casting in the energy industry

Casting in the Energy Industry

Casting in the Energy Industry 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Casting method has been used for centuries to use metals. This traditional method is frequently used for economic reasons and efficiency. Metals that are treated with this method can be used in many industries.

Casting industry plays a major role in many industries such as agriculture, rail transport, construction, automotive, energy, air, maritime, defence, space and so on. Especially in the energy industry, aluminium pressure die casting method is important in manufacturing parts and components that play a major role in energy transmission, transformation and generation.  We, as Kalkancı are actively working in casting in the energy industry.

Use of Aluminium in the Energy Industry

Aluminium is one of the metals that are used the most, following iron and steel in the world. Aluminium, in compound form, can be made more usable after going through several processes. Aluminium, known for its lightweight, durability and conductivity, is highly sought out especially in the energy industry.

Sheets, plates, pipes, bars, wire rods can be produced with aluminium. As a result of its high durability, it is a metal frequently preferred for transmission of electricity and thermal energy. Additionally, it can be recycled and easily bent and shaped which makes it a popular choice for many industries.

Aluminium Casting in the Energy Industry

There are a variety of methods used for casting. Casting method used for each metal also differs. Single-use and permanent moulds can be used. Aluminium metal casting methods are listed below;

  • Continuous Casting,
  • Sand Casting,
  • Pressure Die Casting

In continuous casting, liquid aluminium is poured into moulds. During this process, water cooling is used to cool the outside of mould to solidify the liquid metal. Moulded production is achieved when metal is solidified. Processes may differ.

Sand casting is a casting method that is frequently used not only for aluminium but also for other metals. Sand casting may differ depending on the type of moulds used. One of the reasons why sand is chosen is that it can be shaped easily and used as a mould material. Although sand moulds are for single-use, they are quite effective for large, multiple and detailed casting. Although cooling of metals takes long with this process, it is cost effective.

Pressure die casting is used to produce high and large volume parts and components.  High pressure is applied on the liquid metal in the mould. When liquid metal is solidified, the pressure is released and the material is taken out of the mould. It is a casting method used to produce precision, detailed and complicated parts. These casting methods are used frequently for producing or shaping aluminium.

Aluminium Alloy Parts in the Energy Industry

Aluminium is combined with other elements and changes its durability, ductility and conductivity. Types of aluminium alloy are listed below;

  • 1XXX; is pure aluminium.
  • 2XXX; is an alloy where aluminium is mixed with copper and magnesium. This is frequently used in the aviation industry with its high strength and durability.
  • 3XXX; is the addition of manganese to aluminium; this alloy is mostly preferred to produce pipes etc.
  • 4XXX; this alloy with silicon is preferred in producing parts, steels, bars in the automotive industry with its high wear and corrosion resistance.
  • 5XXX; this is a strong and hard aluminium alloy that contain magnesium. It has a high seawater corrosion resistance and that’s why it is mostly preferred in the marine industry.
  • 6XXX; this alloy that contains silicone and magnesium, with its high ductility, is preferred for parts that are produced with compression moulding.
  • 7XXX; is the strongest aluminium alloy and contains copper, magnesium, chrome and zirconium.  It is used in productions where high strength is required.  It is especially preferred by the aviation industry.
  • 8XXX; is an aluminium alloy with lithium and tin and it is the most expensive alloy. This alloy is used especially in space and aviation industries.

Aluminium alloys are also used quite often in the energy industry.  They have a wide variety of use, from thermal insulation of houses to solar panels.  Durability, ductility and conductivity of aluminium and its convenience and availability makes it a high demand in the energy industry.

energy industry

Why Aluminium Die Casting for the Energy Industry?

We have discussed before that die casting is the most preferred method to shape aluminium. Using pressure in permanent moulds to shape aluminium is very important to produce more precise and smoother parts.

Producing parts in the required shape and quality which do not need further treatments increases efficiency in production. It is possible to achieve high quality in the production of complex and detailed parts using this casting method. Therefore the energy industry generally prefers pressure die casting.

What is the Advantage of Aluminium Die Casting in Energy?

The biggest advantage of aluminium is that it is a light material with high strength. Another advantage is its low cost. Aluminium casting in the energy industry contributes significantly to budgets due to high ductility of aluminium. Increased energy saving and efficiency is of course another advantage of aluminium. Being a conductive metal, aluminium helps significantly in heat and energy transmission. And one of the biggest advantages is that it offers long term protection against corrosion. The above mentioned are the main advantages as to why aluminium is preferred.

Kalkancı Aluminium Casting Production Company for Automotive Components

Founded by Hüseyin Paçacı, the company first produced moulds and then also started to work in casting.  With increasing demand as a result of the high quality of the work, Kalkancı built a factory and specialized in metal injection and continues to work in this field. The company that produces parts and components for the automotive industry has aimed and succeeded to move further.

With its vision emphasizing high quality, Kalkancı provides its services in many industries. The company which produces aluminium alloy products for automotive, lighting, energy, construction industries and lately for electric vehicles is one of the most important companies in these industries.

Kalkancı Casting in Energy Industry

Kalkancı stands out with its success in high pressure die casting methods in the energy industry. The company works systematically with high pressure die casting method which provides advantages in quality and cost in continuous/serial production. Complex and detailed parts are produced in the best way with high pressure die casting and the production goal is set accordingly.

Kalkancı Aluminium Die Casting in the Energy Industry

High pressure die casting method is used to produce aluminium parts and components. Aluminium cold chamber casting benches with 4000 and 22000 kN pressure power are used in aluminium production.

Project Experience in Energy Components

Kalkancı has always followed innovation closely and integrated them in its production processes. This company, which first started to work with the automotive industry, has been a pioneer in the production of aluminium parts that are needed and in demand.

Kalkancı which has maintained efficiency and quality at the highest level in production has also met high quality standards with success.  Kalkancı has gained experience in production in the

  • Automotive,
  • Energy,
  • Lighting,
  • Construction
  • Industries and in electric vehicle parts and continues its production.

Please do not hesitate to contact us to obtain more information about what Kalkancı can offer and about Casting in the Energy Industry.