or MIG welding, to join aluminum tubes. Ensure proper shielding to prevent oxidation and achieve strong, corrosion-resistant welds.
Mechanical Joining: Utilize mechanical fasteners like bolts, nuts, and rivets to connect the tubes. Select the appropriate fasteners and tightening torque to ensure secure and durable joints.
Adhesive Bonding: For certain applications, adhesives can be used to bond aluminum tubes. Choose a high-strength, structural adhesive that is compatible with aluminum.
Finishing
Cleaning: Thoroughly remove any weld spatter, debris, or adhesives from the tubes before finishing.
Sanding and Polishing: Use sandpaper or abrasive materials to smooth the surfaces and create the desired finish.
Anodizing or Painting: Anodization enhances corrosion resistance and provides a decorative finish. Painting offers additional protection and aesthetic options.
