Custom Metal Extrusions
Deeco Metals is committed to providing quality custom extruded profiles in a variety of alloys to those with the vision to see the potential of these materials.
Our custom extruded shapes are supplied in copper & copper based alloys (brass & bronze). Aluminum alloys and stainless are also available. Complex custom extruded shapes can be fairly easily produced in aluminum, but are considerably more difficult in brass or bronze or copper and even more difficult in stainless. Deeco's mills state-of-the-art equipment helps supply some of the most complex custom extruded shapes in the industry in sizes from very small to very large.
Our engineers will use their expertise, in manufacturing and materials, to recommend the ideal material from both performance and a cost standpoint.
We offer precise tolerances, consistency of product, reliable service and a reputation for problem-solving, all supported by extensive research and experience.
To save 10-20% over your current supplier, send us your extrusion samples or drawings.
Custom Metal Extrusion Applications
- Plumbing parts and fittings
- Naval and marine window and door profiles
- Valve, pump, tap and faucet fittings
- decorative shapes
- Door and lock parts
- Window and door frames
- elevator cab and landing sills
- Large heavy industrial uses
- Electrical components from sockets and contacts
- Highly complex electrical switchgear
- General engineering
- Cold-formed brass screws
- Machined components requiring precision tolerances
- And much, much more
- Precision engineered doors and window suites
- Handrails and balustrades (as seen in many major building projects around the world)
- Sports and recreation (some of the world’s favorite fishing lures)
Common Extrusion Materials
In its basic form Brass is an alloy of copper and zinc, but most alloys contain additional elements. For architectural purposes Brasses are widely used, however, the building industry commonly refers to some of these alloys as Bronze; although it is a misnomer, it is accepted practice.
In its basic form Bronze is an alloy of copper and tin. Within architectural applications, true bronze is rarely used. In the USA we refer to Architectural Bronze extruded shapes even though it is a brass.
In its basic form, Nickel Silver is an alloy of copper, nickel, and zinc, which has a warm silver appearance.
Uses of Extruded Metal Parts
Copper alloys possess different properties and as a result, have varied uses. Some alloys are used for casting, some for extrusion and hot forging, and others for sheet and strip manufacturer.
Across the range of alloys, a number are used for manufacture in more than one condition; for example, a given alloy may be capable of being used for both casting and extension.
The most important thing for an architect to know is that the appropriate use of Brass and Bronze alloys can result in an over-all color matching system.
- Screws, belts, rivets.
- Extensions can be custom designed to incorporate a snap’ or ‘slide’ fit to loin various shapes (for example see Shape Nos. 3626, 3711, 3685 & 3683 on Page 50).
Sheets can be laminating to steel, plywood or similar substrate. (See also Dissimilar Metals). Brass and Bronze can also adhere to itself if intersecting members are mechanically aligned, for example with a sleeve and locking pins.
- Brazing - A medium temperature joining method in which filler material is melted along a seam line, without melting the base material. Because color matching of brazed fillers is difficult, brazing is best done with blind or concealed joints. Brazing is the preferred metallurgical joining method as it does not distort the base material.
- Soldering - A low-temperature joining method used for sealing joints which does not result in a strong bend and is, therefore, best used in conjunction with mechanical fasteners.
- Welding - A high-temperature joining method which fuses base materials, but is generally not used for architectural work because of color matching and joint distortion problems. This would be only done on unseen surfaces.
Brasses and Bronzes should not be used in contact with steel or aluminum as this tends to accelerate corrosion of the steel and aluminum. When the two metals do adjoin they should be separated by some form of insulating material, for example, neoprene, felt or a bituminous coating. With mechanical joining of dissimilar metals, stainless steel fasteners are recommended.
Mechanical Surface Treatments
- As Manufactured - The finishes imparted by normal production of extrusions, forgings, castings, etc.
- Buffed - A process consisting of grinding, polishing, and buffing. Finishes range from low luster polish to smooth mirror finish.
- Directional Textured - The most common finish on architectural profiles. This finish is produced by polishing the metal surface with near parallel lines, resulting in a smooth, velvety appearance often referred to as ‘satin finish’.
- Non-Directional Textured - Matte finishes of varying degrees of abrasion.
- Patterened - A combination of textural finishes. This is often referred to as embossing’ or ‘coining’.
Most Brass and Bronze alloys have a GOLDEN HONEY color in their natural state and a RICH STATUARY BRONZE in their chemically colored state. Brasses which contain aluminum exhibit a BRIGHT YELLOW coloring in their as-manufactured state, but the color changes to HONEY when polished. PINK Brass and Nickel Silver are also available when alternative coloring is required.
Natural honey colored Brass & Bronze is as the name suggests, however, the difficulty with it lies in the fact that, given enough time, it will weather to a brown color. Obviously, this occurs more rapidly when it is exposed to weather. The rate of weathering depends on the degree of humidity, and the level of pollutants in the air. A greater problem occurs with fingerprints. Acids from the body leave marks on the natural Brass & Bronze and for this reason natural honey Brass & Bronze needs to be protected, either by coating or by cleaning and/or polishing regularly if it is handled constantly, as in the case of handrails and door furniture.
Chemical coloring is a process with great dependence on the experience of the craftsman. In general, all types of chemical coloring artificially weather the Brass or Bronze from its natural color to a darker color. This is accomplished by converting the surface of the metal into a colored protective film, using an oxide or a sulfide.
For architectural use, chemical coloring is used to achieve a ‘statuary’ finish (i.e. a medium to dark brown appearance) through either of two methods. The first method is to dip the custom extruded profiles in a chemical bath and is practical for small pieces. The second method is to brush on and wipe off one of the several available chemicals. This is more appropriate for larger custom metal shapes and can be performed in the factory or on site.
It is sometimes impractical, costly and unnecessary to have a finisher handle every piece of custom extruded profiles of Brass or Bronze, however, the talents of a craftsman should be used when:
- The Brass or Bronze piece in question cannot be readily immersed in a chemical bath.
- Precise color matching of separate pieces is made necessary by immediate adjacency.
- The surface area of Brass & Bronze custom extruded profiles is sufficient to require an even-handed wrought appearance
- Special circumstances of manufacture and/or delivery of Brass & Bronze makes hand-finishing the only choice.
Examples of fittings which may require hand coloring are:
- Status Door Pulls
- Special Doors and Frames custom metal shapes
- Lift Entrances and Cabs
- Timber/Bronze Doors
Chemically colored Brass & Bronze should be maintained and protected by the repeated application of oil or wax (linseed, lemon, and paraffin oils are commonly used). The frequency of oiling will decrease over time as layers of oil build up to create a protective surface and result in what is known as oil rubbed bronze’.
When a piece of oil rubbed Brass or Bronze is repeatedly touched, as with door knobs, the oil, and colored surface wear through to the natural base color.