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Top 10 Global Casting Producers 33.5 million tons


1. China Gray iron


Ductile iron Steel


Nonferrous 2. U.S. 3. Russia* 4. India 5. Japan 6. Germany 7. Brazil 8. Italy 9. France 10. Korea


10.8 million tons Gray iron


Ductile iron Steel


Nonferrous


7.8 million tons Gray iron


Ductile iron Steel


Nonferrous


6.8 million tons Gray iron


Ductile iron Steel


Nonferrous


6.7 million tons Gray iron


Ductile iron Steel


Nonferrous


5.8 million tons Gray iron


Ductile iron Steel


Nonferrous


3.4 million tons Gray iron


Ductile iron Steel


Nonferrous


2.6 million tons Gray iron


Ductile iron Steel


Nonferrous


2.4 million tons Gray iron


Ductile iron Steel


Nonferrous


2.1 million tons Gray iron


Ductile iron Steel


Nonferrous


16.4 million tons 8.2 million tons 4.6 million tons 3.8 million tons


3.5 million tons 3.6 million tons 1.2 million tons 2.5 million tons


3.3 million tons 1.8 million tons 1.3 million tons 1.2 million tons


4.5 million tons 790,000 tons


910 million tons 550,000 tons


2.8 million tons 2 million tons 300,000 tons


1.5 million tons


2.7 million tons 1.8 million tons 220,000 tons 900,000 tons


1.6 million tons 680,000 tons 320,000 tons 250,000 tons


920,000 tons 650,000 tons 90,000 tons 980,000 tons


860,000 tons


1.1 million tons 110,000 tons 330,000 tons


1 million tons 600,000 tons 150,000 tons 270,000 tons


*Production total for Russia based on 2007 numbers. Imports of valves are estimated to exceed exports by 30%.


U.S. Transportation Report An increase in the substitution of aluminum for iron in motor


vehicle applications is expected to accelerate in the next five years. A recovery of truck production is expected in the second half of 2010 to supr an increase in gray iron shipments. A freight car deliveries are estimated to have dropped to 23,000 in 2009.


Motor Vehicles - Aluminum Short Term Growth ‘09/’11 .................................................................................. 37% Long Term AGR ‘09-’19 ....................................................................................... 6.9% Forecast Factors: Conversion of blocks, heads, suspension and differential parts to aluminum • Growth to 280 lbs. of aluminum per vehicle • Loss to plastics and magnesium • Gain in passenger cars


Light Vehicles - Gray Iron Short Term Growth ‘09/’11 .................................................................... 35% Long Term AGR ‘09-’19 ......................................................................... 3.7% Forecast Factors: Loss to aluminum, plastics & imports


Light Vehicles - Ductile Iron Short Term Growth ‘09/’11 .................................................................... 40% Long Term AGR ‘09-’19 ............................................................................ 8% Forecast Factors: Loss to aluminum in suspension and differential parts • ADI growth • Replacement of malleable iron • Some crankshaft loss to forgings • Imports down


Medium to Heavy Trucks - Gray Iron Short Term Growth ‘09/’11 .................................................................... 35% Long Term AGR ‘09-’19 ............................................................................ 9% Forecast Factors: Growth in truck, trailer in 2011


Medium to Heavy Trucks - Ductile Iron Short Term Growth ‘09/’11 .................................................................... 34% Long Term AGR ‘09-’19 ......................................................................... 8.7% Forecast Factors: Truck and trailer production rebound in 2011 • Replacement of steel and malleable iron


Trucks and Military - Steel Short Term Growth ‘09/’11 .................................................................... 22% Long Term AGR ‘09-’19 ........................................................................ -2.8% Forecast Factors: Substitution by ductile iron


Aircraft and Parts - Aluminum Short Term Growth ‘09/’11 ................................................................................. 26% Long Term AGR ‘09-’19 ...................................................................................... 5.5% Forecast Factors: Loss to titanium and imports


Railroad - Steel Short Term Growth ‘09/’11 .................................................................... 16% Long Term AGR ‘09-’19 ......................................................................... 6.9% Forecast Factors: Freight car deliveries up in 2011


Imports of commodity-type valves and pipe fittings should show the strongest growth. The strongest demand for valves and fittings should come from the energy-industry related sector.


U.S. Valves and Fittings Report Valves/Fittings - Gray Iron Short Term Growth ‘09/’11 ..................................................................... 17% Long Term AGR ‘09-’19 ......................................................................... 2.9% Forecast Factors: Growth in housing starts • Loss to plastic & ductile iron • Imports more than 100,000 tons.


Industrial Valves - Copper-Base Short Term Growth ‘09/’11 .................................................................... 18% Long Term AGR ‘09-’19 ......................................................................... 4.1% Forecast Factors: Imports gain


Valves/Fittings - Ductile Iron Short Term Growth ‘09/’11 .................................................................... 18% Long Term Annual Growth Rate (AGR) ‘09-’19 ........................................ 4.6% Forecast Factors: Industry growth • Replacement of malleable and gray iron • Imports drop


Valves/Fittings - Steel Short Term Growth ‘09/’11 ..................................................................... 17% Long Term Annual Growth Rate (AGR) ‘09-’19 ........................................ 3.2% Forecast Factors: Imports high


26 Metal Casting Design anD PurChasing January/February 2010


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