Die Casting

Castings for Lighting Industry in Die Casting Foundries

Castings for Lighting Industry in Die Casting Foundries

Castings for Lighting Industry in Die Casting Foundries 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

In the modern lighting industry, aluminum pressure die casting plays a vital role in producing high-quality lighting casting parts that illuminate our lives and many parts used in this sector. As a leading foundry company in the Kalkancı Pressure Die Casting, it has embraced this advanced manufacturing technique to meet the increasing demands of the lighting industry. Lighting products produced through the Pressure Die Casting method are carefully designed to provide high performance. Lighting products must continue to operate even in high temperatures and varying climates. Therefore, the design and production of these products are a highly delicate process.

Kalkancı Pressure Die Casting and Aluminum Pressure Die Casting: Illuminating Excellence in the Lighting Industry

Advantages of Using Aluminum Pressure Die Casting

Aluminum pressure die casting is a manufacturing process that involves injecting molten aluminum into a pre-designed mold to create complex lighting components. This process has become a preferred option for lighting manufacturers due to its exceptional flexibility, precision, and cost-effectiveness. The process ensures consistent quality, dimensional accuracy, and excellent surface finish. Additionally, aluminum is popular due to its high corrosion resistance and ease of machining.

Aluminum Pressure Die Casting in the Lighting Casting Industry

Like many other industries, using Aluminum and Aluminum Pressure Die Casting in the Lighting Casting Industry provides numerous benefits. These benefits include:

  • Lightweight and Durable: Aluminum pressure die casting parts are ideal for lighting fixtures because of their lightweight nature. They provide structural integrity and durability, ensuring longevity and resistance to corrosion and other environmental factors.
  • Design Flexibility: The die casting process allows for intricate and detailed designs, enabling manufacturers to create aesthetically pleasing lighting fixtures that meet various customer needs.
  • Heat Conductivity: Aluminum has excellent heat conductivity, making it an ideal material for dissipating heat generated by lighting elements such as LED modules. This feature enables efficient heat management and extends the lifespan of LEDs.
  • Cost-Effective Production: Aluminum pressure die casting enables high-volume production with minimal post-processing requirements. The process is highly automated, reducing labor costs and providing competitive pricing for lighting manufacturers.
  • Aluminum is easily formable due to its easy machinability.
  • Aluminum Casting allows for the high-volume production of complex and precise parts to be used in the Lighting Casting Industry.
  • Its lightweight nature makes assembly and transportation easier.
  • Aluminum provides better protection and is corrosion-resistant compared to other metals like stainless steel. It is resistant to outdoor conditions and does not deteriorate when exposed to high temperatures, moisture, and sunlight.
  • It is commonly used in lighting systems due to its ability to work at high temperatures.
  • Aluminum is a recyclable material and causes less harm to the environment.
  • Its high light reflectivity capacity allows for brighter and more efficient lighting systems.
  • It is aesthetically appealing and popular in modern design trends.

Application of Aluminum Pressure Die Casting in the Lighting Industry

The application of Aluminum Die Casting in the Lighting Industry involves the casting, processing, and finishing of molten aluminum under high pressure using specialized molds. In its simplest form, the process is as follows:

  1. Mold Making: To cast aluminum, a mold must first be made in the desired shape and size. This process is typically done using computer-aided design (CAD) and computer-aided manufacturing (CAM) technologies.
  2. Aluminum Melting: The aluminum used for casting is melted at high temperatures in a melting furnace. Aluminum needs to reach approximately 660°C to melt.
  3. Mold Filling: The molten aluminum is poured into the prepared mold under high pressure using appropriate machinery. Once the aluminum inside the mold cools down, it is removed.
  4. Part Processing: The aluminum part removed from the mold is processed as needed. This process involves cutting, drilling, grinding, milling, or other machining techniques.
  5. Finishing Processes: The processed aluminum part is prepared for necessary color and surface treatments. These processes may include painting, polishing, or coating.

Aluminum  die-cast products are made from alloys such as aluminum, copper, and zinc. A precise process is carried out to ensure product quality and customer satisfaction in aluminum alloy casting. Alloy processes involve sampling products from all processes by professional teams.

