Die Design & Manufacturing

Die Design & Manufacturing

Die Design & Manufacturing


G.James utilises the latest CAD software and an array of CNC Machining centres and EDM wire cutting machines to design and manufacture the extrusion die sets required to produce your specified profile.

Custom Die Design

Dies can be made to form a virtually limitless array of shapes and sizes. G.James can assist with your custom section design to ensure adequate extrudability. Please contact us for further information.




Extrusion Press

Extrusion Press

Press Production

G.James is an aluminium extrusion manufacturer and with four Australian-based extrusion presses, we are recognised as a reliable supplier to the general extrusion market throughout Australia and the Asia Pacific region.

Using the direct extrusion process, a heated aluminium billet is placed inside a container and a powerful hydraulic ram pushes the billet through a shaped orifice known as a die to produce the desired shape. The die is stationary as the ram moves through the container as it pushes the aluminium billet through the die.

Press Production Capabilities
E29 E37 E42 E86
Press Capacity (tonnes) 2800 1650 1650 3250
Circumscribing Circle Diameter (mm) 200* 178 178 200*
Maximum weight per metre G.James are able to extrude up to a maximum weight of 12kg/m
Minimum length on press 3 metres (shorter lengths can be fine tolerance cut)
Maximum length on press Determined by weight per metre
View our list of Alloys and Tempers.

G.James Extrusion meets the following Australian Standards, Accreditations and Certifications.

AS1866:1997
Aluminium and aluminium alloys— Extruded rod, bar, solid and hollow shapes
AS1231-2000
Aluminium and aluminium alloys- Anodic oxidation coatings
AS3715-2002
Metal finishing—Thermoset powder coatings for architectural applications of aluminium and aluminium alloys
AAMA 605
Voluntary Specification for High Performance Organic Coatings on Architectural Extrusions and Panels
ISO 9001:2000
Accredited Quality Assurance Management System
Boat Building & Marine Certifications:
Det Norske Veritas (DNV), Lloyds (LR), Germanischer Lloyd (GL), American Bureau of Shipping (ABS)

Warehousing

Highrack Storage Warehouse

Highrack Storage Warehouse

G.James has commissioned a High Rack Storage System (HRSS) with the capacity to store up to 3000 baskets of mill finished aluminium.

This fully automatic warehouse system, is not only a different way of storing aluminium extrusions, but provides an improvement in overall efficiency, timing and inventory planning.

The HRSS is divided into two parts. The main part (The Rack) stores and retrieves mini grey baskets. The Rack stores mill finished (not painted, powder coated or anodised) extrusions. This area is completely self-contained and automated. The smaller part on the side (The Annex) contains handling equipment and space for moving extrusions to and from baskets.

G.James can accommodate your individual warehousing, packing and dispatch requirements.

Anodising Aluminium

Anodising Aluminium

Surface Finishing

G.James offers a range of different ways to finish the surface of aluminium. The choice of finish is mostly determined by the desired final appearance and application environment.

Surface Finishing includes Anodising (Mechanical Finishing and Bright Dipping), Powder Coating, Wet Paint and Effecta ® (timber look). For more information see our Surface Finishing page or view our Colour Range .

Remelt and Recycling

Recycling is an essential part of G.James and the aluminium industry and makes sense economically, technically and environmentally.

Remelt Furnace

Remelt Furnace

G.James is committed to the efficient recycling of aluminium scrap and operates a specifically designed remelt facility to melt down scrap into ingots for further aluminium extrusion and casting.

G.James sources scrap aluminium from:

Scrap metal from the manufacturing process, or metal provided by the customer can be recycled into new logs.

Aluminium's natural resistance to corrosion ensures a high metal value and once produced can be considered a permanent resource for future recycling. Recycled (or secondary) aluminium billet requires approximately 90% less power to produce than primary billet.

Readily recyclable and with one of the highest recycling rates of any metal, aluminium is an environmentally sustainable material. G.James currently produces approximately 50% of our extrusion production requirements from recycled products. The majority of recycled aluminium products end up used for building & construction applications.

Read more about G.James Glass and Aluminium's Environmental Awareness & Energy Efficient Practices.

Alloys

6060 up to T5
General Purpose / Architectural – high extrudability, medium strength, use for bending quality
6063 up to T6
General Purpose / Architectural – specify for consistent results e.g. higher strength, punching
6463 up to T6
More reflective trim finish – used when bright dipping – bright gold, silver, ornamental, showerscreens
6106 up to T6
Semi structural, good extrudability does not generally require water quenching depending on wall thickness
6005A up to T5
Structural – generally requires quenching on wall thickness greater than 3mm Road transport
6351 up to T6
Structural – requires quenching on wall thickness greater than 3mm. Poor extrudability
6061 up to T6
Structural – requires quenching
6082 up to T6
High Structural – requires quenching. Approved for shipbuilding
1350
Used for electrical busbars
6101
Used for electrical busbars

Tempers

T1
Unaged – may reach T5 if aged at a later date
T4
Unaged – may reach T6 if aged at a later date
T581
Minimum Age – maximum bending quality. It is necessary to specify a particular grade of alloy (eg 6060SF) to maintain consistent bending quality
T582
Medium Age – higher strength bending quality
T5
General purpose age
T6
Maximum strength
Capabilities

Adding Value

To Aluminium