Astham Industries

Manufacturing Process & Heavy Infrastructure

From prime virgin ingot homogenization to computer-controlled artificial aging, automated quenching, and in-line dimensional optical testing, discover the engineering precision behind our extrusion output.

Extrusion Workflow

Our Extrusion Process

Continuous metallurgical monitoring, nitrogen die cooling, and automated temperature feedback ensure optimal grain structures and zero-defect profiles.

STAGE 1/10

Raw Material Inspection & Billet Preheating

Only primary virgin aluminium billets (A8 grade, 99.7% purity) from certified primary smelters are used. Billets are ultrasonically tested for inclusions and heated in automated gas-fired gradient log heaters to 450°C - 480°C.

Preheat Temp 450°C – 480°C
Purity Grade 99.7% Primary A8
Inspection Ultrasonic NDT Check
Raw Material Inspection & Billet Preheating
Equipment Spec

Automated Gas-Fired Gradient Log Heater

STAGE 2/10

Precision Die Design & Tool Heating

Custom extrusion dies manufactured in-house on high-precision CNC Wire-EDMs are inspected and soaked in die ovens at 460°C to match billet temperature, preventing thermal shock and surface defects.

Tooling Process In-House CNC Wire-EDM
Soak Oven 460°C Temperature Match
Die Tolerance ±0.02 mm Micro-Accuracy
Precision Die Design & Tool Heating
Equipment Spec

High-Precision CNC Wire-EDM Die Machining

STAGE 3/10

Hydraulic Extrusion Pressing

The heated billet is sheared and forced under immense hydraulic pressure (up to 1,800 Metric Tons) through the steel die aperture, flowing plasticized metal into complex hollow or solid geometries.

Press Force 1,800 MT Direct Press
Billet Separation Automated Hot-Shear
Die Protection Liquid Nitrogen Shroud
Hydraulic Extrusion Pressing
Equipment Spec

1,800 MT Direct Hydraulic Extrusion Press Line

STAGE 4/10

Intensive In-Line Quenching

As the profile exits the die at speeds up to 50 meters per minute, it is rapidly cooled using controlled high-velocity water mist and forced air jets to lock in alloy alloying elements into solid solution.

Line Speed Up to 50 m/min
Quench Type Water Mist + Forced Air
Metallurgy Solid Solution Matrix Lock
Intensive In-Line Quenching
Equipment Spec

High-Velocity Dual Water-Mist & Air Quench Chamber

STAGE 5/10

Cooling Table & Automatic Pulling

Profiles are guided onto wide graphite slat handling tables by computerized pullers, ensuring zero scratch marks, minimal twist, and uniform cooling down to handling temperature.

Puller Tech Computerized Double Puller
Table Bed Graphite Slat Runout Bed
Surface Standard 100% Zero-Scratch Handling
Cooling Table & Automatic Pulling
Equipment Spec

Computerized Double Puller & Graphite Slat Table

STAGE 6/10

Hydraulic Tension Stretching & De-Twisting

Profiles are clamped at both ends in hydraulic stretching machines and pulled under tension (0.5% - 1% controlled elongation) to achieve absolute straightness and relieve internal extrusion stresses.

Stretching Rig Hydraulic Tension Clamps
Elongation 0.5% – 1.0% Controlled
Core Purpose Internal Stress Relief
Hydraulic Tension Stretching & De-Twisting
Equipment Spec

Hydraulic Tension De-Twister & Stretcher Bed

STAGE 7/10

Precision CNC Saw Cutting

Stretched profiles are conveyed to automated high-speed carbide saws and cut to exact mill lengths or customized client lengths with tight length tolerances (±1.0 mm).

Cutting Tool High-Speed Carbide Saw
Cut Tolerance ±1.0 mm Length Accuracy
Feed Control PLC Auto-Conveyor Stop
Precision CNC Saw Cutting
Equipment Spec

High-Speed Automated Tungsten Carbide Saw Line

STAGE 8/10

Artificial Ageing Heat Treatment

Cut profiles are loaded into thermostatically regulated precipitation hardening ageing ovens and soaked at 180°C - 200°C for 6 to 8 hours to attain peak T5 or T6 temper mechanical strength.

Ageing Furnace 180°C – 200°C Regulated
Soak Duration 6 – 8 Hours Cycle Time
Peak Temper T5 / T6 Ultimate Hardness
Artificial Ageing Heat Treatment
Equipment Spec

Computerized Ageing Furnace (T5/T6 Precipitation)

STAGE 9/10

Quality Lab Clearance, Wrapping & Dispatch

Every batch is tested for Webster hardness, tensile strength, and coating thickness. Profiles are interleaved with protective paper, shrink-wrapped, and packed in wooden crates for safe transport.

Pre-Treatment 10-Stage Chemical Etch
Anodizing Depth 10 – 25 µm Micron Film
Powder Coat 60 – 80 µm Electrostatic
Quality Lab Clearance, Wrapping & Dispatch
Equipment Spec

Multi-Tank Anodizing & Electrostatic Powder Line

STAGE 10/10

Surface Finishing (Anodizing / Powder Coating)

Profiles undergo automated 10-stage chemical pre-treatment followed by either multi-tank computerized Anodizing (10-25 micron) or electro-static thermosetting Powder Coating.

Webster Hardness 12 – 16 Webster (HW)
Laboratory Tests OES + Tensile + Dimensional
Packaging Spec Interleaved VCI Export Crates
Surface Finishing (Anodizing / Powder Coating)
Equipment Spec

Metallurgical Testing Lab & Optical Spectrometer

Aluminium Extrusion Specifications, Alloys & Standards

Direct factual answers to technical procurement questions regarding alloys, dimensional tolerances, custom die manufacturing, and quality certifications.

We specialize predominantly in 6000-series structural alloys including 6063 (architectural and thermal applications), 6061 and 6082 (high-tensile structural and automotive engineering), and 6005A (heavy solar and transport framing). We also produce custom alloy chemistries upon request for defence and specialized electrical requirements.
We manufacture to tight international tolerance standards including IS 733, IS 1285, and BS EN 755-9. For specialized high-precision applications such as pneumatic cylinder tubes and linear motion guides, our in-house tool room can hold critical wall thickness tolerances within ±0.15 mm.
Thanks to our in-house CAD/CAM tooling facility with 5-axis CNCs and wire-EDMs, typical custom die development from approved 2D/3D CAD drawing to physical first-sample extrusion takes only 10 to 14 working days.
For standard existing catalogue dies, our typical batch MOQ starts at 500 kg per section. For custom-developed dies, our initial trial batch is 250-500 kg, followed by commercial production batches of 1,000 kg (1 MT) and above.
Astham operates complete in-house surface finishing lines including: (1) Natural Silver Matt Anodizing (10 to 25 microns), (2) Electro-Colour Anodizing in Champagne, Bronze, and Jet Black, and (3) Automatic Electrostatic Powder Coating (60 to 80 microns) with Qualicoat approved pure polyester, super-durable, and PVDF coatings in over 200 RAL shades.
Yes. Every dispatched shipment is accompanied by an official Batch Mill Test Certificate (EN 10204 3.1) detailing chemical spectrometry, Webster/Brinell hardness, tensile strength, yield limits, elongation, and coating micron thickness reports.

Schedule an On-Site Plant Audit or Tooling Consultation

We welcome OEM procurement heads, automotive engineers, and quality auditors to inspect our Panetha extrusion plant, aging bays, and optical spectrometer laboratory.

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