**Executive Summary:**
The green aluminum alloy building formwork profiles come in a wide variety of shapes and sizes, with complex geometries and high technical demands on mold design and manufacturing. This article focuses on two particularly challenging sections to analyze and discuss the mold design, production process, and innovative features. The comparison of extrusion performance and mold service life highlights the critical role of high-quality molds in the industrial mass production of green building aluminum alloy profiles.
**Keywords:** Green building, aluminum alloy formwork profiles, width-to-thickness ratio 100, flat wide profiles, special widening, shunting, combined modules, high tongue ratio, semi-hollow profiles, shielded protective molds, green building aluminum profiles, mold characteristics, technical challenges, analysis.
**1.1 Overview**
Aluminum alloy building formwork profiles include dozens of varieties and a wide range of specifications. Some are composed of several small and medium-sized profiles with different shapes, with circumcircle diameters exceeding 600mm. These include hollow, solid, and semi-hollow profiles, which require high dimensional accuracy, geometric precision, and excellent mechanical properties (e.g., B330MPa), as well as good weldability, wear resistance, and corrosion resistance. Industrial mass production is essential, requiring specialized molds such as diverter molds, shield profile molds, and wide-width molds to ensure accurate shaping and extended service life—often twice or even three times longer than standard molds. This article discusses the design and manufacturing technology of two typical and more difficult profile molds: WYY1237, a 400mm-wide profile with a width-to-thickness ratio over 100, and WYY1125, a semi-hollow section with a high tongue ratio and precise dimensions.
**1.2 Characteristics and Technical Difficulties of Aluminum Alloy Formwork Profile Dies**
(1) A wide variety of profile shapes and large dimensional variations demand high-quality molds tailored for each specification and structure, requiring extensive testing.
(2) For industrial mass production, increasing mold service life by 2–3 times is crucial, presenting significant technical challenges.
(3) Flat wide profiles with a width-to-thickness ratio over 100 require special wide spread and split flow dies to manage metal flow distribution and ensure dimensional accuracy and plane clearance.
(4) Semi-hollow profiles with a high tongue ratio (over 5) need specially designed molds to maintain precision, strength, and durability, making the design and manufacturing process extremely challenging.
(5) Smooth surface finish, high dimensional and shape accuracy, and long service life require the use of high-quality die steels, advanced heat treatment, and strict machining processes to achieve high strength, toughness, and precision.
**2.1 Design Basis and Technical Requirements for WYY1237 Mold**
(1) The WYY1237 profile uses 6061ET6 alloy, with extrusion performed using precision water, fog, gas quenching, and artificial aging. It requires ultra-high-precision size and shape accuracy, along with balanced mechanical properties, wear resistance, and corrosion resistance.
(2) As a flat, wide, thin-walled profile, WYY1237 has uneven wall thickness and plane gaps, necessitating a special combination die to ensure accurate forming.
(3) Due to its large size, it must be produced on a 7,000-ton extruder with a 418mm barrel diameter. A multi-stage, wide extrusion die is required to ensure accurate width and plane clearance.
(4) The profile's two support legs and wall angles have exceeded GB5237 high-precision standards, requiring careful calculation and balancing of metal flow to ensure angle accuracy.
(5) High-quality mold materials and advanced heat treatment and surface treatment processes are essential to increase mold service life by 2–3 times.
**2.2 Design Basis and Technical Requirements for WYY1125 Mold**
(1) The WYY1125 profile also uses 6061ET6 alloy, with similar requirements for ultra-high-precision size and shape, mechanical properties, and corrosion resistance.
(2) As a semi-hollow profile with a high tongue ratio, WYY1125 features a cantilever beam that is prone to collapse, making it difficult to produce qualified profiles with accurate dimensions and shape.
(3) The profile has three 90-degree corners, with tolerance values exceeding national standards. Ensuring the accuracy of these angles is critical for the overall flatness of the template assembly.
(4) Advanced mold materials, heat treatment, and surface treatments are necessary to improve service life and meet quality requirements.
**3. Design and Manufacturing of Template Profile Molds – Technical Solutions and Innovation Points**
**3.1 WYY1237 Profile Mold**
The design parameters and specifications for the WYY1237 mold are detailed in Table 1 and Table 2. The mold model is F620x350, made from 4Cr5MoSiV1 premium steel, with a hardness of 47–49 HRc. It includes a special wide spread shunt modular design, ensuring accurate metal flow and high precision. The mold features a split ratio of 13, an extensive width of 80mm, and specific angle settings of 25° and 5°. The die hole accuracy is maintained at 0/-0.02mm, with a surface roughness of Ra0.04mm.
**Figure 3** shows the schematic diagram of the special wide-split and split-flow assembly model for WYY1237, highlighting the complexity and innovation in its design.
This comprehensive approach ensures the successful production of high-quality green building aluminum alloy formwork profiles, meeting the stringent demands of modern construction.
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