Aluminum heat treatment uses appropriate furnaces and equipment to actively contribute to the development of professional technology and services in the workflow. In addition, heat treatment to quality standards maximizes durability.

Surface treatments are the last stop in the production line of aluminum die-cast products. Aluminum surface treatment undergoes a process of vibration, polishing, washing, and sand blasting. These application processes help the product get rid of stains and oils, gain shine, and prepare for coating and painting.

Castings for Lighting Industry in Die Casting Foundries 3

Applications of Aluminum Pressure Die Casting in Lighting

LED Lighting Fixtures: The emergence of energy-efficient LED technology has revolutionized the lighting industry. Aluminum pressure die casting is widely used in the production of parts such as heat sinks, casings, housings, and reflectors for LED lighting fixtures, maximizing heat dissipation and ensuring optimal performance.

Street Lighting and Outdoor Lighting: Products produced through aluminum pressure die casting are commonly used in streetlights and outdoor lighting fixtures. Its lightweight structure, durability, and corrosion resistance make it suitable for various environmental conditions.

Decorative Lighting: The design flexibility provided by aluminum pressure die casting allows for the creation of decorative lighting fixtures such as chandeliers, pendant lights, and wall sconces. These fixtures enhance the atmosphere of residential and commercial spaces by combining functionality and aesthetics.

KALKANCI Pressure Die Casting Lighting Foundry

As a leading foundry company in the sector, Kalkancı Pressure Die Casting pioneers aluminum pressure die casting in the lighting industry. Our state-of-the-art facilities, advanced machinery, and experienced team enable us to provide superior aluminum pressure die castings that meet the industry’s highest standards. By closely collaborating with lighting manufacturers, we offer comprehensive solutions from design support to final production, ensuring on-time delivery and customer satisfaction.

Kalkancı Pressure Die Casting: Empowering the Lighting Industry!

Aluminum pressure die casting has become an integral part of the lighting industry, offering advantages such as lightweight construction, design flexibility, heat management, and cost-effectiveness. With its expertise and commitment to excellence, Kalkancı Pressure Die Casting continues to contribute to the growth and innovation in this dynamic industry. By embracing aluminum pressure die casting, the lighting industry can illuminate the world with effective, durable, and visually appealing lighting solutions.

KALKANCI provides professional services and solutions in the foundry industry, offering the most suitable products for the Lighting Sector with its high-tech working areas, experienced engineering team, and R&D teams. KALKANCI’s foundry, is one of the largest mold production bases in Turkey. As an Aluminum Casting Manufacturer providing products to many countries, KALKANCI also provides clear solutions for the desired products in the Lighting Casting Industry. The changing and rapidly evolving needs of this sector are closely monitored by KALKANCI. Changes are integrated into all processes if necessary.

KALKANCI adheres to its fundamental principles to ensure the fulfillment of project realization or aluminum casting activities, delivery dates, and specifications. All production processes are renewed to develop professional technology and services.

Turkish Lighting Casting Industry

As a product of the modern age, the aluminum casting industry is constantly evolving. Lighting casting products occupy a significant place in Turkey. This sector plays an important role in Turkey’s development and progress. The foundry industry is one of the fundamental industries of the manufacturing industry. Therefore, the actors are at the forefront of the production method that provides the highest added value for metal. The lighting casting industry and products in Turkey hold an important.

Castings for Lighting Industry in Die Casting Foundries 2

aluminum die casting tooling types

Aluminum Die Casting Tooling Types

Aluminum Die Casting Tooling Types 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

The word (die) casting, derived from the act of pouring, refers to the release of any fluid substance. In the Aluminum die casting tooling sector this concept refers to the filling of melted metals into spaces, in other words, into the cells, created after the preparation stage.The main purpose of the die casting process is the conversion of molten materials into pre-designed products and to give a form to the molten substance.

