Raw material
Primary or secondary aluminum ingots of 7 and 8 inches in diameter with a length of 225 inches are imported or purchased locally for the production of FISA profiles. The standard alloys extruded at FISA are AA 6063, AA 6061 and AA 6005.
​
In addition to primary ingots, FISA also extrudes ingots produced at its casting plant.
Mould
The importance of the matrix derives from the fact that it is the tool that gives the shape to the aluminum profile. FISA imports matrices from Europe and North America. It also has computer and numerical control manufacturing equipment that allows the design and manufacture of certain matrices. There are two types of matrices: those freely available and those for exclusive use by the client.
​
FISA's die-making department provides free advice on the design of plans analyzing the feasibility of extrusion.
​
For the design of an aluminum profile, it is important to consider the size, complexity and thickness of the walls of the desired figure. To determine the size of an extruded profile, the measurement of the diameter of the circumference into which the cross section of the profile enters is used. This measurement is known as a circumscribed circle.
Extrusion
FISA has four hydraulic extrusion presses for the production of aluminum profiles. This translates to an annual capacity of 52 million pounds. Profiles up to 10.25 inches circumscribed circle can be extruded on our presses.
​
Aluminum extrusion is a semi-continuous manufacturing process in which a preheated ingot is pressed through a die. The result is a product with a uniform cross section given by the geometry of the matrix. A wide variety of solid, hollow and semi-hollow extrusions can be generated thanks to this process. In addition, aluminum is converted from a cast material to a forged material, improving its mechanical properties.
​
After the aluminum has been extruded at high temperatures that increase the plasticity of the metal, it is automatically transferred to the cooling table. The amount of water and/or air used for cooling depends on the size, shape, alloy and required properties of the material. The next step is to stretch the product to obtain straight extrusions and eliminate residual stress. Subsequently, the extruded aluminum is cut to the required measurements to be transferred to the aging oven that provides the desired tempering and hardness.
Liquid Electrostatic Paint
FISA has a vertical liquid paint plant with an annual capacity of 16 million pounds. It has been approved as a certified applicator of Kynar 500 paint by PPG. This paint applied in two coats offers the highest resistance to chemicals and weathering.
​
The process of applying liquid electrostatic paint consists of coating the aluminum profiles with a liquid paint composed of pigments, resin and solvent. Prior to the paint coating, the profiles are subjected to a degreasing and phospho-chromatizing process that provides excellent adhesion and weather resistance. After paint coating, the paint curing is carried out in an oven at high temperatures. Through this process, FISA guarantees a product with excellent anti-corrosion resistance and a uniform, durable, low-friction surface.
Electrostatic Powder Painting
FISA owns two independent horizontal powder coating plants with an annual capacity of 16 million pounds. Three paint application booths provide the flexibility to paint three different colors simultaneously. Additionally, FISA can coat aluminum profiles with virtually any color. The maximum length of profiles to be painted in FISA through this process is 9.1 meters.
​
The electrostatic powder paint application process is a dry process that uses very fine particles of pigmentation and resin that cover the surface of the profile. Before coating with paint, the profiles go through a degreasing and phospho-chromatizing process that provides maximum adhesion and weather resistance. After paint coating, the profiles are cured in an oven at high temperatures. The result of the layer applied in FISA, between 60 and 80 microns, is a profile with excellent anti-corrosion resistance, a uniform, durable and low-friction surface.
Anodized
FISA has an annual anodizing capacity of 13.2 million pounds and can process profiles up to 7.3 meters in length.
​
Anodizing is an electrochemical process that increases the oxide layer of aluminum. The process consists of submerging the aluminum profiles in a solution of acidic or basic pH while the electric current flows through them. Anodizing provides greater anti-corrosion resistance, durability and electrically insulates the metal surface.
​
The natural layer of aluminum oxide is 0.02 microns. After anodizing this layer grows from 5 to 25 microns thick. FISA guarantees an anodic layer that ranges between 10 and 25 microns depending on the product requirements. The anticorrosive resistance increases with increasing the thickness of the anodic layer. In addition to the natural tone of aluminum, different shades can be obtained through a coloring process. Some of these tones are champagne, different shades of bronze, gold and black. FISA has all these colors in matte and polished finishes.
Packing
To ensure that FISA aluminum profiles do not suffer damage during distribution and storage, the packaging process used is divided into two parts. First, a sheet of interlaced paper is placed between the profiles, and then they are wrapped with stretch plastic in a spiral manner through the packaging machines.
All packages have a label with a barcode that contains all the necessary product information.