Casting Market

aluminium parts manufacturing

Aluminium Parts Manufacturing

Aluminium Parts Manufacturing 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Aluminium is used in a wide variety of industries as it is a light metal and easily absorbs heat.   Due to its intense use in many industries, production of aluminium parts is increasing every day in Turkey and in the world. The industries that use aluminium the most include Electrical industry, Defence Industry, Engine and Automotive Industry. Aluminium which is also used in many other industries of course has to be manufactured using different processes.

Companies that manufacture aluminium parts should work diligently and very carefully in production. The quality of aluminium, production process and treatments and where it will be used is highly important.  Aluminium products which are used in many important industries to achieve important goals provide advantages, convenience and functionality to customers.

In order to be used in the High Pressure Casting Industry, aluminium should have the properties that allow production of smooth and textured metal parts. In addition to that, aluminium is corrosion-resistant, has a high conductivity and has a good strength-weight ratio, all of which bring extra advantages for parts production. Due to its properties, aluminium offers more surface treatment options to manufacturers allowing production of lighter materials. Lighter materials are preferable. In addition to that despite its lightweight, aluminium is a very durable material. Its durability results in much longer economic life for parts made of aluminium. In addition to above properties, aluminium can be recycled up to 95%.  This material which has a wide range of advantages will not let the user down provided that it is processed by professionals using the right methods. Aluminium is more cost-efficient compared to many other materials. This offers an advantage both to the manufacturer and the customer.  The reason why the use of aluminium is increasing in every industry is its durability and other favourable properties.

Aluminium Casting Manufacturer

Aluminium is widely used especially in industrial goods sector. It is very important that Aluminium Casting Manufacturers offer high quality and professional work since aluminium is used in a wide range of areas and for wide range of functions. We, at Kalkancı continue to be one of the leading companies in this sector. As an Aluminium Casting Manufacturer we meet capital good needs in all of the industries with our vast experience and experienced team focusing on high quality and solution oriented products. We innovatively combine our advance engineering capabilities with our efficient work force as well as our vast experience in the industry. We continue our activities in Aluminium Casting Manufacturing and provide our services to meet die casting needs of local and international industries.

aluminium parts manufacturing 2

We, At KALKANCI provide our Die Casting services to a range of industries including Energy, Lighting, and Automotive.  Thanks to our extensive manufacturing capacity, we play an active role in every stage, from designing high quality moulds to aluminium casting manufacturing processes. We continue to maintain our position with our brand Kalkancı as one of the leading companies for aluminium parts production not only in Turkey but also in the world. We document our experience and reliability with a range of certifications and improve our work every day and offer products to our customers, which are manufactured in a highly reliable and high quality manufacturing environment.

The certificates we have for Aluminium Parts and Casting Manufacturing are: ISO 14001: 2015 / ISO 45001: 2018 Management System certification, ISO 9001: 2015 ad IATF 16949:2016. Our priority at Kalkancı is to maximize customer satisfaction by ensuring timely delivery and providing total solution oriented services with our qualified staff and high manufacturing capabilities.   We ensure customer satisfaction by making plans to provide durable and light-weight die casting solutions and plans to improve mechanical properties and by choosing the right materials for each project.

Cast Aluminium Parts Manufacturers

Aluminium is a very good alloy therefore it can be used in wide range of areas. Cast Aluminium Parts Manufacturers, manufacture a wide variety of parts for many industries. Companies mostly in the manufacturing industry are the core customers of the aluminium casting industry. The reason for this is that almost all of industrial goods need at last one cast product. Several casting techniques have been developed as a result of wide use of aluminium in the industrial goods. There are three main techniques used by aluminium die casting manufacturers. These three techniques are namely Permanent mould casting, die casting and sand casting and today die casting is the most preferred technique.

Die casting is a technique that involves forcing molten aluminium into a steel mould, which is especially used to manufacture precision products. Although it is possible to manufacture high volumes of products using die casting technique, manufacturers need to be very careful and work professionally during the manufacturing stage. Because one of the main factors that affect aluminium quality is the casting technique and how well this technique is applied. Additionally, factors such as competency and experience of the workers working in every stage of aluminium casting process, their experience in the moulding room and meticulous work from the beginning to the end of the process will also affect the quality of the materials manufactured.

