Transcript Ferrous Casting Shipments

U.S. Metalcasting:
Who and What Are We?
XXXXX
What is Metalcasting?
• Metalcasting is a process in which
molten (liquid) metal is poured into
a mold (made of sand, metal or
ceramic) to form geometrically
complex parts
• All major metals (iron, steel,
aluminum, copper-base,
magnesium, zinc, titanium, gold,
silver, etc.) can be cast
• Metal castings are used in cars,
trucks, planes, trains, Mining and
Construction Equipment, Oil Wells,
Kitchen Appliances, Pipes, Toys,
Space Shuttle, Wind Turbines,
Nuclear Plants, Tanks, Bombs, etc.
Metal Casting Facts
• Most anywhere in the U.S., you are never more
than 10 ft. from a metal casting
• 90% of all manufactured goods contain metal
castings
Profile of the U.S.
Metalcasting Industry
2000 Operating Casting Facilities
– 700 Ferrous; 1400 Nonferrous
– Employs More Than 200,000
– 80% Firms Are Small Businesses
(less than 100 employees)
– 2012: $34 Billion; 12.8 Million Tons
– Global Leader in Casting Application;
2nd in Production
Shipment Mix: Sales
Zinc
2%
Mag
3%
Other
13%
Iron
35%
Cu-Alloy
4%
Aluminum
32%
Steel
11%
Casting End-Use Markets
Pumps &
Comp-3%
Other
19%
Pipe &
Fittings
15%
Municipal
3%
Spec Ind-3%
Cars & Lt
Truck
31%
Railroad-6%
Farm Mach
4%
Valves-5%
Int Comb Eng
5%
Constr.,
Mining,
Oil Field-6%
Global Production
2011 (metric tons)
1. China: 41.3 million—30,000 plants
2. U.S.: 10.33 million—2040 plants
3. India: 9.99 million—4500 plants
4. Germany: 5.47 million—612 plants
5. Japan: 4.76 million—1612 plants
6. Russia: 4.2 million—1350 plants
7. Brazil: 3.34 million—1325 plants
8. Korea: 2.34 million—890 plants
9. Italy: 2.21 million—1111 plants
10. France: 2.05 million—441 plants
The Oscar
• Cast By R.S. Owens,
Chicago
• Cast via Permanent Mold
in Britannia, a CopperBase Alloy
• 8.5 lb, 13.5 in. Tall
• Casting is Plated in
Copper, Nickel, Silver
and 24K Gold
Ice Cleat for the M1 Abrams Tank
• Made of 8630 Steel and
Cast in Green Sand by
Varicast, Portland, OR
• Redesigned to a Casting
From a Steel Forging
• Casting Must Withstand
Temperatures to -40 F
Ruger’s Firearms
• Ruger Investment Casts its Firearms Components
• Cast in Stainless or Chrome-Moly Steel for Integrity,
Cast-In Features and Aesthetics; All Ruger Castings
Are Visible
Golf Clubs
Golf Clubs
• Gold Metal Woods and
Irons Are Cast in
Stainless Steel and
Titanium
• High Strength Material
Provides Hardness that
Transmits to Maximum
Energy Transfer to the
Ball
• Titanium Provides the
Strength of Steel at Half
the Weight
GM SUV Engine Block
• Aluminum Cylinder
Block for GM’s Vortec
4200 SUV Engine Cast
via Lost Foam
• In Lost Foam, a
Polystyrene Pattern is
Produced and
Repalced with Molten
Metal to Form the
Casting
Cell Phone Keypad and Display
• Cast in Magnesium via
Thixomolding Casting
Process.
• The Casting’s Walls Are
0.8-1 mm Thick, with a
Total Casting Weight of
105 gms
• Converted from a Plastic
Part to Magnesium
Corvette Brake Pedal
• Safety Critical Part
• Redesigned to B356 Aluminum
Casting from Welded Steel Assembly
• Cast via the Low-Pressure
Permanent Mold Process
• 71% weight reduction from
conversion (to 1.6 lb)
• Other benefits: cosmetic
enhancement, reduced machining,
and elimination of fixturing, welding
and finish treatments required with
weldment design.
Michael Jordan Statue
• Silicon Bronze Statue is
Investment Cast by Art
Casting of Illinois
• Statue Weighs 2000 lb
and is 12 Ft Tall (17 Ft
Tall Including Granite
Base)
• Jordan Led the Chicago
Bulls to Six NBA Titles