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.
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
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.
| 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 | |||
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
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
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
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:
- Manufacturing process scrap – during the manufacturing or fabrication of aluminium, process scrap is collected in containers and separated by alloy to permit recycling into ingot.
- Recovered scrap from aluminium products that have reached the end of its service life. Old scrap comes via metal merchants who recover aluminium from motor vehicles, building products, household appliances etc.
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