Cast aluminium parts manufacturers that provide services to a wide range of industries are expected to have the capacity and competency to manufacture the required product at the highest quality. Aluminium with its high durability can have even longer economic life when processed professionally and using the best technology available.  Aluminium can meet customer expectations perfectly. Therefore, it is very important for the aluminium industry to follow technological and other developments. We, at Kalkancı differentiate our brand by following developments in all areas, and improving and updating our company in line with such developments. With this vision, we provide services to a high number of companies and industries not only in Turkey but also around the world.

Aluminium Casting Supplier

Continuous development in the aluminium industry requires aluminium parts manufacturers to adopt, develop and improve their businesses. Companies in this industry should both use high quality materials and work with qualified and skilled teams. Customer satisfaction, like in any industry, is one of the most important factors that affect business growth. We, at Kalkancı maintain our success and keep the customer satisfaction at highest level by using the best quality materials with our competent and experienced teams.

We, as a cast aluminium products manufacturer, successfully manage our supply, manufacturing and post-manufacturing processes with the right partners because in our opinion, to be the best in business, one needs to work with competent companies that offer the best work. Only then it would be possible to manufacture very high quality parts that can be used for many years.

aluminium parts manufacturing 3

Cast Aluminium Component Manufacturers

Cast Aluminium Component Manufacturers work with high precision during the production.  Not leaving out any stage while manufacturing cast aluminium components has a direct effect on the quality of end products. The journey of aluminium from the mould to the final surface checks and even to packaging is done with great care and diligence. There are some elements that require extra attention during the production of cast aluminium components. One of them is a product called burr.

Burr is a residual material manufactured on the production lines after casting. In addition to that, materials are unnecessarily poured/spilled in some areas during production. For the final stage of component production, residual materials spilled on cast aluminium components should be removed completely. Removal of such materials is very important to ensure that aluminium takes the intended shape. All of the abovementioned stages should be completed to manufacture a cast aluminium component in the best way possible. No production stage must be left out and all stages should be managed or checked by highly qualified staff.

It is very important to make sure that each piece manufactured is exactly the same as the next one when casting aluminium in mass production. Because High Pressure Aluminium Casting makes it easy to ensure that all pieces manufactured are exactly the same. Furthermore, High Pressure Aluminium Casting allows saving time and money.  This method which is preferred by qualified and professional cast aluminium component manufacturers ensures achieving and maintaining maximum level of customer satisfaction.

Kalkancı, High Pressure Aluminium Die Casting Manufacturer

High quality and high volume of production is very important in aluminium casting. The best method that enables this is the high pressure aluminium casting technique which is also used by Kalkancı.  This technique facilitates mass production. Better quality products can be obtained with meticulous work at every stage. With high pressure casting technique that shortens production time and decrease the cost, even the most complicated models can be manufactured more easily and without defections compared to standard techniques. In addition to making things easier for workers, this method prevents downtime caused by manufacturing defections and also allows fast production of spare parts requested by other brands for different industries.

As one of the companies that use high pressure aluminium casting technique in the best way in Turkey, Kalkancı leads our industry by skilfully combining experienced workmanship and new technology.  We provide our services to many distinguished companies and sectors with our experience of almost half a century, our high engineering knowledge, state of the art machinery, R&D activities and qualified staff. We prioritize innovation and as a result of this we have become one of the leading companies in metal injection in Turkey. Because as the Cast Aluminium Component Manufacturer Kalkancı, we manage all processes with the most advanced techniques, equipment and expert staff.

Aluminium injection, which is mostly used for the automotive industry, is a method used in the production of parts that need to be both precise and robust such as the parts that used in vehicle brake systems, gearboxes etc.  The reason why aluminium injection used in the production of such materials is that this technique minimizes porosity resulting in better durability.  Porosity can be reduced to the minimum with aluminium injection. Thus parts with the intended strength can be manufactured. In addition to the automotive industry, aluminium injection technique is used in industrial tool manufacturing, lighting industry, production of materials required for hydraulic systems and hand tools.

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.

areas for aluminium utilisation

Areas for Aluminium Utilisation

Areas for Aluminium Utilisation 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Many raw materials we extract from the nature around us can be processed and used in production. One of the most outstanding of these raw materials is the “AL” element which is found in the form of bauxite ore. Aluminium is also distinctive thanks to its superior heat resistance which sets it apart as having a more durable structure compared to other elements. It is used widely in many areas of production, especially in the industrial, construction and transport industries. This particular element has achieved such a wide array and popularity of use, that it is favoured in almost every sector.