Metal casting, also known as high pressure die casting is the transfer of melted metals to tool cavities under high pressure. Our company has applications for different types of tools and castings to be used in the energy, lighting, and automotive sectors. Types of tools that are produced with the Kalkancı quality are as follows:

  • Aluminum high pressure casting tools,
  • Trimmingtools,
  • Cutting tools,
  • Compression tools,
  • Crimping Tools,
  • Prototype Tooling up to 120.000 Shots Guarantee with serial quality

Usage Areas of Aluminum Die Casting Tools

Aluminumdie casting tool types vary according to usage areas and the sectors to be applied. Today, types of aluminumtools are used in many sectors and thanks to their recyclable properties, casting types offer low costs per part in high quantities, which directly affects the performance of the products used. Low cost and functional tool variants are produced with the Kalkancı guarantee.

Before the production phase, design, filling, and solidification simulation studies are carried out for each part. The usage areas of aluminum die casting tooling types extend to many sectors such as electronics, energy, automotive and lighting.

Types of Aluminum Die Casting Tools in the Automotive Sector

Lightness of the material, its resistance to high temperatures, its conductivity properties and its resistance to corrosion have an important place in the widespread use of aluminum tools, whose use dates back centuries. Especially in the automotive sector, the use of aluminum tools is emphasized for the changes in environmental factors, problems in consumption of petroleum-derived fuel, and safety of passengers and vehicles.

Expansion of products with casting and tool types, encourages the production process of basic parts in the automotive sector with aluminum. Automotive parts manufactured with aluminum die cast tools, have much lower costs and are more profitable than their counterparts. The use of thin-walled, light and high-strength products in vehicles is also have made aluminum products more popular.

Types of Aluminum Die Casting Tools in the Lighting Sector

Aluminum tool and cast types are used in general outdoor lighting systems for main and side streets, parks, and gardens. Aluminum lighting die casting tools have many advantages. Aluminum alloys with heat treatability, can also be included in decorative lighting poles and systems used as flag poles.

Types of aluminum die casting tools and castings, which have a high durability, are resistant to weather conditions such as wind, rain, and hail. Aluminum die casting tool types with higher corrosion resistance than alternatives, are among the indispensable products of the lighting industry.

Types of Aluminum Die Casting Tools in the Energy Sector

While the structure of the aluminum material allows for 100 percent recovery, it is categorized as a green and environmentally friendly material with its current properties. Therefore, aluminumdie casting tool types are indispensable for the energy sector. Types of aluminum die castings that provide an ideal basis for energy production and energy efficiency, are used for the realization for many projects.

Today, it is possible to frequently come across factories and production facilities that produce their own energy. The main installations of the energy sector, such as power generation, prefer aluminum die casting tools in the production phase.

Aluminum Die Casting Tool Types of Kalkancı

The Kalkancı R&D and project center operates on a technological basis, from production phase to the delivery process. Creating a top-quality range of aluminum die casting tools and contributing to the industry by reducing production costs are among our core principles.

We produce our own qualifiedtools for aluminum die casting in our own tooling room. Our tools are designed to best suit our customers’ needs, in line with limited deadlines and cost efficiency, to produce first-class products throughout the entire process chain.

Affordable price guarantee and product quality are features that reveal the difference of Kalkancı aluminum die  casting applications. The types of aluminum die castings and tools that we produce for the energy, lighting, and automotive sectors, which ensure the continuity of the industry, are used in the production stages of leading Turkish brands. Production and improvement studies carried out within the scope of Industry 4.0, allows us to provide the best service to our customers. To receive more detailed information about our products and services you can request a presentation here.

aluminium casting manufacturer

Aluminium Casting Manufacturer

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

Our Company is active in meeting the industrial needs of many sectors, combining our professional engineering capabilities with years of experience and an efficient workforce to produce innovative aluminium die casting manufacturing. Kalkancı’s services are particularly focused on the energy, lighting, automotive and construction sectors, in which its staff of experts engages in constant R&D work to produce new solutions for changing sector requirements, carrying out casting production to meet market demand. From mould designs with expanded production capacity, to aluminium casting production processes, consignment stock, usage and payment termsour Company, which provides turnkey services, is one of Turkey’s leading enterprises.

Depth of Experience in Aluminium Casting Parts Production

Our Company was established in 1981 as a mould manufacturer and went on to be very active in the foundry sector after 1987. Our first manufacturing plant was in the Maltepe district of Istanbul on the Asian side; we moved to larger facilities at our Pendik factory in 1993 in order to increase our operating capacity due to strong demand from the sectors we serve.

