EIGHT STATES ACCOUNT FOR 56%
ranked fourth with 125 facilities, while Michigan and Illinois rounded out the states reporting more than 100 facilities, with 121 and 116, respectively. T ree states—Alaska, Hawaii and
North Dakota—each have one met- alcaster participating in our research, as does the District of Columbia. The other states with fewer than
10 facilities reported are Idaho, Louisiana, Maryland, Maine, Mis- sissippi, Nebraska, New Mexico, Nevada, South Dakota, Vermont, West Virginia and Wyoming. Dela- ware did not have any participating metalcasting facilities.
Percent of Total U.S. Plants
Ohio continues to be the industry leader in number of metalcasting facilities with 159. The top eight states in total plants represents 56% of the nation’s total.
GREEN SAND EDGES NOBAKE
Casting Process Leader: Green Sand/Horizontally
Parted
Last Place: V-Process Horizontally parted green sand molding is the perennial favorite process, with 655 of the 1,692 facilities (or 38.7%) using it, a slight increase in facilities and percentage compared to 2012. Its vertically parted counterpart, which often is used for higher volumes, is found in only 12.3% of facilities. T e nobake process comes in at a close second with 604 facilities, or 35.7%. Many facilities report using multiple
processes. One hundred twenty facilities use both the green sand and permanent mold processes (7.1%), and 433 facilities use the green sand and nobake pro- cesses (25.6%). Seven facilities reported using the V-process, a casting method with a vacuum holding unbonded sand in a mold during pouring.
Value-Added Services Total Number of U.S. Plants
The total numbers for facilities using each process remained relatively stable compared to 2013. The biggest increase was six (diecasting) and the largest drop was 17 (gas hardened/colbox).
30 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2015
Leader: Finish Machining Last Place: Coating Of the 1,692 facilities that par- ticipated in the U.S. census, 1,187 (70.2%) reported off ering at least one value-added service. Machining was the most popular service, with 908 facilities (53.7% of all responses; 76.5% of facili- ties with value-added operations) of- fering fi nish machining capabilities and 892 off ering rough machining (53.4%; 75.1%). Heat treatment, patternmaking and engineering and design all totaled more than 700 responses. T e vast majority of facilities of-
fering value-added services reported multiple methods, with 1,105 of 1,188
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