The Advantages of Using Aluminium

Being the most commonly found and easily extracted element on our planet, aluminium’s use is further enhanced by its ease and versatility in shaping. Its recyclability means it can form part of a more environmentally friendly production process. Aluminium’s contribution to the global economy is very significant indeed. Some of the advantages offered by this element are:

  • Ease of access,
  • Long-lasting use,
  • Malleable structure which is easy to shape,
  • Environmentally friendly from production to consumption,
  • Easily coloured as desired
  • Safely used in areas such as food etc.
  • Able to conduct electricity.

Eight Areas in Which Aluminium is Currently Most Used

Because of its wide availability in nature, ease of use, durability along with the fact that it transmits the heat, Aluminium can be found in almost any product that springs to mind. As an element that is often used in various industries, it is most important particularly in the Electricity, Construction, Consumer Electronics, Consumer Goods, Transportation, Defence Industry, Thermal pads and Precision Tubes industries.

1. Electricity Sector

Due to the fact that it is a highly conductive element, aluminium is often used in electricity transmission lines. In particular, it is most used in electric power lines and similar functions. These are as follows:

Power Lines

Copper and aluminium are usually the preferred components of electricity distribution lines. In large part thanks to their affordable and durable nature, these two components are indispensable for the electricity sector. Although copper is more affordable, aluminium is more widely used in conductor production because of its greater durability relative to copper. In addition, aluminium is lighter than copper, and the use of lightweight products is also an important factor in high-voltage overhead lines.

Engine Parts

Frequently encountered in this sector due to its lowered noise advantage and longer-term use because of the thermal conductivity it provides, aluminium is one of the most highly preferred materials in today’s engine parts manufacturing. In addition, engines using this element have become even more popular due to the fact that aluminium minimises their environmental harm. As a consequence, aluminium forms an integral part of EURO-6 type engines that are widespread in Europe, confirming the environmental credentials of this raw material.

Television Antennas

The use of aluminium in antennas providing transmission of terrestrial channel broadcasting to televisions is quite significant. Certain alternatives are available for the manufacture of antennas and cables, but copper and aluminium stand out by far. Aluminium’s weather resistance and light weight nature plays a key role in its frequent use in television antennas.

Satellite Dishes

Satellite dishes, like television dishes, are another type of product in which aluminium can be used very effectively. Thanks to aluminium use in antennas, the correct flow of heat is ensured. Furthermore this element provides powerful electrical transmission and an impeccable broadcasting service. In particular, it’s perfect for use in the antennas of satellite dishes, because its longevity prevents probable losses.

2. Construction

Aluminium usage is very widespread in the construction and architecture sectors. Aluminium is used in laying the foundations of buildings as well as in the preparation of external facades. It is also possible to see this element in many of the details of a construction such as in its windows, sheet metal coating and on doors.

High Rise Buildings

Aluminium is essential to both the construction and the post-construction phases because of the fact that when alloyed, it becomes highly durable. The level of durability of the alloyed state of the element allows the building of high-rise structures with complete peace of mind. In addition, aluminium-based facade products have been coming to the fore in recent years for exterior facades. These coating products provide flawless thermal insulation.

Window Frames

Aluminium is the preferred alternative for window frames because of its durability along with the other advantages it offers. The assurance of longevity, combined with the fact that aluminium minimizes distortions caused by external factors, are just some of the features that attract users to this particular material. In addition, aluminium-based windows provide easy maintenance and cleaning.

Architecture

Aluminium can be shaped to produce aesthetically stylish products, which means it is increasingly used by architects as time goes on. Its durability, resistance to abrasions and deformations adds to its popularity from an architectural point of view. Standing out as an environmentally friendly alternative, it is also a key component of the architectural restoration business.

3. Consumer Electronics

Aluminium is a key component of many of the products that we come across in our daily routines which help to make our lives easier. Besides its many advantages such as durability and low cost , aluminium is also visually pleasing and therefore a preferred component in many products.

White Goods

White goods are among the most important products of the consumer sector. Many people use household appliances, especially refrigerators, washing machines and dishwashers in their homes. The use of aluminium in the white goods sector is extremely widespread. The chief reason for this intense use is the lightness and versatile structure of the material.