In 2006, after further progressing our range of services to meet the fundamental needs of the aluminium die casting sector“, we moved to our Tuzla integrated facilities. Today, Kalkancı continues its activities of designing projects, die casting and manufacturing at our sophisticated facilities in Tuzla. We have the following certificates:

  • ISO 14001:2015 / ISO 45001:2018 Management Systems,
  • ISO 9001:2015,
  • IATF 16949:2016.

Our goal is to become a world-class brand by taking customer satisfaction to the next level through our professional and high volume production capacity, timely delivery and ability to offer complete solutions to our customers.

Why Choose Kalkancı?

Our R&D work has vastly improved our ability innovate to produce what the sector requires. 5S, Kaizen and lean manufacturing are just some of reasons why our customers choose Kalkancı: these practices shape our activities, innovative ideas and are reflected in how we approach servicing our customers.

The rapidly changing and transforming needs of the sectors we serve are closely monitored by us and reflected back into all our processes. We know that the complete and timely meeting of customer demands, combined with the high-level of service we provide, are among the chief reasons why customers choose Kalkancı. Our Company has a unique approach to the concept of quality covering the entire production value chain from conception and design to die casting; from producing consignment stock to delivery.

Aluminium Casting Capability

Our Company creates projects and production processes that stand out in the aluminium casting industry. One of our fundamental principles is to meet programme deadlines and technical specifications with total discipline for the projects we undertake and in our field of aluminium casting. All our production processes are upgraded in accordance with technological advancements, and our professional services -combined with the quality local and international standards certificates we possess- help us accelerate our progress in these areas.

R&D and Project Development

Our design centre, which began operating in 2019, continues to provide services in fundamental areas such as industrial-based research, project planning, design and magmasoft simulations through R&D throughout the project development processes. The fact that our R&D centre is located in our Company provides us with a competitive advantage compared to the rest of our industry and helps us strengthen our technology, reduce production costs, etc., which we can reflect back to our customers.

Aluminium Mould Chamber

While aluminium Die casting is the most basic part of die casting activities, its application is also a priority in mould production. The moulding workshop located in our Company has the largest capacity in Turkey’s mould production. Almost all of the problems that are likely to be encountered in production processes can be avoided by simulating mould designs in order to take precautions.

Aluminium Materials

Reducing costs, improving mechanical properties, durability and through its light-weight die casting,Kalkancı helps customers select the most suitable material for their projects in a solutions-oriented manner. Aluminium is one of the most fundamental materials for our sector’s future and occupies a very important place in global trade. Among the aluminium materials we use are:

  • Traditional alloys.
  • Special alloys produced from primary materials.
  • Rheinfelden Alloys; special alloy alternatives.

Aluminium Melting

Our Company carries out activities in its melting workshop, aiming to prevent metal losses in processed aluminium. To increase the efficiency of projects through research and development support, it’s possible to reduce existing costs, actively use recycling materials, and achieve high-level quality standards through aluminium melting activities.

Aluminium Alloy Casting

Die casting production is made with alloys such as copper, zinc and aluminium. Our Company carries out aluminium alloy casting with the aim of achieving the highest level of customer satisfaction. Alloying processes are monitored by our professional teams using sample collections during the production process.

Aluminium CNC Machining

In all sectors of the industrial manufacturing, CNC machines are an indispensable part of production process. CNC machining is used in a wide range of areas, from the automotive sector to construction activities, from industrial machinery production to the defence industry. One of the reasons why our Company is highly ranked is that we include CNC machining in all the project work we perform.

Aluminium Heat Treatment

Furnaces and heat treatment equipment, which are actively used in the services our Company provides, provide products with high strength, high efficiency, and with different mechanical properties. The heat treatment processes carried out to very high quality standards, bringing the level of durability for products produced to the maximum level possible.

Aluminium Surface Treatments

The last stop of our activities along the production line is our surface treatment. Aluminium surface treatments include vibration, polishing, washing and sand blasting. These applied processes help to remove burrs and oil from products, giving them a shine and readying them for the coating and painting processes.

Our Production Packaging Process

Professional manufacturer systems and state-of-the-art equipment ensure packaging of products leaving our production lines. As with all that we do, our product packaging processes are carried to a very high standard of quality.

