Die Casting

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.