4. Consumer Goods

It is possible to come across aluminium in almost all of the products we find in our homes. It is used commonly to increase the durability of many consumer products, whether small or large. Tools and utensils which contain this material are considered optimal, particularly when it comes to kitchen utensils. This is due to the fact that aluminium has good thermal insulation and provides the desired cooking performance. The use of this element in the packaging and entertainment industry is also quite common.

Packaging

Aluminium is easy to produce and relatively environmentally friendly making it popular for brands to use in their packaging designs. Most noticeably, aluminium is found in the production of canned drinks and tins. Featuring long shelf life and heat resistance, aluminium ensures that consumer products can be stored intact and presented to the consumer without complications.

Sports and Auto Racing

Aluminium is also one of the most important components in the production of sports equipment. Durability and style are the leading reasons why the sports and motorcar racing sectors choose aluminium. For example, aluminium is widely used in the construction of bicycle skeletons, sledges and golf clubs. As for the entertainment industry, the effect of aluminium can be observed in the construction of safe vehicles. Without aluminium, racing vehicles produced for motor sports such as Formula 1, Moto GP and NASCAR would not be currently possible.

5. Transportation

Aluminium alloys have been indispensable raw materials in the production of aircraft for quite some time. Even though other materials are increasingly used in this industry, aluminium continues to be a major contributor to this sector. Thanks to its lightweight structure and heat resistance, aluminium continues to be essential in the construction of transport structures.

Automotive Industry

Featuring high resistance to corrosion and ease of shaping and durability, aluminium is intensively used in the automotive industry. Used to optimally shape the largest to the smallest parts in the Auto sector, aluminium is used in almost every part of a vehicle; from engine parts to suspensions, from engine mounts to the battery bodies of electric vehicles. Produced with impeccable precision by KALKANCI, these structured parts constitute an important place in the automotive sector. For more detailed information about the importance of aluminium in the Automotive Sector we recommend that you read our article titled “Automotive Casting Industry”.

Spacecraft Parts

Aluminium is also used in the construction of rockets and other types of spacecraft. NASA often chooses to work with aluminium components, especially in rocket construction. It has proven to be reliable in durability and heat management in its alloyed state even in the challenging environment of outer space.

Ships

Found frequently in ship design, aluminium enables ease of ship construction thanks to its lightweight nature. Its use on the hull and superstructures of ships adds durability to the overall construction. You can find this element in storage at many shipyards.

Trains

Aluminium can also be found commonly in the production of trains and passenger vehicles. The manufacturing of wagon parts on trains includes this material. From steam trains to high-speed trains, the entire range of trains will always include aluminium in some form or other.

Individual Vehicles

Our cars contain many aluminium parts. In order for us to enjoy safe transportation, the structure of our cars must be both durable and provide comfort of use. It is for this reason that this material is almost always included in the production of car parts. Aluminium plates, plaques and profiles are also used in the body parts of vehicles such as the engines, radiators and on wheels.

6. Defence Industry

Because of its resilient and durable structure, aluminium is also used very effectively in the defence industry, for example in constructing military vehicles. Aluminium can be used in weapons production, military equipment, vehicles and many other defence industry products, and is also an important component in design of aircraft because of its lightweight structure. It can also be found in parts of unmanned drones produced today.

Aircraft Parts

Aluminium alloys are used as a raw material in aircraft production. They are very important in aircraft construction because of their durability and resilience. Aluminium does not lose its integrity when confronted with pressure or weather changes, and this is way it is so important in aircraft production to provide maximum safety.

Another key advantage which leads to its widespread use is that it is easy to shape. The durability that results as a consequence of being alloyed, combined with the fact that it is easy to shape, results in high versatility of use.

7. Heat Sinks

Many electronic products and cables experience distortion and deformation problems due to overheating. Heat sinks play an important role in preventing electronic goods from deteriorating from excessive electric current and fires that may occur.

Heat sinks are usually made of metallic materials, and aluminium is the most common element chosen by manufacturers. In addition to being low-cost and easy-to-obtain, aluminium allows heat conduction with ease. Its use as a heat sink can in some measure be attributed to its lightweight nature.

8. Precision Pipes

Precision tubes or pipes, though possessing lighter weight, nevertheless ensure a safe construction process. They are ideal because of their durability, paint absorption and flexibility. Aluminium precision pipes are also beneficial due to their environmental friendliness. Because of their long service life, aluminium pipes are optimal for infrastructure systems. Precision pipes are commonly used in the following industries:

  • Shipping,
  • Airlines,
  • Agriculture,
  • Electric,
  • Automotive.