How does Kalkancı handle Casting Projects?

The quality we aim to provide in aluminium casting and die casting projects covers each and every stage of manufacturing through to the delivery process. Our R&D work supports our project design process in order to fully meet the expectations and needs of our customers.

Kalkancı advanced Aluminium Casting production equipment

Kalkancı uses state-of-the-art equipment in all its manufacturing processes, such as for aluminium casting and die casting. Our moulding workshops are equipped with CNC machines, heat treatment tools and modern and high-tech equipment which are used in all of our basic processes. Contact us for detailed information about all of our services and solutions to meet your specific project needs here.

Aluminium High Pressure Casting

Aluminium High Pressure Casting

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

Aluminium High Pressure Casting in its simplest definition is the pouring of molten aluminium raw material via a runner at high pressure (400-1,000 bar) and speed (30-100 m/s) into a mould made of metal. The process of applying high pressure is continued until the solidification process is completed. Thereafter, the mould is opened and the process is finished off by removing the part from the mould using forceps. After the process of spraying the mould with separator oil, the mould is sealed and locked again in preparation for the next cycle.

The part taken from the mould is cut off from the runner area and processed, heat treated, coated, etc. as needed to create the finished product.

There are two types of applications of the die casting process. The first of these is the Hot Chamber and the second is called theCold Chamber application. The Aluminium Material‘s structure and characteristics play a decisive role in which application should be chosen.

Hot Chamber Machines:

In the production of materials with a low melting point, such as lead, zinc and tin, Hot Chamber Machines are used. When using the hot chamber casting method, the accuracy rate for the finished product is ±0.05 mm at completion. There are two types of hot chamber casting machines which vary according to how they operate.

  1. Plunger Machines; The material in the crucible is melted and the construction comprises a cylinder which plunges into the crucible and which has a plunger inserted into it. This is how the process works for Plunger Machines. After the mould is closed, the plunger moves downwards, and the material that enters the cylinder is pushed into the mould.After the material solidifies in the mould, the plunger is pulled back and the mould is opened.
  2. Pressure Machines; The material that melts in the crucible is filled into the mould with a plunge cell and a lever system. Pressure Machines these are usually not the preferred method for aluminium casting.

Cold Chamber Machines:

Cold Chamber Machines are commonly used for the casting of high melting point alloys such as aluminium, copper, magnesium. In these machines, the melting furnace is located in a separate section. Molten metal can be removed manually with a hand scoop or an automatic scoop and a larger amount is poured into “the cold chamber” of the part to be produced. It is compressed with a plunger to fill the mould cavity.

Advantages of the Aluminium Casting Method;

Constituting an indispensable method in the production process, the Method of Casting Aluminium has the following advantages.

  • An Efficient Process: After investing in the mould, you can produce hundreds of thousands of identical parts using machining and additional labour. Particularly in the automotive industry, the Aluminium Casting Method is the answer to the problem of mass producing units.
  • Stable and Repeat Production: With the precision in die casting, you can repeat orders especially engineering parts and make high-spec products.
  • Special Finishing Operations: In line with customer requests, you can obtain parts with the desired surface roughness.
  • Flexibility of Production: In addition to the surface quality, you can carry out the production of complex-shaped parts of different cross-sectional sizes.
  • Longevity: Welding, riveting, etc. of complex-shaped parts can be produced without the need for a joining process. The production of parts in a single procedure increases the part’s strength. One other reason why parts produced in this way are durable is that they are heat resistant and dimensionally stable.
  • Low Cost: Aluminium Cast Parts are cheaper than parts made with other metal alloys.

Drawbacks of the Aluminium Casting Method;

Although it has many advantages,the drawbacks to the Aluminium Casting Method also exist. These drawbacks, that may cause an engineer or manufacturer to think again when choosing casting processes when determining their preferred production method, are as follows.

  • Casting sizes are limited. Very large pieces can not be cast.
  • The design of their moulds is difficult.
  • The investment cost of the casting machine and the associated auxiliary equipment is high.
  • The cost of mould maintenance is high.
  • The high degree of porosity in the casting complicates the heat treatment and welding processes.

