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I


PRODUCTION PER PLANT


n 2011, world casting production returned to pre-2008 levels, at 98.6 million metric tons, marking a 7.5% increase vs. 2010, accord- ing to this year’s MODERN CASTING Census of World


Casting Production. Indeed, the figure has exceeded the 2007 peak of 94.9 million metric tons, indicating the global metalcasting industry has emerged from the economic downturn. Twenty-eight of the 37 countries


that provided census data reported growth in annual volumes for 2011. Five countries reported contraction. Belgium is down 53%, with 51,035 fewer metric tons produced vs. 2010. Denmark, Pakistan, and South Africa also reported contraction. Tis is a greater number of contracting


countries than in 2010, but it was offset by dramatic growth in countries includ- ing Bosnia and Herzegovina (169%, producing an additional 31,770 metric tons), the Czech Republic (34%, an addi- tional 115,568 metric tons) and the U.S. (21.5%, an additional 1,769,767 metric tons). Growth in countries that showed the largest gains in 2010 has slowed but not stopped, with Brazil reporting a 3% casting production increase vs. 41% from 2009 to 2010, and Taiwan coming in at 11% vs. 42% from 2009 to 2010. Te U.S. narrowly overtook India


on this year’s top 10 list, regaining the 2nd


spot, while the remaining cast metal


producing country rankings are the same. China is number one, having produced 41.3 million metric tons in 2011. Te U.S. produced 10 million metric tons, followed closely by India at 9.9 million metric tons. Japan closely surpassed Germany with 5.47 metric tons. Russia, Brazil, Korea, Italy and France occupy spots six through 10 on the list. Te top 10 nations produced 88% of the total global castings, as in 2009 and 2010. Production per plant is another


area where gains in the U.S. are showing, at 24.5% vs. 2010 (4,979 metric tons per plant). Germany’s productivity increased significantly,


World Totals


Gray Iron


45,870,050


Ductile Iron


24,782,540


Malleable Iron


1,381,461 Steel 10,342,738 26 | MODERN CASTING December 2012


Copper Base


1,799,294


Aluminum 13,197,181


Magnesium 181,931


Zinc 505,614 Other


Nonferrous 532,313


Total 98,593,122


Eight of the top 10 nations reported growth in productivity per plant (calculated as total tonnage divided by number of plants) in 2011. Of the top 10, the U.S. showed the greatest increase at 24.5%, followed by Germany at 14.4%.


also, at 14.4%. Germany remains the most productive country at 8,933 metric tons per plant. Asia suffered a dip in productivity, with China down 9.7% and Japan dropping 12%. Productivity is calculated as total tonnage divided by the number of plants reported. Gray iron continues to comprise 48% of the world’s ferrous metal castings vs. 25% ductile iron and 10% steel. Of the nonferrous metals, aluminum takes the lion’s share at 13% of the global total. Nonferrous castings overall increased by more than 1 million tons. The data reported in the 46th Census of World Casting Produc- tion is supplied by each nation’s metalcasting association or similar representatives. Countries that did not participate this year were Croatia, Mexico, Mongolia and the Ukraine. These countries remain listed according to the last year they participated.


Slovakia has returned to the list,


this year, producing 71,000 metric tons. Its metalcasting output has increased 56% since 2008, with the majority of its tonnage in aluminum (46,000 metric tons). Its iron produc- tion trends to ductile at 18,200 metric tons vs. 2,700 metric tons gray iron.


Economic Rebound Global casting production has


returned to pre-2008 levels, but some countries continue to lag. Despite a devastating tsunami and nuclear disaster, Japan showed 15% growth in 2011, yet the country remains below its 2008 level. Among the other top 10 producers, U.S. casting volumes have not yet exceeded the 2008 figure. Rus- sia remains significantly below its 2008 volume, while China, India and Korea have exceeded their prerecession levels. Other countries reporting produc- tion above their 2008 volumes include Hungary, Poland, Portugal, Slovakia, South Africa and Turkey.

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