KALKANCI, has been serving the Turkish metal sector industry since 1981 through its significant contributions and has today achieved a unique momentum in the field of moulding, offering the most optimal solutions to all our customers’ production needs. In particular, we are experts in casting, mould design and production; and our impeccable processing, vibration and sandblasting services are also available. KALKANCI‘s export ratio is 98%, definitive evidence of our superior capability in partnering with our customers to find the best solutions to their production needs.

Automotive Casting Industry

Automotive Casting Industry

Automotive Casting Industry 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Automotive Casting refers to a casting technique carried out using aluminium materials for the production of automotive parts. Under Kalkancı’s warranty Automotive Casting is produced by the aluminium technique for the reason that the finished product resists corrosion and has a high degree of durability. In order to achieve maximum durability during the implementation of this technique, the melted aluminium is poured into moulds by applying pressure. The technique of Automotive Casting can be implemented in two ways, being either as hot or cold chamber die casting.

The Application of Aluminium in Automotive Industry

With the combination of several factors including the environment, cost of oil as well as other different factors in automotive industry, there is a tendency towards aluminium usage. Aluminium parts, which can be produced by casting and extrusion methods, have also been introduced to the automotive industry due to being lower in cost than their alternatives.R&D studies carried out worldwide and the production of alloys in the automotive sector represents casting techniques which are mostly used together with aluminium at present.

The Application of Aluminium Casting in the Automotive Industry

Aluminium, which is widespread in its application for Die casting, is actually a challenging element for casting. Despite this, the proportion of its durability to its light weight is ideal. The application of aluminium casting in the automotive industry is preferred for its malleability, high conductivity, and recycling features. As car spare parts are usually very small in structure, aluminium subjected to the casting processes is suitable for the casting of these intricately constructed minimal parts.

Aluminium Alloy Parts in The Automotive Industry

The increasing competitive environment of the industry and the awareness about environmental protection have created the quest for an alternative to the elements of steel and iron in the production of parts for cars. Aluminium alloy parts, which are provided as an alternative to these materials within the sector, enable reductions in fuel consumption in automobiles whilst increasing driver safety. The automotive industry’s indispensable alloy parts are listed below:

  • Aluminium silicon alloys,
  • Aluminium manganese alloys,
  • Aluminium copper alloys,
  • Aluminium zinc magnesium alloys.

Why Use Aluminium Die Casting in The Automotive Industry?

The casting process takes place by forming melting materials via the method of pouring them in different shaped moulds. The main purpose of casting processes is to melt substances and convert them into useful products. The aluminium die casting processes are used to ensure that even the smallest parts are produced in the most optimal way. Die casting systems produce shapes by pressing the melted metals into the mould cavities under high pressures. These techniques are used in the industry to ensure that automotive parts are recyclable, provide high performance and are value for money in terms of cost.

What is the Advantage of Aluminium Automotive Castings?

Our brand, which is a leading solutions provider for Automotive Casting techniques, offers many advantages to the industry in terms of the cost to benefit analysis for automotive parts. It is clear that aluminium‘s use is more advantageous when compared with steel materials in terms of its density and durability ratios. Additionally, the use of Automotive Casting improves the axle vibrations of vehicles as well as their absorption properties against impacts and sounds. The production of much stronger and compatible parts than steel materials is only possible with Automotive Casting.

Kalkancı Aluminium Casting Company for Automotive Components

The casting components that we produce at Kalkancı for the automotive casting technique are listed below as follows:

  • EN AC 46000,
  • EN AC 46100,
  • EN AC 44300,
  • EN AC 47100,
  • EN AC 43400,
  • A380 & A383,
  • Custom / EN AC 43500 & EN AC 51500,
  • RHEINFELDEN Components,
  • Magsimal,
  • Silafont,

Kalkancı Automotive Casting Capabilities

The Kalkancı brand has production capabilities in Automotive Casting with the following techniques:

  • Aluminium Casting Anti-Vibration Components
  • Aluminium Casting Engine Components
  • Powertrain components
  • Water pump shafts and lids (electric and heavy duty)
  • Circulation pump shafts and lids
  • Hydraulic powertrain parts
  • Integrated Power System Enclosures
  • PCB board carriers
  • Chassis Assembly
  • Chassis Support
  • Chassis Brackets
  • Engine Connection Housings for Electric Trucks
  • Light Vehicle Products: Insulators and Dampers | chassis
  • Active Hydro Engine Assembly Housings
  • Electronic Control Unit Housings and Lids
  • Electric Vehicle Battery case
  • Outdoor lighting housings
  • Lighting solutions
  • Drum support and pulley for white goods
  • Inverter Housings, Brackets and Lids
  • DCDC Converter Housings
  • Refrigerant Storage
  • Casting mounts valve housings

Kalkancı’s Automotive Aluminium Casting Manufacturing Capabilities

At our company, all casting operations are carried out in special foundries. The high-pressure casting technique, which is one of the most preferred methods of casting at present, enables mass production at our foundries. This method offers both price advantages and high-quality performance for Automotive Casting. The automotive equipment we make use of in our aluminium casting manufacturing is listed as follows:

  • Robots for lubrication of moulds that are actively used on all our work benches.
  • Obtaining raw materials from soldering systems on work benches.
  • Dosing furnaces.
  • Casting robots operating on 6 axes in accordance with cell systems.

The other equipment that strengthens our manufacturing capabilities also include aluminium cold chamber casting benches. Machines with a high volume of processing power work together with industrial robots for high-quality production. At the same time as our Automotive Casting production and management systems are being carried out online, data collection software is used to perform monitoring and planning.

Project Experience regarding Automotive Parts

Kalkancı Design Centre provides services offering professional solutions on the following issues.

  • Magmasoft Simulation,
  • Project Design,
  • Industrial research,
  • Laboratory studies.

Project skills in the production of car spare parts are constantly improved with the use of up-to-date technological means. The development process also aids in changing production parameters more accurately.The project expertise backed by R&D studiesenables the design and planning of products before beginning production, providing a complete solution in terms of design and simulation. The goal of this is to make possible the calculation of the required raw material supply, production and targeted sales performance for each part to be produced. Project planning and studies enable complex calculations such as financial expenditure units, cost and benefit ratios, and also enable risk planning to be performed. The design process provides a production flow that can be managed on behalf of enterprises.

Kalkancı, Automotive Casting Company

Contact us by clicking on the contact link to benefit from the range of comprehensive and professional services Kalkancı provides in the Automotive Casting Industry.

The Aluminium Casting Market

The Aluminium Casting Market

The Aluminium Casting Market 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

With its high strength, pliability and light weight, the Aluminium Casting Market is preferred in many industries today for being an area of production which has high added-value. Due to the fact that aluminium is an excellent alloy, the variety of products that can be obtained is the chief reason its being preferred in much industrial manufacturing.

In general, companies in the manufacturing industry and sector represent the Aluminium Casting Market’s basic customer base. Countries which possess a strong supply industry and which have superior production capacity comprise the Aluminium Casting Market’s majority markets. So much so that, in most cases, at least one casting product is needed for all industrial products.

The main reason why Aluminium is preferred to such an extent in all these sectors and in production is its durable structure based on its resistance to corrosion and electrical conductivity. During the production phase, Aluminium Castings are manufactured by forcing a particular mould from molten metals using a high pressure system and they are additionally prized due to their affordability and highly stabilized sizing potential. In the Aluminium Casting Market, during the casting of aluminium for the production of parts, many techniques such as Sand Casting, Metal Injection Casting, and Low Die Casting are employed. This varies depending on the quantity, shape, physical properties of the product to be produced, allowing the needs relating to aluminium parts production to be met with ease. Consequently, Aluminium is the preferred material in many sectors due to its advantages and because it can be modified according to requirement.

Why Choose Aluminium Casting?

  • Aluminium Casting products are lightweight in general and are practical to use.
  • Their production efficiency is high; energy costs and carbon absorption are low.
  • Materials produced by aluminium casting are used in many sectors such as in electricity, electronics, telecommunications, the hardware, industry, automotive, hardware stores, lighting, retail, etc.
  • They are highly conductive.
  • Aluminium casting enables fast production due to ease of shaping during manufacturing.
  • It is not a toxic alloy.
  • It has a recyclable and durable structure.
  • Aluminium casting results in a fine reflective surface.