Developments in Aluminium Casting

Continuous process improvements are made to increase the mechanic properties and sealing strength of the parts produced.

  • The use of vacuum systems to expel gas trapped in the mould during casting,
  • Heat treatment applications,
  • The application of a semi-solid metal process,

The improvements made to Aluminium Alloys and to the pressure treatments are ongoing, and Aluminium Die Casting applications are spreading as an alternative material in every sector.

KALKANCI: The Aluminium High Pressure Casting Company

Combining historic experience with an innovative forward looking vision, KALKANCI can provide its services in a professional manner to meet all kinds of customer need for Aluminium High Pressure Casting. KALKANCI understands the different needs of each discrete sector and develops appropriate processes to meet each separately; continuing to work successfully with its customers in a range of countries. If you too want to receive the benefit of the professional service we can provide in this regard to complete your casting process error-free, please contact us.

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.

Aluminium Alloys Used in Die Casting

Aluminium Alloys Used in Die Casting

Aluminium Alloys Used in Die Casting 1024 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

As a consequence of the fiercely competitive nature of this new century and because we face an increase in environmental protection requirements, car manufacturers have begun developing materials as alternatives to steel and iron. While efficiency and costs are prioritised in production, vehicles that consume less fuel, and which have higher and simpler recycling combined with driving safety and comfort are produced. For these reasons, aluminium alloys have become an indispensable material for the automotive industry.

Features that lead to aluminium being the most preferred material are:

  • It is the second most widely available metal on earth
  • It is highly recyclable; it can be re-melted using only 5% of the energy required for production from its raw state
  • Aluminium alloys can be worked at high temperatures
  • Its use in the production of low weight/high strength products: aluminium is three times lighter than iron
  • It can be produced to a thickness of thin wall panels.
  • Resistant to corrosion
  • High thermal and electrical conductivity
  • Easy to shape and format
  • It is environmentally friendly: replacing every kilogram of steel with 500g of aluminium will result in ten kilograms fewer emissions over the life of the vehicle.

High-strength alloys can be formed by adding elements such as copper, silicon, zinc, magnesium, manganese, etc. to pure aluminium, which is soft and low in strength.

The classification according to alloying elements in EN standards is as follows

AlloyingFeatureAreas of use
1XXXPure aluminiumDrawn tubes (pipes), chemical equipment, foil, electrical conductors, aircraft parts
2XXXAluminium-copper alloysAircraft parts, aluminium coated sheets, cryogenic equipment, space shuttle, various tanks
3XXXAluminium-manganese alloysSheets, rigid sheets, decorative products, beverage cans
4XXXAluminium-silicon alloysAutomotive, white goods, lighting, architectural products
5XXXAluminium-magnesium alloysAutomotive, marine, cryogenic products, aircraft
6XXXAluminium-magnesium-silicon alloysAutomotive products, products manufactured by heat treatment and extrusion technology
7XXXAluminium-zinc-magnesium alloysMoulds, aircraft parts, parts where great toughness is required
8XXXLithium, iron, etc. alloys from elementsProducts which need to withstand high temperatures, electrical cables

Al-Si, Al-Mg, Al-Cu, Al-Zn alloys are widely preferred, although different alloys are prepared according to place of use and product requirements.

Material density, desired mechanical properties, melting temperatures are important factors in selecting the alloy to suit your design needs.

Aluminium Silicon Alloys

Al-Si Alloys: This type is the most commonly used aluminium alloy. When the ratio of silicon in aluminium alloys approaches 11.7%:

  • The fluidity of the liquid metal therefore its castability increases
  • Solidification resistance is reduced
  • Increases sealing under pressure
  • Reduced tendency to crack or tear during solidification
  • Hardness increases
  • The specific weight decreases
  • Thermal expansion is reduced
  • Resistance to corrosion is improved

Al-Si alloys are used in the production of welded structures, sheet production, cylinder heads, engine blocks and valve bodies.

 

Aluminium Manganese Alloys

Al-Mg Alloys : Manganese is the element that contributes to co-proportional deformation in aluminium alloys.

In aluminium alloys, when manganese rises above 0.5%, it significantly increases yield and tensile strength without reducing ductility

The addition of manganese also improves corrosion resistance and welding outcomes.

