U.S. Metalcasting: Who and What Are We? XXXXX. What is Metalcasting? Metalcasting is a process in...
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Transcript of U.S. Metalcasting: Who and What Are We? XXXXX. What is Metalcasting? Metalcasting is a process in...
![Page 1: U.S. Metalcasting: Who and What Are We? XXXXX. What is Metalcasting? Metalcasting is a process in which molten (liquid) metal is poured into a mold (made.](https://reader034.fdocuments.net/reader034/viewer/2022052509/56649c995503460f9495679c/html5/thumbnails/1.jpg)
U.S. Metalcasting:Who and What Are We?
XXXXX
![Page 2: U.S. Metalcasting: Who and What Are We? XXXXX. What is Metalcasting? Metalcasting is a process in which molten (liquid) metal is poured into a mold (made.](https://reader034.fdocuments.net/reader034/viewer/2022052509/56649c995503460f9495679c/html5/thumbnails/2.jpg)
What is Metalcasting?• Metalcasting is a process in which
molten (liquid) metal is poured into a mold (made of sand, metal or ceramic) to form geometrically complex parts
• All major metals (iron, steel, aluminum, copper-base, magnesium, zinc, titanium, gold, silver, etc.) can be cast
• Metal castings are used in cars, trucks, planes, trains, Mining and Construction Equipment, Oil Wells, Kitchen Appliances, Pipes, Toys, Space Shuttle, Wind Turbines, Nuclear Plants, Tanks, Bombs, etc.
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Metal Casting Facts
• Most anywhere in the U.S., you are never more than 10 ft. from a metal casting
• 90% of all manufactured goods contain metal castings
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Profile of the U.S. Metalcasting Industry
2000 Operating Casting Facilities– 700 Ferrous; 1400 Nonferrous– Employs More Than 200,000– 80% Firms Are Small Businesses
(less than 100 employees)– 2012: $34 Billion; 12.8 Million Tons– Global Leader in Casting
Application; 2nd in Production
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Shipment Mix: Sales
Mag3%
Other13%
Aluminum32%
Cu-Alloy4%
Zinc 2%
Iron35%
Steel11%
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Casting End-Use MarketsOther19%
Cars & Lt Truck31%
Spec Ind-3%
Municipal3%
Pumps & Comp-3%
Railroad-6%
Int Comb Eng 5%
Valves-5%Constr., Mining,
Oil Field-6%
Farm Mach4%
Pipe & Fittings
15%
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Global Production 2011 (metric tons)
1. China: 41.3 million—30,000 plants2. U.S.: 10.33 million—2040 plants3. India: 9.99 million—4500 plants 4. Germany: 5.47 million—612 plants5. Japan: 4.76 million—1612 plants6. Russia: 4.2 million—1350 plants7. Brazil: 3.34 million—1325 plants8. Korea: 2.34 million—890 plants9. Italy: 2.21 million—1111 plants10.France: 2.05 million—441 plants
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The Oscar
• Cast By R.S. Owens, Chicago
• Cast via Permanent Mold in Britannia, a Copper-Base Alloy
• 8.5 lb, 13.5 in. Tall• Casting is Plated in
Copper, Nickel, Silver and 24K Gold
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Ice Cleat for the M1 Abrams Tank
• Made of 8630 Steel and Cast in Green Sand by Varicast, Portland, OR
• Redesigned to a Casting From a Steel Forging
• Casting Must Withstand Temperatures to -40 F
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Ruger’s Firearms
• Ruger Investment Casts its Firearms Components• Cast in Stainless or Chrome-Moly Steel for Integrity, Cast-
In Features and Aesthetics; All Ruger Castings Are Visible
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Golf Clubs
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Golf Clubs• Gold Metal Woods and
Irons Are Cast in Stainless Steel and Titanium
• High Strength Material Provides Hardness that Transmits to Maximum Energy Transfer to the Ball
• Titanium Provides the Strength of Steel at Half the Weight
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GM SUV Engine Block
• Aluminum Cylinder Block for GM’s Vortec 4200 SUV Engine Cast via Lost Foam
• In Lost Foam, a Polystyrene Pattern is Produced and Repalced with Molten Metal to Form the Casting
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Cell Phone Keypad and Display
• Cast in Magnesium via Thixomolding Casting Process.
• The Casting’s Walls Are 0.8-1 mm Thick, with a Total Casting Weight of 105 gms
• Converted from a Plastic Part to Magnesium
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Corvette Brake Pedal• Safety Critical Part• Redesigned to B356 Aluminum
Casting from Welded Steel Assembly• Cast via the Low-Pressure
Permanent Mold Process• 71% weight reduction from
conversion (to 1.6 lb)• Other benefits: cosmetic
enhancement, reduced machining, and elimination of fixturing, welding and finish treatments required with weldment design.
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Michael Jordan Statue
• Silicon Bronze Statue is Investment Cast by Art Casting of Illinois
• Statue Weighs 2000 lb and is 12 Ft Tall (17 Ft Tall Including Granite Base)
• Jordan Led the Chicago Bulls to Six NBA Titles