BP Aluminium Extrusion Sdn. Bhd
BP Aluminium Extrusion Sdn. Bhd
BP Aluminium Extrusion Sdn. Bhd
BP Aluminium operates a Quality Management System approved to MS ISO 9001 : 2015. Quality is our hall mark and hence we attach great importance to this aspect of our products. Every section is subjected to rigid quality control at various stages of production to confirm that all critical dimensional toleranaces are kept. If special tolerance are specified extra care is taken to see that each piece of the extruded section confirms in all respects to the specifications given. To carry out quality control, we have the latest imported equipments. We at our end is committed to produce flawless products and providing products and services to customers, meeting & exceeding their expectations. We endeavour to meet this commitment by continuos improvement in the quality of products and services through individual and team efforts.
BP Aluminium offers its customers technical & technology know-how in the area of aluminium profile production, own knowledge on properties & behaviour own knowledge of aluminium & aluminium alloys, thus facilitating to design aluminium profiles with the most suitable characteristics, sizes and shapes for customer’s products.
The added value in the form of technical advisory and services, surface treatment and fabrication identifies and promotes company ambition to become part of customer’s production chain.
Our business structure is designed to make our deliveries as fast and efficient as possible. Stocks for standards profiles are readily available to provide fast and efficient order fulfilment and deliveries.
The manufacturing process for aluminium factory that produces aluminium profiles basically consist of 2 major processes which is extrusions & surface treatment. Under surface treatment, there are 2 components of finishes namely anodizing and powder coating.
The raw material used in the aluminium extrusion industry is supplied under the form of billets. Alloys vary according to the intended application of the aluminium profile. The 6000 series has good extrudability & can be solution heat treated at the extrusion temperature. Furthermore, these alloys have medium to high strength, are easy to weld & offer good resistance to corrosion, even in marine environments. The bulk of extruded materials for load bearing construction is made from these qualities. They are used for load bearing constructions both on land & at sea. The 6063 alloy offers medium strength & is easy to extrude even for complicated cross sections. This alloy is one of the most used extrusion alloys. It has good formability during bending in the T4 condition.
It is a process of mechanical forming through the plastic deformation of an aluminium billet.
The billet is heated and then placed in the container. By means of the hydraulic power of the press, it is pressed
against the die, thus shaping the profile and changing the aluminium’s structure. The aluminium profile, already in its final shape and size, is then removed from the die, rapidly cooled and subsequently submitted to a cold stretching process & cut into its final dimensions. Finally, the profile undergoes a tempering thermal treatment, which gives it the specified mechanical properties. Throughout the extrusion process, the following Tests/Trials are conducted;
Under extrusion, it covers extrusion dies, extrusion process and heat treatment or ageing.
This section is responsible for all services related to the verification, preparation, correction and maintenance of dies, so that we may guarantee dimensional compliance and surface quality in the extrusion process. Dies are made of tool steel with an opening, the size and shape of the intended cross-section of the final extruded products. There are two main groups of dies designed as solid dies, which produces solid profiles and hollow dies, which produces hollow profiles. Solid profiles are produced using a two-part die. In hollow dies, the mandrel that shapes the cavity in the profile is supported on a bridge. During extrusion, the metal separates around the bridge. The other part of the die shapes the outer contour of the profile.
Based on the intended use of aluminium profiles, they are required to have different mechanical properties such as strength & hardness. These properties are achieved in two operations. The first one involves the above-mentioned cooling of profiles in the extrusion process through the proper temperature adjustment and control of extrusions leaving the die. This operation, however, not always allows to achieve the required parameters of mechanical properties. Consequently, the aluminium profiles are passed through the other process of heat treatment known as artificial ageing in the separate technology equipment.
Even before surface treatment, the appearance and surface quality of extruded aluminium profiles is perfectly satisfactory for many applications. However, there are many other reasons for treating the surfaces of profiles. Most of metal and non-metal materials are exposed to ever increasing mechanical and chemical stresses. As a result, the premature ageing occurs in which corrosion plays a major role. The corrosion can be defined as a material deterioration caused by chemical and physical physical impacts of surrounding environments.
The corrosion results in both aesthetic changes and economic losses in materials. The losses due to corrosion can be substantially prevented by the application of a properly designed surface treatment. The corrosion prevention, however, is not a single reason for application of surface treatment. There are several methods and techniques how to increase quality, aesthetic appearance and mechanical and chemical properties of aluminium and aluminium alloy surfaces. The most frequently used ones include anodizing and powder coating.
The choice of proper surface protection system is a highly challenging task not only for technologists but also for designers and architects, because the effectiveness of extending the the product lifetime depends not only on the proper choice and application of the surface treatment, but also on the product design. Consequently, the choice can be a complicated and time-demanding process because of variety requirements & options available. When proposing any surface protection system, considerations should include type of material and method of its processing, method and intended use of particular products, choice and application of surface treatment & other specific requirements. The protection system must provide realible performance as well as an aesthetic appearance of the treated surfaces.