Magnesium is light in weight and has a durable structure for certain cast parts. The use of magnesium components instead of heavier aluminium components can contribute to lower fuel costs in vehicles and car manufacturers are developing new technologies to exploit the unique properties of magnesium.

But magnesium is difficult to cast because it is used at high temperatures and oxidizes quickly. It is selected for structural products, boilers and tanks, land and rail vehicles.

 

Aluminium Copper Alloys

Al-Cu Alloys: Copper is the oldest element used as an alloying element for aluminium.

Copper content in the range of 2 % – 3 % increases tensile strength and hardness at high temperatures and improves mechanical properties

Copper also improves the machinability of alloys.

But copper has a negative effect on aluminium’s ductility and corrosion resistance. During solidification its sensitivity to cracking is high.

Al-Cu alloys are especially chosen for where high strength and heat treatment is needed particularly in high-tensile parts, aircraft structural elements, fringe forged parts, heavy-duty vehicle wheels, cylinder heads and pistons.

 

Aluminium Zinc Magnesium Alloys

Al-Zn Alloys: Zinc-aluminium alloys are favoured for casting parts with narrow tolerance and thin walled cross-section parts. Like magnesium and aluminium, zinc has good corrosion resistance and dimensional stability, high strength and electrical conductivity.  Zinc alloys are generally referred to as ZAMAK in the market.

Other Surface Treatments

Aluminium Die Casting

Aluminium Die Casting 1920 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Aluminium Die Casting is a preferred casting technique with its many features. In the technique used for the application of metal castingmachines, aluminium is preferred for its corrosion resistance and great strength. At the root of this process is the fact that molten aluminiumis resilient to being poured into a metal mould under pressure. This process is executed in two different ways as follows: hot chamber die cast and cold chamber die cast. It offers a more affordable production in comparison with precision casting and metal working methods.

What is Aluminium Die Casting?

Aluminium Die Casting it is a widely used method of casting. It is one of the most utilised methods, ranking commonly after iron and steel. It is the preferred method for the production of unit aluminium parts. At a very high pressure, the copper piston pushes liquid aluminium to the mouth of the runner. The incoming liquid spreads into the aluminiumdie cast and is finally compressed. It is a technique that consists of these three stages described. A high quality alloy is used to produce Aluminium Die Casts. Consequently, all these processes take place in seconds, producing aluminium material that is resistant to wear, fatigue and high temperatures.

When applying the aluminiumdie casting method, two different metal die casting machines are used depending on the material to be produced. Cold Chamber Die Casting Machinesare generally preferred in the production of aluminium parts. Zamak Casting is the name given to the types of parts produced in Hot Chamber Die Casting Machines. Machines with a hot chamber run faster than those with a cold chamber. The method in which the plunger cylinder mechanism is installed in the crucible and the molten metal is pushed through this mechanism and injected into the mould takes place using Hot Chamber Die Casting machines. In this system, the internal structure of the casting part is near perfect, as the molten metal almost never comes into contact with air. Cold Chamber Die Casting machines use independent stove and injection systems. The molten metal bucket is automatically transmitted to the hopper. The raw material moves into the mould by means of the push of the castingpiston. The rapid nature of this castingsystem can cause air mixing and unwanted gas porosity in the casting part.

Aluminium Die Casting Companies and Their Areas of Expertise

Aluminium used in the production of aluminium die casting, though difficult to cast, is a preferred product as it is a material of great strength and lightness. Additionally, preference is given because it is easy to form, has high conductivity, and is recyclable. Aluminium die casting is suitable for casting smaller parts with complex structures.

In terms of quality controls, after the casting process aluminium is put through many tests such as X-Ray inspection, materials analysis, compression tests, smoothness test, microscope tests, CMM test, gauge/visual inspections. Each test phase is performed in order not to receive negative feedback from the customer. Used commonly in both domestic and foreign sectors, it is also used by different sectors in Istanbul. It has uses in many different sectors such as automotive, orthodontics, medical and dental devices, firearm components, hardware, lock parts, computers, electronics, and energy. It can be used either as a part, as the entire component part, or in the production of thousands of parts such as sunroofs, seating mechanisms, fuel injectors, steering columns, braces, trigger, sight, shallots, lock cylinders, etc.