Aluminium Casting Companies

Aluminium Casting Companies, use three basic techniques for Aluminium Casting manufacturing. These are Die Casting, Permanent Mould and Sand Casting, of which Die Casting is the most common. This technique, which can also be described as the forcing of molten aluminium into a steel mould under the influence of pressure, is very effective for manufacturing precision products. This process should be executed specifically by Aluminium Casting Companies using meticulous implementation to result in high-volume production.

Aluminium Casting requires both the casting ability and technical experience of its employees, as well as meticulous attention to the completion of the processes and the high standards of moulding roomunits in order to increase the quality of the output product.

It is for this reason that companies engaged in casting, should have the competencies to serve their customer base in the entire spectrum. Many sectors such as the Automotive, Lighting, Defence, Transportation, Medical, Energy industries prioritise working with qualified personnel providing Aluminium Casting Services in order to expand their activities by products that are durable and sustainable in the long-term.

KALKANCI is ideally positioned in this broad spectrum of services and stands out as an Aluminium Casting company that can provide services globally. KALKANCI provides professional services both in its domestic market Turkey as well as in many countries thanks to its high-tech equipment and its team of experts.

KALKANCI’s Aluminium Casting Manufacturing

Aluminium Casting Manufacturer KALKANCI is professionally active in the energy, lighting and automotive sectors. As a Casting Manufacturing Company we are able to provide a holistic service in “meeting market demands”, which is one of the most important expectations of the sector. Our ability to produce high quantity orders without a decline our service and product quality sets KALKANCI apart and positions us as one of the leading producers in our sector both domestically and globally.

KALKANCI’s main production of Aluminium Casting activities serve three main sectors – automotive, energy and lighting- which are where market distribution is the most intense. Aiming to achieve maximum efficiency in as short a period of time as possible within the limits of the quantity, shape, physical characteristics of the product to be manufactured, KALKANCImakes it possible to meet the demand in the aluminium parts production space.

Production of Aluminium Parts

Aluminium Casting Manufacturer KALKANCI provides high quality professional services in the Production of Aluminium Parts for the energy, lighting and automotive sectors by meeting their Aluminium Casting needs. Our Company offers innovative solutions and efficiency in the high-tech space, bringing its affordable products to market thanks to its experienced engineering team. As a leader among companies providing aluminium casting services in Turkey, it is powerfully active in a wide range of production areas: from hydraulic systems to the automotive sector, from lighting products to power units.

KALKANCI has driven the reduction of margins of error on mechanical parts production with Aluminium Casting, offering product support globally to many industrial cities as a premier casting manufacturer. Our Company excels at high-level service quality in power and components requiring attention to detail for vehicles such as brake parts, gearboxes, industrial robots, finding definitive solutions to the need for high-pressure aluminium casting. KALKANCI has the capacity to produce products that ensure the highest level of industrial efficiency in a short time, assisting company workflows by supplying the casting industry with a new paradigm.

KALKANCI Casting Factory

Providing services on the principle of maximum efficiency in order to be responsive to sector needs of companies, KALKANCI enables the saving of both time and cost, and delivers products for the casting industry addresses in a short time. Our company, serving as a manufacturer of high-pressure aluminium casting at an affordable cost, strives towards error-free production as its goal due to its rigorous working principle. Thanks to its experience in accelerating the routine operations of industrial branches, its

8 different casting robots with 6 axes, its comprehensive equipment such as its automatic mould lubrication robot technology, automatic bucket system, our Company is able to accelerate production exponentially.

Priority in the Casting Industry: Maximum Efficiency

KALKANCI offers different solutions for the casting industry with products prepared according to cell systems on production machines and affordable prices, making it possible to collect data automatically through on-line management systems. The target when producing on Aluminium Cold Chamber Casting Benches by use of high-volume industrial robots, is to provide reliable and high-quality services to all companies in their respective fields of Automotive, Electrical and Energy. KALKANCI adds value to projects through its approach to solving the high unit production and sector needs in a short time frame, also collecting samples obtained from the products during the post-casting process in order to perform quality controls.

Our Company’s journey of powerful team work in all areas of casting production serves to meet industrial requirements completely by employing automation systems at its CNC Machining centres where data can be stored on-line 24/7. KALKANCI has completed its necessary internal analysis processes in order to minimize any problems that may arise in the production process and is one of Turkey’s leading aluminium casting companies thanks to its wide spectrum of working areas.

Istanbul’s Aluminium Casting Manufacturer KALKANCI

Please contact us to find out more about how KALKANCI can serve your Aluminium Casting needs.

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