Anodizing is used to create new appearance, to enhance corrosion resistance, to create a dirt repellent surface that satisfies stringent hygiene requirements, to create a deco- rative surface with durable colour and gloss, to create a “touch-friendly” and abrasion resistant surface and not at the last, to give surfaces an electrically insulating coating. Aluminium and aluminium alloys are remarkable for their special ability to resist corrosion thanks to a thin but effective layer of aluminium oxide that forms spontaneous when the metal is exposed to air. This is widely applied in the marine industry because of strong resistance to seawater. When scratched, the layer of aluminium oxide does not wipe off. The aluminium oxide layer can be produced on certain, usually very bright surfaces as a protective or decorative film. The anodized aluminium alloys are used practically in all industrial sectors. Proper formation of aluminium oxide coatings provides aluminium alloys with an increased resistance to corrosion & abrasionon one side & a decorative appearance on the other side. Structural components made from anodized aluminium alloys are vital to the aviation, automotive and marine industries as well as to the building industry for outdoor and indoor applications.
The pre-treatment operations include degreasing, pickling, satin finishing & brightening. Obviously, every surface treatment starts with degreasing. The degreasing takes place in solutions based on alkaline or acid degreasing agents. The pickling, being referred to as standard EO, takes place in alkaline environment. A qualitatively higher level of surface treatment is provided by the satin finishing, being referred to as standard E6-finish, which is one of the most important pre-treatment operations prior to actual anodizing operation. Satin finishing includes light etching to produce aluminium surfaces with a smooth matt gloss or matt satin look. The brightening operation is used to clean the pickled surfaces from heavy metal hydroxides that have not been removed previously in the alkaline baths. There are formed as grey deposits on aluminium surfaces on completion of alkaline treatments. Aluminium pieces are immersed into the brightening bath to give profiles a bright aluminium look.
The necessary pre-treatment operations are followed by the phase of an actual anodizing, i.e. formation of anodic oxide layer. The anodizing is conducted using either AC or DC current in an electrolyte bath, which is based on sulphuric acid, where the aluminium profile to be treated forms the anode electrode; the cathode is usually aluminium or lead. The final layer depends on the respective production parameters, such as electrolyte characteristics, type of current, process duration, operating temperatures and voltages, density of current & composition of material to be treated. The process continues until the desired layer thickness (usually 5 – 25 μm) is reached. Obviously, white coatings are obtained as a result of sulphuric acid oxidising. During the anodizing process, a considerable amount of heat is generated. Most of the produced heat is removed by forced convection (agitation) of the electrolyte and cooling down. On completion of anodizing, any residues of sulphuric acid must be thoroughly removed as they would cause deep corrosion. The properly conducted anodizing results in formation of a thin protective film suitable for decorative and anticorrosive purposes. The sulphuric acid electrolyte normally operated at low low temperatures (- 5°C to + 5°C), under higher current density produces an exceptionally hard hard film The film thickness can range up to several hundreds of micrometers. These protective films known as hard coats are widely used in the engineering industry.
The third phase in the anodizing process is colouring of anodized aluminium. The anodic oxide layer can be coloured by several methods that differs each other with the character of colouring substances and their position in the oxide layer. The most common colour tones produced by chemical or electrochemical colouring processes include, besides the natural look of base metal, gold & bronze shades. The method of interference colouring adds further options to broaden the available colour scale.
The last phase in the anodizing process is sealing because of oxide layer containing a large number of pores. Sealing is intended to increase the corrosion resistance and to reduce the wettability, the sensitivity to touch and the absorbency of the anodic oxide layer. There are three ways of the sealing applied across industries – hydrothermal sealing (hot) or energy-saving cold impregnation or the combination
In addition to anodizing, there are also other methods of surface treatment. One of them is powder coating. In general, there are absolutely no limits to the choice of colour. The foremost characteristics of powder coating include high repeatability, resistance to abrasion & impact & use in open air thanks to UV and corrosion resistance. Coating thickness is normally 60 – 140 µm (microns). It is essential that the pre-treatment, application of coatings & subsequent treatment are performed precisely in order to ensure proper adhesion of coatings. The main objectives are to achieve maximum adhesion & durability as possible, therefore the pre-treatment is very important operation. The surface pre-treatment includes degreasing & pickling followed by chemical treatment. The chemical treatment provides good adhesion and effective resistance to corrosion. The method of applying powder coatings employs triboelectric charging of powder particles (the particles are charged by friction) or electrostatic charging. After application of powder coating, the profiles are passed through the curing oven (the curing temperature is approx. 180 °C). The curing time is about 15 minutes, depending on profile design.
We undertook our packing seriously and all profiles arpacked with utmost care inview of aluminium profiles are delicate & can be damaged easily if it is not done accordingly QA/QC are also carried on packing because Customer(s) satisfaction is always a priority to Us.
We follow very strict QA/QC procedures during our extrusion, anodizing and powder coating process so as produced quality finished products. It is the Company policy and commitment to produced quality finished products from our humble beginnings of the commencement of our factory operations.
Aluminium is the second most used metal and an application of it is nearly in all industrial areas. A reason is a combination of unique characteristics of the metal