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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 - PowerPoint PPT Presentation
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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
Mag3%
Other13%
Aluminum32%
Cu-Alloy4%
Zinc 2%
Iron35%
Steel11%
Casting End-Use MarketsOther19%
Cars & Lt Truck31%
Spec Ind-3%
Municipal3%
Pumps & Comp-3%
Railroad-6%
Int Comb Eng 5%
Valves-5%Constr., Mining,
Oil Field-6%
Farm Mach4%
Pipe & Fittings
15%
Global Production 2011 (metric tons)
1. China: 41.3 million—30,000 plants2. U.S.: 10.33 million—2040 plants3. India: 9.99 million—4500 plants 4. Germany: 5.47 million—612 plants5. Japan: 4.76 million—1612 plants6. Russia: 4.2 million—1350 plants7. Brazil: 3.34 million—1325 plants8. Korea: 2.34 million—890 plants9. Italy: 2.21 million—1111 plants10.France: 2.05 million—441 plants
The Oscar
• Cast By R.S. Owens, Chicago
• Cast via Permanent Mold in Britannia, a Copper-Base 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
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