Die Casting |

21 September 2022

Casting in the Energy Industry

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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.

21 September 2021

Aluminium Alloys Used in Die Casting

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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

Alloying	Feature	Areas of use
1XXX	Pure aluminium	Drawn tubes (pipes), chemical equipment, foil, electrical conductors, aircraft parts
2XXX	Aluminium-copper alloys	Aircraft parts, aluminium coated sheets, cryogenic equipment, space shuttle, various tanks
3XXX	Aluminium-manganese alloys	Sheets, rigid sheets, decorative products, beverage cans
4XXX	Aluminium-silicon alloys	Automotive, white goods, lighting, architectural products
5XXX	Aluminium-magnesium alloys	Automotive, marine, cryogenic products, aircraft
6XXX	Aluminium-magnesium-silicon alloys	Automotive products, products manufactured by heat treatment and extrusion technology
7XXX	Aluminium-zinc-magnesium alloys	Moulds, aircraft parts, parts where great toughness is required
8XXX	Lithium, iron, etc. alloys from elements	Products 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.