Hydrometal Factory is considered the best aluminum factory in Egypt, with decades of experience in the field. It is a pioneer in both the local and regional markets, for several key reasons:

• The factory owns multiple modern extrusion lines, equipped with extrusion presses ranging from 1000 to 3000 tons, enabling the production of high-quality profiles from various alloys.
• It offers a wide range of finishes, including anodizing in different colors, high-quality electrostatic powder coating that resists various weather conditions, and high-precision wood grain effects.
• The factory employs specialists in internal die design, and sometimes collaborates with European or Chinese companies specialized in die manufacturing. It can produce custom designs based on client requirements.
• The factory holds international quality certifications, and all its products meet global standards.
• Hydrometal enjoys a strong reputation and a long-standing history in the aluminum industry, with a large client base that includes major real estate and contracting companies, in addition to exports to Arab and African markets.

Aluminum Extrusion Die Manufacturing

Manufacturing aluminum extrusion dies is a highly precise engineering process that forms the foundation of the entire extrusion operation. The quality of the die directly impacts the accuracy of the final profile. The die is a metal mold with a cavity shaped like the desired profile. Heated aluminum is pressed through this cavity to form the profile. Dies are usually made of high-hardness steel to withstand heat and pressure.

Steps of Aluminum Extrusion Die Manufacturing

• Profile Design: The required profile is designed using advanced engineering software like AutoCAD, considering wall thickness, angles, curves, and balance to prevent deformation.
• Metal Flow Analysis: Aluminum flow within the die is analyzed to ensure even distribution throughout the profile and to detect any bottlenecks or cracks that may affect quality.
• Raw Steel Block Preparation: High-hardness steel alloys are used and cut to the required die dimensions.
• Cavity Formation: Several methods are used to create the die cavity, including:
  • CNC (Computer Numerical Control) machines for extremely accurate shaping, ideal for complex profiles.
  • Manual or semi-automated milling and drilling for standard or simple shapes.
  • EDM (Electrical Discharge Machines) for precision cutting of detailed or intricate sections using electric sparks.
• Heat Treatment: The dies are heated to high temperatures and cooled gradually to enhance hardness, corrosion resistance, and their ability to withstand the pressure and heat of the extrusion process.
• Polishing and Finishing: The internal surface of the die is polished to reduce friction and ensure successful extrusion. Dies are often coated with nitriding layers to improve resistance to wear and other stresses.
• Testing and Installation: Hydrometal conducts initial trial runs to test the die. Any required modifications are made to optimize metal flow and profile balance.