Metalcasting Industry Roadmap Metalcasting Overview
Metalcasting is the most cost-effective method to manufacture a shaped metal component. The process consists of pouring molten metal into a mold containing a cavity of the desired shape. Metalcasting is one of $PHULFD¶V oldest and most important industries, established in 1642. In 1776, seven foundry men signed the Declaration of Independence. Metalcasting is vital to the economy and security of the U.S. The industry helped the U.S. become the world leader in manufacturing, science, medicine, and aerospace and is helping it to sustain this position.
In addition to underpinning the transportation, aerospace, and defense industries, cast metal products are
found in every sector of the
economy including energy exploration and production, mining, construction, maritime, fluid power, instrumentation, computers, and a myriad of consumer products. Cast metal components include the following: engine blocks; suspension parts for railcars, trucks, and autos; fluid flow and power components, including valves, pumps, faucets, pipes, and fittings; mining, oil field, and energy producing equipment; surgical equipment and prosthetic devices; and components for many of the household and electronic devices used every day. Markets for products containing metalcastings are increasingly competitive and manufacturers are placing greater emphasis on the
rapid production of high-quality, Facts about Metalcas ting
x When you s tand in the middle of the average U.S. city, you are never more than 10 ft from a metalcas ting
x U.S. cas ting s hipments to taled $28.5 billion and 10.8 million tons in 2015
x 7KH 8 6 LV WKH ZRUOG¶V VHFRQG OHDGLQJ cas ting producer
x There are 1,961 metalcas ting facilitie s in the U.S.
x The industry employs more than 200,000 people
x Most metal cas ters are small bus ines s es , and 80% employ les s than 100 people
competitively priced castings delivered in small quantities. A major challenge for the industry is that the vast majority of metalcasters are small businesses that do not have the resources to perform the advanced research and development necessary to remain competitive. Figure 1 provides a snapshot of important facts about the metalcasting industry.
x Leading metalcas ting s tates include Alabama, California, Indiana, Illinois , Michigan, Ohio, Penns ylvania, Texas , and Wisconsin
Figure 1: Metalcasting Facts1 Proces s Energy (% of total cos ts )
Melting 55%
Moldmaking 12%
Coremaking 8%
Heat Treatment 6%
Post Cast 7%
Other 12% Figure 2: Process Energy2 14
Additionally, metalcasting is one of the most energy-intensive industries in the
U.S.
Approximately 55% of its energy costs are consumed in melting.
making, heat treatment, and post-cast operations also use
significant energy
Mold making, core (see Figure 2).
Research to improve these operations and reduce melting requirements will help the industry save energy, reduce the environmental impact globally, and improve competitiveness.
The future holds great promise for the metalcasting industry. New advances have Overview
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