Istanbul’s Aluminium Die Casting Companies

Based in Istanbul, globally ranked and one of the main trading centres in Turkey, KALKANCI exports its Aluminium Die Casting products all over Turkey to many countries around the world. We stand out in this sector as a leading company undertaking the design, production and delivery of all kinds of parts that are required and wanted. Our high quality and innovative service approach to all the industries we work with adds value through our improved product characteristics, process management and tolerances, light-weight solutions related to product design and cost efficiency; aiming always to be your partner in providing solutions. To obtain more information about our services and about how you can benefit from the professionalism that KALKANCI can bring to your needs, please contact us.

Die Casting

High Pressure Aluminium Die Casting

High Pressure Aluminium Die Casting 1920 500 Aluminum High Pressure Die Casting | Kalkancı Aluminum Die Casting and Mold

Capable of manufacturing a large number of components in serial production and in a much shorter time compared to other methods, the High Pressure Die Casting Method is one of the most preferred methods in the production of aluminium parts. High-performance mass production offers the advantage of lowered costs and an affordable price, while producing the part you need promptly and flawlessly, enabling time savings.

In addition to its performance and price advantage, the High Pressure Aluminium Die Casting Method enables the production of complex piecesin an extremely high quality standard, with identical spare parts, resulting in an uninterrupted workflow. Therefore, spare parts required for different sectors are produced faster and more flawless, resulting in the quicker output of important industrial processes.

What is the working principle of High Pressure Aluminium?

High Pressure Aluminium Die Casting comprises of casting the molten metal into a hardened mould, solidified under pressure before removal,to provide the shortest route from molten metal to the finished component. High-pressure aluminium casting is an affordable method that saves time, particularly when high-density components are needed.

Firms which use High Pressure Aluminium Die Casting enable extremely cost-effective production compared to methods used by other firms as the molten metal solidifies in mere seconds. When it comes to mass production, this is a much more efficient and error-free process in comparison to other types of production.

Although it does also depend on the size of the component, the thickness produced by high-pressure aluminium die casting can be as little as 1 mm. This in turn, is an important factor in creating a very smooth lining with an extremely light and precise casting.

High Pressure Aluminium Die Casting Firms , work within the high-tech industry principle, which minimizes the margin of error and creates the aluminium component in the fastest way. This working principle ensures that the casting process is performed in the most precise way and that the output is produced according to the desired shape. This technology, which minimizes the unit time between casting and cooling, is made possible by high pressure.

In which areas do Aluminium Die Casting Companies Operate?

Aluminium Die Casting Companies operate in the production of parts which are both sensitive and need to be powerful, such as industrial robots, parts used for vehicle brakes, and gearboxes.
High-pressure Aluminium Die Casting Companies produce in different industrial cities, especially in Istanbul, by providing maximum power and efficiency to reduce porosity to a minimum in these types ofproducts for which mechanical properties are at the forefront.

Aluminium Die Casting Companies operating in Turkey

In Turkey Aluminium Die Casting Companies engage in the production of raw materials and spare parts. The sector component, which has attained a deserved place in the automotive sector especially, possesses a wide range of products ranging from industrial tools to lighting, from hydraulic systems to hand tools.

Aluminium die casting companies in Turkey, which export a significant part of the raw materials and spare parts they produce, combine high technology, innovation and creativity with reasonable pricing, great quality, minimum margins of error and a guarantee of short delivery times.

High-pressure Aluminium Die Casting Firms located in Istanbul

Starting with mould manufacturing and achieving the status of becoming one of the most significant players in the Turkish metal die castingindustry,KALKANCI applies an innovative approach to its workforce combined with solution-based performance, believing in the power born through the meeting of craftsmanship and technology.

Transforming forty years of experience into sophisticated production using advanced technology,KALKANCI has an important place amongst Istanbul’s High Pressure Aluminium Die Casting Companies. Reflecting years of advanced engineering, creativity and approaching each of its spheres of activity dynamically,KALKANCI serves the automotive, lighting, construction and energy sectors.

If you also want to access professional services in the area of High Pressure Aluminium Die Casting, please contact us.

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