Presentation on theme: "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."— Presentation transcript:
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 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.
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
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; 2 nd in Production
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
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
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
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
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
Cell Phone Keypad and Display Cast in Magnesium via Thixomolding Casting Process. The Casting’s Walls Are mm Thick, with a Total Casting Weight of 105 gms Converted from a Plastic Part to Magnesium
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.
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