employees. And 32% of respondents reported fewer than 30 employees. Only 16% of respondents have more than 250 employees. Te average num- ber of employees per facility is 100, down three from last year. Te survey results were comparable to 2010, with the exception of the highest number of employees, which was 3,000 in 2010 and 2,000 this year.
Breakdown by End-User
Leader: Valves/Pipe Fittings Last Place: Special Industries (Textiles/Wood/Paper/Food)
Percent of Responses: 33% Almost half of the report-
ing facilities produce castings for the valves or pipe fittings market. However, castings for machines and equipment, both for mining and farming, are not far off, with about 43% of facilities reporting they cast components for these end-markets. Almost all metalcasting facilities produce parts for multiple end-users.
Breakdown by Coremaking Process
Leader: Shell Core Last Place: Ceramic Cores Percent of Responses: 57%
Te shell coremaking process is
the leader in the core room, with two thirds of facilities claiming the process; however the nobake process follows closely behind. Ceramic and hotbox/ warmbox cores are the least popular processes—each is used by only 100 facilities, or 11% of the respondents. Many facilities report using several coremaking processes.
Breakdown by Value-Added Services
Leader: Rough/finish machining Last Place: Salt spray testing Percent of Responses: 76%
Overwhelmingly, facilities have
multiple value-added services for their castings. Seventy-seven percent of respondents have rough/finish machining, 60% of respondents have pattern shops and 59% of respondents have engineering and design. Only 33 facilities have salt spray testing, and it is the only value-added service where fewer than 150 facilities use it.
The shell core and nobake processes are the two most popular coremaking processes.
Breakdown by Melting Process
Leader: Coreless induction Last Place: Reverberatory Percent of Responses: 69%
About 38% of facilities use the
coreless induction melting process. Crucible melting follows closely behind with 505 facilities, about 33% of the industry, using the process. Cupola, channel induction, electric arc and resistance all fall in the middle of the pack with about 100 facilities claiming each of the processes. Only 16 facilities use reverberatory melting. Many facili- ties report using more than one type of melting process.
Breakdown by State
Leader: Ohio Last Place: Delaware, Hawaii, North Dakota
Percent of Responses: 100% Average: 34.5
Ohio, with 175 metalcasting facili-
ties, is the leader in number of facili- ties per state. Pennsylvania, California, Wisconsin and Illinois make up the rest of the top five, each with more than 100 facilities.
ONLINE RESOURCE Visit
www.ModernCasting.com to see how many facilities are in your state.
Aluminum remains the most popular metal cast, with 55% of the industry pouring this material. December 2011 MODERN CASTING | 21
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