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1,000 and 200,000 (the largest in the sample). Throwing out the highs and the lows, the average production run across all facilities was 1,498 pieces. The median production run, which is less susceptible to distortion by outliers, was 200.


Breakdown by Material


The data collected in the MODERN CASTING survey (Fig. 2) yielded similar material breakdown results to the American Foundry Society’s forecast data, which projects the de- mographics of all 2,040 metalcasting facilities believed to be operating in the country at this time. The MODERN CASTING survey found aluminum to be by far the most often poured material, with greater than 45% of the survey respondents using it. (Note: most U.S. facilities pour multiple ma- terials.) Iron was produced at more than 30% of the facilities reporting. Titanium casting capabilities were reported by only 19 domestic facili- ties. (For a report of the sales dol- lars forecast to be produced by each material segment of the metalcasting market in 2011, see the full industry forecast on p. 26.)


Fig. 3. Nobake casting has grown to rival green sand casting for the most used process in the domestic metalcasting industry.


Breakdown by Process Green sand is still the dominant pro-


cess in the U.S. metalcasting industry, with 54.9% of surveyed facilities utilizing it. (Note: many U.S. facilities use mul- tiple processes.) The nobake process


was employed by more than a third of the metalcasters reporting. Diecasting maintains a hold in 22.4% of facilities. The least used process was v-process casting (0.4%), with continuous casting a close second to last (1.6%).


MC


Oh Canada I


n addition to the U.S., the MODERN CASTING survey reached 172 Canadian metalcasters. Following are a few of the findings:


• Of the Canadian plants operating, the majority (47%) are in Ontario.


• The largest metalcaster in Canada employs 900. More than half (52%) of Canadian facilities employ 60 or more workers.


• Only 15% of the Canadian facilities (26) were willing to divulge their sales information. Almost all of them (25) said they took in more than $1 million annually. Seven-


MODERN CASTING / January 2011 teen of them said they made more than $5 million.


• Canadian metalcasters make bigger castings than U.S.- based operations. Out of 41 companies that answered the question, 24 (58.5%) reported an average casting weight at or above 20 lbs.


• Similarly to U.S.-based companies, the majority (57.7%) of Canadian metalcasters produces on average pro- duction runs of 1-299 pieces.


• Canada’s metalcasters pour similar materials to those in the U.S., with 45.9% pouring aluminum, 33.1% pouring iron and 22.7% pouring steel.


MC 39


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