The production of aluminum billets is a precise industrial process in which raw or recycled aluminum is transformed into a cylindrical shape of specific length and diameter. These billets are later used in extrusion processes to produce aluminum profiles, rolling processes to create sheets and coils, or as a base material for specialized industrial or engineering applications. Hydrometal is considered one of the leading aluminum billet production companies in Egypt and the Middle East.

Stages of Aluminum Billet Production

Aluminum billets are the primary raw material used to create the desired form of raw or recycled aluminum, which is later utilized in manufacturing various final products. The production process involves several critical stages:

• Raw Material Preparation: This may include alumina in the case of primary production, pure aluminum scrap in recycling plants, or alloying elements such as silicon, magnesium, and iron to produce alloys with 99.7% purity like 6063 or 6061.
• Melting: Aluminum is melted in high-temperature electric or gas furnaces that can reach up to 800°C. During melting, additional elements are introduced to form the desired alloy composition.
• Chemical Analysis: A sample of the molten metal is taken and analyzed using specialized equipment. Based on the analysis, element ratios are adjusted precisely to meet the target alloy specifications.
• Continuous or Direct Casting: The molten aluminum is poured into vertical round molds to produce billets of specific diameters, typically ranging from 5 to 10 inches. The billets are then water-cooled to ensure uniform solidification.
• Heat Treatment: After cooling, billets are reheated to around 500°C for a specific period to homogenize the crystalline structure and relieve internal stresses. This heat treatment step is crucial for facilitating later extrusion processes.
• Cutting and Finishing: The billets are cut to required lengths, typically around 6 meters (customizable). Then, the billet ends are carefully smoothed to remove surface defects. Each billet is then numbered and packaged according to specifications.

Applications of Aluminum Billets

Aluminum billets are a fundamental raw material used across various metallurgical and engineering industries. They serve as a base for further processes such as extrusion, rolling, or machining. Key applications include:

• Extrusion of Aluminum Profiles: Billets are heated and extruded through special dies to produce profiles in different shapes—such as window and door frames, glass facades, shading systems, HVAC components, and industrial profiles like angles, tubes, and squares. Alloys like 6061 and 6063 are commonly used.
• Rolling for Sheet and Coil Production: Billets are passed through rolling mills to reduce thickness and form sheets, coils, foil wraps, and cladding panels. These are widely used in food packaging, air conditioning systems, refrigeration, and building facade panels.
• Mechanical and Engineering Fabrication: Some factories use billets directly in machining and turning operations to produce mechanical parts, auto and bike components, and aerospace industry parts. Alloys like 6082 and 6061 are suited for this purpose.
• Electrical Conductor and Cable Manufacturing: Specific billets are used to produce power-conducting wires after appropriate processing and drawing. High-purity alloys like 1050 and 1070 are typically used.